Specs on a 2002 XC800 - HCS Snowmobile Forums

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Old 10-06-2008, 05:11 PM   #1 (permalink)
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Hey, I just got a 2002 XC800 which needs powervalves. One of the powervalves was already removed by the person I bought it from. I looked down the hole where the valve goes in and I can see the piston. Looks like it has some minor scratches and pieces of aluminum stuck onto it. I took the other powervalve out and looked into that hole and the piston is fine. I am going to have to remove that one cylinder and inspect. Does anyone have the specs on piston/cylinder for this machine? Also, would it be alright to replace just one piston for the time being or should I just run it how it is, if it's not too bad? Thanks
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Old 10-06-2008, 06:48 PM   #2 (permalink)
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Replacing one piston is fine. As far as specs, not sure what your after, chunks of a luminum missing is from detonation, time to throw piston away.

For the heck of it do a compression check on each jug.
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Old 10-06-2008, 06:50 PM   #3 (permalink)
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Sounds like it may have eaten the valve. I don't know for sure, but I think you can replace just one piston if it's bad.
As far as specs go, my service manual says:
bore-3.3464"
piston to cylinder clearance-.006" to .0074"
service limit-.0074"
piston ring end gap-.016" to .022"

Hopefully this helps. Let me know if you need any more specs.
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Old 10-06-2008, 06:58 PM   #4 (permalink)
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I didn't see the valve that was already removed. Hopefully it didn't break and cause too much damage. Compression on both cylinders is 145+/-. It starts and runs fine.
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Old 10-06-2008, 07:44 PM   #5 (permalink)
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Do you know why the seller removed the E.V., and what it looked like when he removed it? This may help to diagnose the aluminum pieces you see stuck to the piston. Are the scratches and aluminum pieces on the side of the piston or the top?
Compression numbers sound good, like jugs and pistons are still mostly intact. No major blow holes anyway.
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Old 10-06-2008, 09:09 PM   #6 (permalink)
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He took them out to clean them and noticed it was bent. I'll probbly just take the jug off and clean any aluminum off of it. I hear muriatic acid works. The scratches are on the side of the piston.
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Old 10-07-2008, 10:13 PM   #7 (permalink)
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Ya get new valves I had to do it last year. 112 a power valve for the new updated version which is Stainless Steel. My one melted off got stuck in the piston chewed the piston all up and the jug. I had to get a new jug pistons and rings and gaskets. Cost me 800. We talked to my dads buddy which has his own snowmobile shop and mopar parts shop about 5 miles away cause I was going to replace the one piston. He said you got the money do it the right way and replace both. Its not necessary to do it but its the best and right way.
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Old 10-07-2008, 10:16 PM   #8 (permalink)
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O and if you need parts he is usually pretty reasonable if not the best price. He has guys come from canada which is a good 45 minutes to the michigan canada border so coming just to him. He has a website www.mcbperformance.com He might be apart of this website I dont know though. I havent been on here in forever.
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Old 10-08-2008, 03:38 AM   #9 (permalink)
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Bought some stuff from Matt @ MCB 8 years ago, still got his carb/clutch kit on my 99 xc700. Good guy to deal with.

For exhaust valve kits, I bought them from www.babbittsonline.com , their prices are hard to beat.

I also agree in replacing both pistons (depending of mileage) if one can afford it. OEM pistons cost around $130 ea. last time I checked. (Planning to replace both on my 02 XC800 this winter, around 5500 miles on them now)

Also if cylinder is damaged, it can be sent out to get re-nicasiled, much cheaper than a new one.
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Old 10-08-2008, 04:46 PM   #10 (permalink)
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Ya he is a really nice guy and knows his stuff. But I have been hearing bad things about babbits. Takes forever and half the stuff dont show up. I have ordered from them never had a problem. They have good deals. But the more I have been hearing I would be leary
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