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  1. #1

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    Carb disassembly xp800

    Just picked up a 96 xp800. The guy I got it from had taken the carbs off because of a high end bog. Before I put them back on I want to rebuild them.

    BUT, I can get the damn things apart. Is there a trick to removing these screws without stripping them. Maybe SD used loctite and I have to heat them up?

    Oh and where can i get the screws to replace the ones I stripped?

    I cant describe the bog since I never rode the ski, but would a bog on the high end be a carb issue, or more likely the raves? Raves come out today for cleaning reguardless.


  2. #2

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    When I pulled the rave caps, one had no spring between the cap and the valve. Could this be the cause of the bog? (assuming the guy didn't lose the spring while trying to figure out the prob)

  3. #3
    Master of the Dooniverse
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    no raves only really make difference on the bottom. they are basically out of the equation on top except the fact that they get out of the way.

    those screws should come out with a "snap" if you keep good pressure on them when turning. i've had to use a impact driver on stubborn ones. if they are salted you may be in for some punishment. chekc the adjuster screws. if they are stuck the carbs might be junk.

    the bog is probably clogged internal filters.

  4. #4

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    Yea u hit the nail right on the head, Internal filters were filled to the top with crap. Probably time to change out those grey fuel lines.

    Impact driver is a great idea, I can't believe i didnt think of that.

    Thanks for the help, I hope all goes well when the carbs go back on tomorrow.

  5. #5
    steach's Avatar
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    Quote Originally Posted by fboncore View Post
    Impact driver is a great idea, I can't believe i didnt think of that.
    Monkey Style: hold the carbs on a flat board with your feet and whack away. Yup, remove & clean the selector and fuel tank too.

  6. #6

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    Quote Originally Posted by steach View Post
    remove & clean the selector and fuel tank too.
    Will do, I'll let you guys know how it turns out

  7. #7

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    For anybody looking to remove stubborn screws, check out Aircraft Tool Supply pt# AT540A-KIT or AT540B-KIT. They fit into a pneumatic hammer which pounds away at the fastener fully seating the bit while allowing you to apply gradual rotational force to remove the screw. Use a variable rate air hammer and you have (IMHO) the most powerful fastener removal tool available. I have yet to damage a screw head using this tool. Apparently they are also called "screw-knockers" or "woodpeckers".

    Anyone else use these? I didn't even know they existed until a few years ago.

  8. #8

    Join Date
    Jul 2008
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    Long Island, NY
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    That air hammer tool sounds like a good idea, Ill have to pick one up.

    Now another question about the carbs. How do I make sure that the ski is not running lean?
    I know I can listen for detonation, but I'm not sure I could hear any over the rattling that goes on when running on the hose.
    Anyone have a sound clip or video of 800 detonation?

    Any other ways to make sure its getting enough fuel?

    Most of my ski's have been yamaha triples, so I'm not sure if the twins just run a little rougher

  9. #9

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    Reading the spark plugs will tell you a lot about how your engine is running. This link has good representation of conditions...

    http://www.dansmc.com/spark_plugs/sp...s_catalog.html


    If your carbs are stock and on a stock motor, you shouldn't have to worry about running lean as long as your carbs (passages and jets) are clean.

    If the ski is responding to full throttle for extended lengths of time...most would say that's a good sign that the engine is getting enough fuel.

  10. #10
    Tool Bag water worx's Avatar
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    You cant detonate on the hose,the motor has no load on it.

    If your ski is stock & you set the carbs to stock & everything is right,it will be fine.

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