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1996 XP 800 rebuild…

Banshhe1

Member
So long story short I sold a mint 95xp 720 for an even cleaner 96xp 800. It’s had basically everything replaced it’s really nice, but now it needs it all done again, me not happy!
 

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So the wife is not exactly happy that I sold a perfectly running Ski, for this thing lol. What makes the most sense here, buy a full engine rebuild kit, crank, pistons etc and do the work myself. There’s a guy locally to me that has all the specialty tools that I need. Or a rebuilt short block from SBT or some other shop. Try and source take out locally on marketplace or the like. This needs to be as budget friendly as possible. The wife ain’t happy as mentioned
 
Don’t buy SBT, to much risk that it will be garbage, either spend the money and rebuild it yourself but do it right or keep your eyes open for a running 787 on marketplace
 
Well do you have any recommendations on where to get a complete engine rebuild kit?
I don’t have any recommendations on an all in one kit but I’ve seen competitive crankshafts mentioned on here numerous times for quality crank rebuilding. Pro X pistons. Only my opinion but if cost is an issue as I believe you had mentioned it is, I would look for a good used machine rather than an SBT rebuilt crank, not a used crank individually but a machine that let’s say had no spark or won’t run correctly for whatever reason but the engine rolls over smoothly by hand.
 
First post last picture… Not seeing any chamfer on the ports.
Looks to me like the kit on eBay has a WSM crankshaft.
eBay kit gives a choice… Pro X pistons
 
As @tobytd said, poor machine work caused it. No chamfer caused the ring to snag and that is why it broke the piston crowns off at the ring land.

If you are going to keep this ski for years send the crank to Competative Crankshafts and the cylinders to Group K. OEM pistons are the best, second is Pro-X which Group K can supply or you can have them drop shipped to them once you find out the size needed. Third best is WSM.

Stay away from anything SBT unless you just want the cheapest reman to flip the ski.
 
Well I found a complete engine out of 1997 gxs. It’s never been apart and has 148psi compression on each cylinder. I think this will be my best option
 
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