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  1. #1

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    Unhappy GP800R oil line came off - rebuilding Round 2

    Hi everyone. I am new to the forum and unfortunately this is not a fun first post. I was recently given an 03 GP800R from a family member that no longer used it. It has low hours (only 24), but sat for about a year since lat being used. The last time it ran before I got it, it was having issues stalling and dying. I got it and took it to a local shop to have it checked out. The said the pump was filled with sand, shells, etc., and corroded so the wear ring was grinding against the impellor. They replaced the pump and impellor and got it running. They said it was running rough, and I should try taking it out with some fresh gas to see if it cleared up, otherwise I was looking at having the carbs cleaned or rebuilt.

    Yesterday I took it out, and it ran for about 5 minutes, but didn't feel like it had much power. Since I never rode it when it was running well, I wasn't sure if that was normal. After 5 minutes, it died. When I tried to restart it, it just clicked and the motor didn't turn over. After waiting a few minutes, it started up, ran for a couple of minutes, and did the same thing again.

    This morning I thought I would do a compression check (which I should have done first thing), because I couldn't figure out how a bad carb would prevent the motor from turning over right after it died. Before I did the compression test, I noticed a significant quantity of oil in the hull. That made me nervous, so I traced the oil lines and found that the supply line going from the oil pump to the rear cylinder had come off. I put it back on and clamed it, but as feared when I then did the compression test, front cylinder has 120 psi, but the rear had zero.

    So I assume I am in for a rebuild of some flavor, and that's where my questions come in. What can I expect for a rough cost to have the engine rebuilt? What about if I do it myself - how much should I expect that to cost? I realize it will depend on how much damage there is, but I am trying to understand my options before I go too far.

    I am not a serious mechanic, but have done a little work here and there and do a lot of woodworking, so I am OK with tools. Is this something I vcan reasonably do myself? How hard is it to tear things apart and get the head off to see how much damage there is?

    Because I paid for my pump repars on Black Friday, I ended up with $240 of store credit at the dealer where the work was done. I really don't trust them to do more work for me since they didn't notice the bad cylinder, but maybe I could use the credit to buy a bunch of the parts I need and keep my costs down. Thoughts?
    Last edited by mfabel; 04-09-2012 at 01:52 PM. Reason: update title


  2. #2

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    I downloaded the service manual. Looks like it wants me to remove the whole engine before pulling the heads. Is that really necessary, or is it possible to pull the heads while the ingine is still in the hull?

  3. #3

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    Photos

    OK, I managed to get the heads off without removing the entire engine. As expected, the front cylinder and piston look fine to my untrained eye, but the rear looks bad. What's next? This is all new to me . . . How do I check to see if there is any damage to the crankshaft or something else?

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  4. #4

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    How do I tell if I need to have the cylinder re-plated or just honed? Can you tell from the pictures?

  5. #5
    Happily Self-Employed WFO's Avatar
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    most like you will need a re-plate or replacement cylinder

    you also need to remove the cylinder to see if the crank was damaged

  6. #6

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    I pulled the jug off and took a few photos of what you can see of the crank.

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    I also got some muriatic acid at the suggestion of RX951 and will try cleaning the cylinder and see how it looks.
    Last edited by mfabel; 01-18-2012 at 10:37 AM. Reason: spelling

  7. #7
    jdakrt's Avatar
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    You need to pull the whole thing. Split the cases and clean and inspect the crank bearings. No way that cyl is going to need just a hone. new plating/piston at the least. I would check the head for pitting also and replace if any. you dont want hotspots on you new piston.

  8. #8

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    I spent some time this evening cleaning the cylinder with muriatic acid. There were a couple of spots that kept bubbling so I spent extra time on them. Turns out it was pitted in those areas. So I suspect this means I need to send the to Millenium for replating. Does this looks like something Millenium can handle?
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  9. #9

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    Also spent a little more time looking at the crank. I still need to pull the piston off, but I noticed what looks to me like some oil at the bottom on the case.

    Does that look like oil, or could it just be gas? I am hoping there was a little oil getting in to help the crank.
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  10. #10
    Oil in the bottom of the case is normal. Pull the whole thing out and split it open.

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