Hey guys. So I have recently bought a 1997 XP 800 that was in pieces. I put a new crank in it and have put it all back together. Now when I go to start it it has a really harsh "bang" from the engine, so harsh it has already snapped one starter motor. It even does it with the spark plug caps off but with no spark plugs it's like normal. I have tried messing around with the rotary valve and still does it. Can anyone shed some light on what this might be? Cheers
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XP 800 won't run
- Thread starter Adzy110
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andrewterri
Active Member
Im bored and at a stopping point on my ski so I'm just throwing this out there but have you looked at the top of the pistons to see if it's contacting the plugs? Bangs with plugs in but not with them out. Does the electrode look smashed at all? Glad to see someone posting in the forum beside just me. Winter is slow
andrewterri
Active Member
Did you change rods and piston when you replaced the crank? Sounds like compression is the contributing factor to the sound.
andrewterri
Active Member
I am by no means the expert on here and probably ask more question anyone, but I will try to help you until the experts get back on here. It is 1:57am here in the central u.s.
andrewterri
Active Member
Have you checked compression? Off the top of my head I believe factory compression is 150psi on the 800
andrewterri
Active Member
Are the rods the same length? Do you have the same stroke or is it within spec
andrewterri
Active Member
Did you use the same is cylinder base gasket? Don't know if lowering you quash gap would change your compression. I am out of my element as I have never done lower end work. Just trying to throw ideas out there for you. However, do not take anything I am saying as truth. I know you said it only makes noise with compression but have you checked to make sure nothing got caught up in the rotary gear during the rebuild? And you verified you had the correct bearing for you crank right? Racking my brain trying to think of what would be "banging" because of compression. The compression must be causing something to be slapping. Does it sound like a piston slap?
andrewterri
Active Member
What thickness base gasket did you use
If you can turn it over by hand it isn’t hitting anything and the pistons can’t hit the spark plugs.
You need to check the squish gap for sure. You can’t just make a gasket on these as they sell different thicknesses for a reason.
If it cranks with the plugs out but not in it would be starter related. I have seen them when you try to start with plugs in it keeps going clunk, clunk, clunk but doesn’t fully turn the engine over.
It is either crap starter, corroded cables or bad connections, bad battery or starter solenoid.
You need to check the squish gap for sure. You can’t just make a gasket on these as they sell different thicknesses for a reason.
If it cranks with the plugs out but not in it would be starter related. I have seen them when you try to start with plugs in it keeps going clunk, clunk, clunk but doesn’t fully turn the engine over.
It is either crap starter, corroded cables or bad connections, bad battery or starter solenoid.
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