Page 1 of 2 1 2 LastLast
Results 1 to 10 of 19
  1. #1
    TaulmanServices's Avatar
    Join Date
    Aug 2015
    Location
    Orlando
    Posts
    128
    +1
    3

    2002 XLT 1200- Bone Stock to Basic Tune & Mikuni CARB Questions- HELP!

    Hi, My name is Nate. I have just purchased 2 x 2002 Yamaha XLT 1200s. I am an engineer so I am mechanically inclinded and have worked on many cars but not jetskis before. I have been reading all this information about the Mikuni BN44 carbs on this thread and I want to do a tune up on both jetski carbs as well as do the nessary upgrades as the jetskis are stock right now. I have the factory manual which shows the stock information:


    That being said I must first address what I have been reading are the required upgrades from stock :

    1.Replace Stock Battery with Deka 20XL 310 CCA- old battery sucks, $100 Amazon

    2.Wave Eater Clips & Couplers - prevents PV from coming lose
    $90 Amazon

    3.Oil Block Off Kit - Turns engine into Pre-Mix (32:1 or 40:1?) & removes dangerous oil lines falling off
    $20 Riva

    4.Carb Primer kit from riva- allows choke plate removal and easy start vs hard stock start
    $60 Riva

    5.Install D-Plate & Cat Chip - Removes garbage stock cat converter
    $100 Amazon

    6. Epoxy/Fiberglass Fortify Arch& Re-Install Pump Shoe Hull Inserts- Area weak on 1200GP units- same on XLT 1200s?
    $60 Amazon

    7. Rebuild Carbs-
    a. ISLAND RACING
    CARB JET KIT
    IR-CJK-66V $119.95 XL1200LTD / XLT1200
    Needles / Seats
    •High Jets
    •Low Jets
    •Springs
    •Acc. Pump B/O Kit
    b. ISLAND RACING
    CARB SOCKET BOLT KIT
    IR-CSBK-66V $19.95 Stock w/ Acc. Pump
    c.HIGH SPEED T-HANDLE ADJUSTER - XLL / XLT1200
    SA-300 $13.50
    d.LOW SPEED T-HANDLE ADJUSTER - XLL / XLT1200
    SA-200 $13.50
    e.3 X MIKUNI CARBURETOR REBUILD KIT
    MK-BN44I-YAM $56.95

    8. WSM FUEL FILTER 006-541 $13.95 - Replace old Fuel Filter

    END


    My question for you is after doing these items:
    1.these change will alter the jet size in the carbs yes?

    2.do I need to buy both the carb jet kit on island racing and the mikuni carb rebuild kit?

    3 do i need to get new needles as well? if so do i need to change the size of these? I read after the dplate install you do.

    4. deleting the choke plates- that happens when installing the primer correct?

    5. what are the list of tools needed to do the carb rebuild? I see this 2mm ball end allen wrench- lol i have never used or heard of a tool like that before.

    6. Also are there spare parts in addition to the carb kits that i will need for this job? - I see in the below thread he broke or lost some pieces when he was doing it. Maybe since its my first time doing this I should get some spare parts too. Especially those clear gasket pieces

    I see all the information but its kinda all over the place. I am going to follow what was done on here for these carbs but its missing the information above:

    Main Overview Article
    http://www.greenhulk.net/forums/showthread.php?t=130613

    Carb BN44 Rebuild
    http://www.greenhulk.net/forums/showthread.php?t=185410


  2. #2
    TaulmanServices's Avatar
    Join Date
    Aug 2015
    Location
    Orlando
    Posts
    128
    +1
    3
    Additional Upgrades- Post Nessary Upgrades:

    9. IR-L1-XLT1200 - This mod upgrades the entire proplusion system $629.95 R&D Rideplate, R&D Intake Grate, Solas Concord Impeller YF-CD 13/19, R&D Pump Seal Kit
    OPTIONS
    3M 4200 Fast Cure Sealant +$29.99
    10.Worx Sponsons +$273.00- Bolt to side of rear of jetski, help stabilize
    11. Yamaha 5 Degree Pump Nozzle ( w/ Reverse ) +$199.95- adds extra horse power
    DSS COUPLER REMOVAL TOOL
    TOOL61-5 $36.95
    DSS DRIVESHAFT HOLDER TOOL
    TOOL56 $21.95
    12.Exterior - HYDRO-TURF MATS
    HT784 $79.95
    13.Exterior -HYDRO-TURF SEAT COVER
    SEW785 $165.00 XLT1200 (01-04) / XLT800 (02-04)
    14. Exterior -HYDRO-TURF SPLASH GUARD
    TS03 $64.95
    ISLAND RACING

    15. Exhaust - FREE FLOW EXHAUST - XLT800 / XLT1200
    IR-FFE-Y-XLT $69.95
    16. Frame Support (Not Needed due to previous upgrade 6?) -ISLAND RACING
    HEAVY DUTY BRACKET KIT XLT PUMP SHOE
    IR-HDBK-XLT-PS $59.95
    16. Frame Support (Not Needed due to previous upgrade 6?)ISLAND RACING
    HEAVY DUTY BRACKET KIT XLT RIDEPLATE

    17. No Idea what this does???
    HOLESHOT KIT PRO
    IR-HSK-P $169.95
    18. Like Previous Pump - ISLAND RACING
    PUMP NOZZLE 5 DEGREE
    $199.95
    19. Flush Kit- ISLAND RACING
    QUICK CONNECT FLUSH KIT
    IR-QCFK-SE-B $54.95 ( Blue )
    20. Flush Kit-ISLAND RACING
    QUICK CONNECT FLUSH RELOCATION KIT
    IR-QCFRK-B $64.95 Blue
    21. ISLAND RACING
    SPARK PLUG INDEX WASHER KIT
    IR-SPIWK $24.95
    22.ISLAND RACING
    VF3 REED VALVE SYSTEM XLT1200
    $629.95 Kit
    23.LEO'S 2 DEGREE PUMP WEDGE
    LEO-PW2 $199.95
    24.NUJET IMPELLER
    YM-C60 $177.95 Stock / Limited 1200
    YM-C65 $177.95 Limited / Mod 1200
    25.PRO-TEC STEERING NOZZLE
    11-9443 $114.95 +12mm Silver
    26.PROK FLAME ARRESTOR KIT
    PROK-FAK-66V $199.95 XL1200LTD / XLT1200
    27.R&D ANTI CAVITATION CONE
    162-12003 $87.95
    28.R&D AQUEVEIN INTAKE GRATE
    112-12001 $169.95
    29.R&D HYDRO FORCE STEERING NOZZLE
    162-14000 $135.13
    30.R&D PUMP SEAL KIT
    162-00001 $73.45
    31. R&D RIDEPLATE
    122-12004 $199.95
    32.SOLAS BILLET IMPELLER CONE
    SLA009 $14.95
    33. SOLAS CONCORD IMPELLER
    YF-CD 11/14 $219.95
    YF-CD 12/18 $219.95
    YF-CD 13/19 $219.95
    34.SOLAS DRIVESHAFT HOLDER
    WR007H $14.95
    35.SOLAS IMPELLER TOOL
    WR007 $11.95
    36.WORX INTAKE GRATE
    WR216 $218.00
    37.WSM BEARING HOUSING ASSEMBLY
    003-400-01 $138.53
    38.WSM COUPLER SHAFT 003-255 $191.13 800 XLT / 01-05 XLT1200
    39.WSM DRIVESHAFT 003-181 $258.77 02-03 XLT800 / 02-05 XLT1200
    40.IMPELLER HOUSING W/ PLASTIC WEAR RING
    JPH508 $209.95
    41.REPLACEMENT WEAR RINGS
    JPH508RR $34.95

  3. #3
    remember, on the carbs it's 3x... so instead of $56.95 for the rebuild kit, it's $170.85... I think the same goes for the other carb parts.

  4. #4
    TaulmanServices's Avatar
    Join Date
    Aug 2015
    Location
    Orlando
    Posts
    128
    +1
    3
    yes I know- ok can you answer the questions above? Like do I need all of those carb parts- what are the jet sizes?

  5. #5
    quadzilla's Avatar
    Join Date
    Apr 2007
    Location
    LOCH NESS Monster-Land
    Posts
    1,178
    +1
    29
    Quote Originally Posted by TaulmanServices View Post
    yes I know- ok can you answer the questions above? Like do I need all of those carb parts- what are the jet sizes?

    Hey there taulman... (Nate)

    First things first... Welcome to the forum..

    Second..
    - Man, you really need to slow down just a beat or two..

    Holy fuck you'll be sending Carl (long Island Racing) On a Caribbean vacation if you buy all that SHIT..!! (lol at least twice)
    - (OK, to be fair it's not all shit, BUT you don't need very much of it just now)

    How many hours on these ski's.?
    Are they known to you. do you know if they've been well maintained.?
    Have any modifications been carried out previously.? catalytic converter been removed for example.?

    OH....
    "I see this 2mm ball end allen wrench"
    that's basically an Allen key that can swivel somewhat in the socket head of the allen bolt..

    this:.
    Click image for larger version. 

Name:	ALLEN KEY.jpg 
Views:	52 
Size:	12.1 KB 
ID:	368048

    .

  6. #6
    TaulmanServices's Avatar
    Join Date
    Aug 2015
    Location
    Orlando
    Posts
    128
    +1
    3
    hey there thanks for the response. ok so I am going to take pictures when I do all of this. I do not know the maintance history and non of these modifications have been done. one of the skis has a carb issue and needs starter fuild in to start it. the other has a new sbt engine according to the guy I bought it from and only has 5-10 hours. I got these and a trailer. I need answers to the above questions as if the compression test passes I am going to go ahead with the mods. My goal is to just have something reliable the unnessary upgrades can wait. I just want to do the required ones

  7. #7
    TaulmanServices's Avatar
    Join Date
    Aug 2015
    Location
    Orlando
    Posts
    128
    +1
    3
    thank you for the response- further questions after reading the mikuni carb manual and reading forums- there is no information on how adjustments on one carb affect the adjustments on the second or third? and also do I need to add t-pins for each high and low speed screw for all 3 carbs (this is if I go the FA option) which would mean 6 t-pins?

  8. #8
    Quote Originally Posted by TaulmanServices View Post
    thank you for the response- further questions after reading the mikuni carb manual and reading forums- there is no information on how adjustments on one carb affect the adjustments on the second or third? and also do I need to add t-pins for each high and low speed screw for all 3 carbs (this is if I go the FA option) which would mean 6 t-pins?
    You would need 6, but there are 3 "HIs" and 3 "LOWs".. and the HIs and LOWs are different. You don't NEED these, it just makes it a bit easier to make the adjustments, expecially considering how hard it is to get to the carbs to begin with.

  9. #9
    Quote Originally Posted by TaulmanServices View Post
    the other has a new sbt engine according to the guy I bought it from and only has 5-10 hours. ..... if the compression test passes I am going to go ahead with the mods. ....My goal is to just have something reliable
    You might want to do a bunch of searching in this forum before you dump a bunch of money into mods on the SBT engine. I don't have any personal experience, but others I know have (and others on this forum). The SBT might be fine for a 'stock' replacement, but you might be further ahead putting money into building a better engine for that one rather than a bunch of mods, and then lose the engine (just my opinion though).

  10. #10
    TaulmanServices's Avatar
    Join Date
    Aug 2015
    Location
    Orlando
    Posts
    128
    +1
    3
    Yes for mods i mean i just want to get the required stuff so the skis run well. which are the
    1. pump shoe area
    2. the dplate
    3. primer
    4. oil block off
    5. wave eaters
    6. rebuild carb

    i just want to get the thing running correctly. so i dont really need all 6 t-pins? how do you synchronize all three carbs if you make changes on one of them? do you start with the 1st and carry the changes through to 2 then 3 carb?

Page 1 of 2 1 2 LastLast

Thread Information

Users Browsing this Thread

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

Similar Threads

  1. Mukini SBNI 44 Carb POP OFF Issues Tuning 2002 XLT 1200
    By TaulmanServices in forum Yamaha PWC Performance (2-stroke)
    Replies: 8
    Last Post: 10-27-2015, 04:02 AM
  2. 2002 XLT 1200- Bone Stock to Basic Tune & Mikuni CARB Questions- HELP!
    By TaulmanServices in forum Yamaha PWC Performance (2-stroke)
    Replies: 4
    Last Post: 08-14-2015, 12:39 PM
  3. FS Sweet Deal now on Ebay-2002 XLT 1200 & 2006 VX110 Deluxe. low reserve.
    By VX110FireGuy in forum Yamaha 2 Stroke Skis
    Replies: 2
    Last Post: 11-25-2009, 06:10 PM
  4. 2002 XLT 1200 Issue
    By pooner in forum Yamaha PWC Performance (2-stroke)
    Replies: 2
    Last Post: 06-18-2009, 07:37 PM
  5. Stinger Removal in a 2002 xlt 1200
    By crownline99 in forum Yamaha How To & FAQs
    Replies: 5
    Last Post: 04-08-2009, 09:28 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
  •