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  1. #1
    butterbean_29512's Avatar
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    xlt800 carb mods

    Hello all, getting my winter work going and I have a question about the carbs on the xlt800. Rebuilding these for a customer, and doing the reliability mods to his machine. I haven't worked on the 800, and I was wondering if there is a drilled return mod that needs to be done to these? If so, what size jet is needed for it? Thanks in advance! Jack


  2. #2
    Mpeavler's Avatar
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    No , no need .. just Make sure you get the 44 Ibody kits not the standard ones for the SBN's.

  3. #3

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    I drilled the returns, and used 90 pilot. Worked fine all summer...I increased pilots to 92.5 at that time, piston wash still looks a little lean, so just up them to 97.5. They are truly borderline lean from the factory, any restriction in the pilot jet,(same as my 1200 was) will heat up and crack the pv. Then it will shatter and hit the piston. Speaking from experience, time's three, but it was a free jet ski..f
    Last edited by Crazypirate; 12-02-2016 at 11:00 AM.

  4. #4

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    Wouldn't installing a larger return jet lower fuel pressure which would be more likely to get less to the cylinder since it would be entering the engine with less pressure? I am just asking out of curiosity?

  5. #5

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    Technically yes, but...you are shooting for 1 to 2 PSI fuel pressure at idle, then 4ish at Wot coming from both carbs. As long as I have sufficient volume, I'm really not concern about +/= one psi. Two ways to justify that....did you set your popoffs at (example) 54 psi or 54.5psi? Both carbs? Since the fuel pumps are a mechanical devices and independent, odd's are the two carbs see different pressures from the factory, on 2000 an above, both carbs are jetted the same. Why then 97.2 jet's? That is what European 1200 used, (No EPA) State side, 800 and 1200 used 90s, same carbs. Ran 97.25 earlier this year with 2.0 seats and 90g spring..ran good, I now want to try them with the 115g.
    Last edited by Crazypirate; 06-15-2017 at 07:58 AM.

  6. #6

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    Ok, 97.5 is crispretty on the trailer with heavy springs, might drop it in tomorrow, to see piston wash....suppose to be 76 degrees...we will see.

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