Cylinder Piston Rebuild Kit for Yamaha XLT 800 2002-2004

Cylinder and Piston Rebuild Kit for Yamaha

This cylinder and piston rebuild kit for Yamaha is a complete top-end assembly that replaces the worn cylinder and piston together, restoring compression and reliable running on compatible 800cc marine engines.

Overview

This cylinder and piston rebuild kit for Yamaha bundles the parts needed to refresh a worn top end in one package. The cylinder and piston rebuild kit pairs a machined cylinder with a matching piston so bore clearance stays within spec from the start. It suits owners of compatible Yamaha personal watercraft doing a full top-end service.

Built For Performance

• Cylinder and piston matched as a set for consistent bore clearance
• Piston cut for the port timing of the 800cc two-stroke engine
• Cylinder bore machined to factory dimensions for correct ring seal
• Kit format saves the cost of sourcing cylinder and piston separately
• Built for the heat cycling of a marine two-stroke powerplant

Fits These Machines

• for Yamaha XLT 800 (2002-2004)

On-The-Job Use

• Full top-end rebuild after low compression or a seized piston
• Refreshing an engine before a full season on the water
• Replacing a scored cylinder and worn piston in one job
• Restoring factory compression on a high-hour 800cc engine

Specs At A Glance

Good To Know

Q: Why buy a cylinder and piston as one kit? A: Buying them together means the bore and piston are matched to work as a set, which reduces the risk of clearance issues from mixing components. It also simplifies ordering for a full top-end job.

Q: What else should I replace during this rebuild? A: Plan on new gaskets, wrist pin bearing, and circlips alongside the kit, since those parts are not reusable once the top end is apart. Check ring end gap before final assembly as well.

Slight variation in finish or dimensions may occur between production runs, and fit can depend on serial number, so confirm compatibility before ordering.