Page 1 of 2 12 LastLast
Results 1 to 10 of 19
  1. #1

    Join Date
    Aug 2015

    03 xlt 1200 blown cylinder help

    First time posting...
    Looking for some help/advice on what to do. I bought an 03 xlt 1200 with 56hrs on the clock. Took it out for an hour and it ran great. The next week I took it out and it blew the PTO cylinder after about 2 hours of riding. Ski shut off and then would not turn over like the battery was dead. While trying to re start it i got a water temp alarm.

    Checked compression and got 120,120, and 30.
    I tore the engine down and found the PTO cylinder and piston are toast. So the apart i need help with is figuring out what caused it. Ski has 1/4 tank of treated fuel and the oil tank is half full. Oil line did not pop off and is not leaking. PTO cylinder was dry when I took the head off. The other 2 cylinders look perfect. powervalve did not drop in. Ski does have cat con but is in excellent condition not broken or clogged.

    Any ideas or things to look for?

  2. #2
    800AMSOIL4U's Avatar
    Join Date
    Aug 2006
    Morgan Hill, CA
    Rear seal went out or crap in the carbs. The head gasket is good? Post up some pics for us to help you figure it out.

  3. #3

    Join Date
    Aug 2015
    Here are some picsClick image for larger version. 

Name:	IMG_1274.jpg 
Views:	136 
Size:	66.5 KB 
ID:	367274Click image for larger version. 

Name:	IMG_1275.jpg 
Views:	125 
Size:	64.9 KB 
ID:	367275Click image for larger version. 

Name:	IMG_1276.jpg 
Views:	115 
Size:	64.9 KB 
ID:	367276Click image for larger version. 

Name:	IMG_1277.jpg 
Views:	128 
Size:	66.7 KB 
ID:	367277Click image for larger version. 

Name:	IMG_1278.jpg 
Views:	122 
Size:	64.8 KB 
ID:	367278

  4. #4

    Join Date
    Aug 2015
    here are some more Click image for larger version. 

Name:	IMG_1279.jpg 
Views:	123 
Size:	86.1 KB 
ID:	367279Click image for larger version. 

Name:	IMG_1280.jpg 
Views:	111 
Size:	58.7 KB 
ID:	367280Click image for larger version. 

Name:	IMG_1281.jpg 
Views:	221 
Size:	73.9 KB 
ID:	367281Click image for larger version. 

Name:	IMG_1282.jpg 
Views:	136 
Size:	60.8 KB 
ID:	367282

  5. #5

    Join Date
    Aug 2015
    Ok I finally got around to pulling the carbs. I opened them up and they look pretty good filters were not clogged and returns were not clogged. I believe the head gasket is ok since there wasnt any water in the engine or signs of it leaking. How can I tell if it is good? I had already pulled the cylinder so I wont be able to perform a leakdown test until I put it back together. I have a good used oem cylinder and piston to replace the bad one. Any tips or tricks for install? Once I get the head back on I will pressure test and post the results. I will try to make some time this weekend to get it back together.

    Any advice or comments would be appreciated

  6. #6
    Is that an indent in the top of the piston? Pretty sure I don't have that same indention on my pistons. Did the piston impact the spark plug? If that's the case then you could have had a bad wrist pin bearing.

  7. #7

    Join Date
    Aug 2015
    Yes there is a chunk of the piston missing. Spark plug doesn't look damaged so I don't think it hit. Either way I am going to replace the wrist pin bearing.

  8. #8
    TX21's Avatar
    Join Date
    May 2007
    North Texas
    Those ware marks on 4 corners like that mean (I think) the piston is too big.

  9. #9

    Join Date
    Aug 2015
    The marks on the piston are deep scratches and gouges. The engine is all original so I don't know why it would be too big.

  10. #10

    Join Date
    Aug 2015
    I got the engine back together and did a leakdown test. It was able to hold 6lbs for more than 6min. I sprayed down all the gasket areas with soapy water and didn't see any leaks. I will move on to the carbs next.

    Is there a way to test the oil injection pump?

    Is it a good idea to put an inline fuel filter after the water separator to keep the filters in the carbs from clogging up?

Page 1 of 2 12 LastLast

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Similar Threads

  1. 2002 XLT 1200 Blown Cylinder #2 Help! with Pictures!
    By TaulmanServices in forum Yamaha PWC Performance (2-stroke)
    Replies: 11
    Last Post: 08-28-2015, 07:12 AM
  2. 2002 Yamaha XLT 1200 Blown Motor Pics- Cause?
    By nightrider05 in forum Yamaha PWC Performance (2-stroke)
    Replies: 27
    Last Post: 10-27-2010, 11:24 PM
  3. WTB 01 xlt 1200 valved cylinder
    By SARTYSRNR in forum Yamaha Classifieds
    Replies: 3
    Last Post: 07-12-2010, 08:55 PM
  4. Factory carb settings 03 xlt 1200?
    By spham in forum Yamaha PWC Performance (2-stroke)
    Replies: 7
    Last Post: 05-19-2010, 09:56 AM
  5. yamaha xlt 1200 (i need help)
    By bscg1 in forum Yamaha PWC Performance (2-stroke)
    Replies: 18
    Last Post: 06-03-2009, 08:32 PM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts