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  1. #1

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    03 GP1200r - Need a bit of help.

    Hi Everyone, hope all is well.

    I recently acquired a beautiful 2003 Gp1200r with a blown engine. Rod bearing went on #1.

    Anyways, doing a complete rebuild and looking to keep everything stock.
    I need some help with a few things.

    Is there anyone that perhaps has a workshop/repair manual for the ski? I searched the forum but all the links I found was dead.
    Also, regarding power valves. Is each valve made for its specific cylinder? A cylinder jug that was swapped has no valve in it. Would a valve from a other cylinder fit properly?
    And finally, is there anything else that should be done to the ski for preventative maintenance?

    I'm in process of lubing the cables and a few other small things while I wait for parts.

    Thanks in advance!
    Last edited by YFZR750; 10-10-2016 at 10:42 PM.


  2. #2
    jeffg426690's Avatar
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    Jul 2015
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    Congrats on your new (to you) ski, welcome to GH
    Pm me your email address for service manual - or - http://bfy.tw/86Ms
    Power valves are the same for all jugs and common points of potential issue.
    Pm stuff:
    Power valve clips (wave eaters)
    Re-jet carbs with FA's
    D-plate to get rid of CAT
    Seal the pump shoe

    Create a build log, easy way for folks to help you along the way

  3. #3
    mudslanger's Avatar
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    Do you actually have a 03 1200r? The 03 were 1300r look at the last 2 digits of the HIN for the year and does your engine have carbs or fuel injection. Post some pics of the ski and engine.

  4. #4

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    Thanks for the warm welcome Jeff, p.m sent, I would post a few pictures soon. I had a look in the exhaust and I noticed it does have a D-shaped opening in it so im guessing it has been fitted or probably came out with it this side of the world. Will read up on the other points you mentioned.

    Mudslanger, yes thats what I checked before I bought it. It clearly states 03 at the end of the H.I.N at the end of the ski. Will post pictures soon. It has carburetors on it, similar to the 97 gp1200. Its a White ski with blue stickers.

    Another question I have is, the original cluster took on salt water and has some serious corrosion in it. Theres no way I can afford getting it from Yamaha and nothing on ebay. Can I fit 3 individual clocks on this ski like I did with my older Gp1200? Im assuming not as it seems a bit more computerised than the older one? Picture in third post: http://www.greenhulk.net/forums/show...er+alternative

    Thanks!

  5. #5

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    Click image for larger version. 

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    Here's a few pictures. All the (WSM) pistons are toast, one has serious damage to the top, the others have scratches on the skirts. Oil starvation? I will be going premix. There is only one cylinder that is fine. And there's light marks on it. Very, very slightly can be felt.
    I have searched but couldn't find any solid info to this, would resleeving all 3 cylinders with a steel liner be an option? Its going to be a standard ski. If its advisable, im guessing a different clearence should be used? Going to use a new set of WSM pistons.
    Thanks in advance

  6. #6
    Mike's GPR's Avatar
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    Your ski sounds like a 2002 GP1200R.

    My avatar is a 2003 GP1300R

  7. #7
    jeffg426690's Avatar
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    You can use a gauge from an xlt as well, easier to find and less $

  8. #8

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    Hi all.
    Hope all is well around the world.


    Decided to go again with 3 individual guages for rpm, temp and fuel level. Will do a build thread on that.

    I recently got my crank back, one of the rod bearings suffered severely damage. Looks like the cage broke and the needles started climbing. And in turn ovalised the big end resulting in lockup.

    My question is, what causes such damage? And also what causes the deep scoring on the pistons?

    I would like to avoid all of that in future so would like to have and idea. My thought was that sea water got into the engine and it stood, rusting the bearing. And then someone managed to start it And the rust started destroying the bearing when the engine started?
    And I can only assume the scoring on the pistons was caused because that it ran without oil for a time?

    Many thanks and best wishes!

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