Hi everyone, i'm new to this forum and have a few questions. I recently got my 96 xp fired up from its long winter nap only to find out the right cylinder jug had not 1 but 2 cracks in it.. Is there a difference in jugs between the 787 and 800? also i'm not sure if it is still at standard bore? i was reading some other posts and noticed that someone on here sells used parts. I removed both jugs and want to put it back together right, hopefully without having to go threw the boring process but i guess it's possible i'll have to. if i have to can the whole thing be put back like stock or do you have to get into adjusting the rave part of it..I just want to do this as cheap as possible..oh and the same piston in that cylinder is scarred pretty good so i atleast have to replace 1 piston..any and all advice will be greatly appreciated..Thanks bob
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which engine do i have,787 or 800?
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Dr Honda
Well-Known Member
the 800 engine displaces 787cc's. (same engine, just a different name)
If you don't want to deal with boring a jug, and fitting a piston... just take your jug to a weld shop, and have them weld the crack... and put it back together. The cracks in the water jacket are normally superficial.
If you don't want to deal with boring a jug, and fitting a piston... just take your jug to a weld shop, and have them weld the crack... and put it back together. The cracks in the water jacket are normally superficial.
Thanks for the info Tony, it's not that i mind boring the jugs and fitting new pistons, it's just that i don't know if someone before me has already done so. I just want to make sure i get a replacement jug that matches the one that is good, meaning i need not to bore it and change the pistons ect. As long as i can find out the bore and piston size, i can order what parts i need, i do want to do this right and have it last. Do you think that welding the cracks would hold up? I found out what caused it, the elbow comming off the bottom of the head had gotten totally clogged with sand ans debris, thus not letting the head drain and it froze over the winter and cracked it. I guess what i'm trying to say is as long as i find out the bore and piston size, i can get another factory bore size jug and bore it up to what it is now, or bore both up if i have to and replace the pistons. i'm doing all this with the motor in the ski by the way....not fun. Again any advise will be helpful. Again i want to find a used jug, new ones are waayyy to expensive.. Thanks Bob
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Dr Honda
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The clog isn't good... but you are supposed to put anti-freeze int he engine over the winter, if it's going to subject to freezing temps. SO... even if there is still water in it... it won't freeze.
As I said... the crack is superficial. If it was my project... I would either weld it, or do a entire top end. (if you want to do it right) Pistons and rings have a finite life... and if you have one new, and one old piston... the old one could fail after the first ride. (not saying it will, but it can) SO... if I have to top-end apart on an older engine... I would do a top end, so I don't have to pull it apart for a long time.
As I said... the crack is superficial. If it was my project... I would either weld it, or do a entire top end. (if you want to do it right) Pistons and rings have a finite life... and if you have one new, and one old piston... the old one could fail after the first ride. (not saying it will, but it can) SO... if I have to top-end apart on an older engine... I would do a top end, so I don't have to pull it apart for a long time.
Tony how long do you think the welds will last? honestly i think they will last a long time cause it is an open system....no thermostat. also the reading i'm getting when checking the bore is 3.265. standard bore is 3.228 and first over is 3.238...not making a whole lot of sense to me, how about you? anyway i'm gonna have the head welded and maybe even put it back together with the same rings, your thoughts on that? thanks Bob
Dr Honda
Well-Known Member
The weld will last forever... or until it gets frozen again.
It sounds like the engine has been cut twice... OR... the first time needed to be cut deep. Not a big deal. The reason the manual only shows one over size on the 800 engine is because anything bigger than 0.010" over, and you will have to cut the RAVE valve for clearance. You can get 0.040" over sized ROTAX pistons... and I think people like Wiseco go 0.060" over.
It sounds like the engine has been cut twice... OR... the first time needed to be cut deep. Not a big deal. The reason the manual only shows one over size on the 800 engine is because anything bigger than 0.010" over, and you will have to cut the RAVE valve for clearance. You can get 0.040" over sized ROTAX pistons... and I think people like Wiseco go 0.060" over.
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