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2004 GP 800R Power valve split in two--at thick valve part chunk fell into piston!

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  • 2004 GP 800R Power valve split in two--at thick valve part chunk fell into piston!

    We found engine would only turn 1/4 around. the actual power valve broke in half with the thick chunk falling half way into cylinder---the piston hit and cut big chunk in half-----this crushed piston in one small area causing ring to squish out----then ring was pulled out a little causing piston to be range bound with ring on piston hitting top and bottom of exhaust port----1/4 turn of movement. We could not get cylinder off piston. By the way--at one time we were going to cut rod---there are no nut on connecting rod---how does this come off? well we pulled some on the protruding ring with vise grips locked on ring----could not budge----then took channel locks on base of vise grips and levered against cylinder and very slowly---pulled piston ring out like a bad tooth----got 2 fairly straight pieces of piston ring for effort. Cylinder came off easy---

    What to do? so far new piston/rings and power valve. any idea,s how this happened?

    We bought this on ebay--seller said they drove it awhile---parked at dock---then only clicked when trying to start--as if battery was dead---we kinda knew what was going to be done and paid accordingly.

  • #2
    Re: 2004 GP 800R Power valve split in two--at thick valve part chunk fell into pisto

    The crank has to be taken apart with special tools and a press. It is not serviceable by the average person. SBT sells a reman crank with your as an exchange, as for the damage to the cylinder and piston with the power valve, post pics of what they look like so we can help determine the best way to repair the ski. Purchase a service manual since you will be doing your own repair, its a must have to do the job.
    SBT Tech Support is here to help with your problems.
    We try to answer each question quickly and accurately.
    Please do not use Private Messaging for Tech Support, use the forums.

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    • #3
      Re: 2004 GP 800R Power valve split in two--at thick valve part chunk fell into pisto

      i have pics now----but no "url" to post image---pics are on computer---any idea,s

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      • #4
        Re: 2004 GP 800R Power valve split in two--at thick valve part chunk fell into pisto

        Send them to tom@sbtontheweb.com
        SBT Tech Support is here to help with your problems.
        We try to answer each question quickly and accurately.
        Please do not use Private Messaging for Tech Support, use the forums.

        Comment


        • #5
          Re: 2004 GP 800R Power valve split in two--at thick valve part chunk fell into pisto

          sent on monday----pics---did you get them?

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          • #6
            Re: 2004 GP 800R Power valve split in two--at thick valve part chunk fell into pisto

            No I did not, only send 2 at a time, try re-sending
            SBT Tech Support is here to help with your problems.
            We try to answer each question quickly and accurately.
            Please do not use Private Messaging for Tech Support, use the forums.

            Comment

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