Page 1 of 2 1 2 LastLast
Results 1 to 10 of 11
  1. #1

    2003 GP1200 Engine Rebuild/Exchange - advice needed

    Hi, I'm new here having bought a 2003 GP1200 2 weeks ago with 154hrs on it. I did a compression test after I bought it approx 95-98psi in all 3 cylinders. It ran fine for 14hrs over the xmas break until it now has a bad engine rattle. Did another compression test today, 1 & 3 are still 95-98, #2 nothing. I'm curious to know how much it would run into to rebuild. I'm tossing up between rebuilding & just going with an exchange engine with 12mths warranty. Mine is a 67X, what are they like?
    P.S Ski is still running oil pump. Should I block this off & run premix?
    With the jetski now having 168hrs on it, what else should I be repairing/replacing whilst I have the engine out?
    Regards Mick


  2. #2
    Any suggestions on what else I should be doing to a ski with 168hrs would be appreciated. Thanks

  3. #3
    Looks like I found the where the engine rattle was coming from. Failed middle cylinder big end bearing. Will post photos & video once I get them uploaded from my phone.
    Now, can someone please explain likely causes & what I need to do to ensure it doesn't happen again. I'm thinking I'll replace the engine with a rebuilt exchange unit from Jetsport Southport, QLD Australia. Figure I should also have the carbies rebuilt/replaced as they may have been a contrubiting factor??? Should I then also block off the oil injection & run 40:1 premix??? What else should I be doing to a 2003 ski with 168hrs on the clock whilst the engine is out?

  4. #4
    Myself's Avatar
    Join Date
    May 2007
    Location
    North Central Arkansas
    Posts
    3,194
    +1
    172
    I'm betting you'll find the oil injector line not connected to that cylinder anymore. Common issue, they shrink up and pull loose.

  5. #5
    Mpeavler's Avatar
    Join Date
    Dec 2005
    Location
    Anderson, Indiana
    Posts
    5,260
    +1
    185
    It's always #2 or #3 oil line that falls off and or lack of rebuilding the Ibody 44's resulting in a lean condition and boom. Keep in mind these were 'Emission" series carbs....ran so lean they needed a accel pump to make it even go at all from the factory.

    M

  6. #6
    Quote Originally Posted by Myself View Post
    I'm betting you'll find the oil injector line not connected to that cylinder anymore. Common issue, they shrink up and pull loose.
    No, all oil lines were in place & appeared to be in good condition

  7. #7

    This is the failure on the bigend bearing on the middle cylinder.

  8. #8
    Mpeavler's Avatar
    Join Date
    Dec 2005
    Location
    Anderson, Indiana
    Posts
    5,260
    +1
    185
    Then it's likely it ran lean and fried it. I put in at least 10-15 66v and 68x engines each year from oil line or from running lean .

    To be on the big end .. I'd question water injestston or from someone not letting off going in/out of chop and tweaked the crank /bearings

  9. #9

    I'm after opinions on what caused this & what I can do to ensure it doesn't happen again to the exchange engine when I put it in.
    Thanks
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

Name:	20170104_184452[1].jpg 
Views:	122 
Size:	81.7 KB 
ID:	405065   Click image for larger version. 

Name:	20170104_225925[1].jpg 
Views:	119 
Size:	89.1 KB 
ID:	405066   Click image for larger version. 

Name:	20170104_225951[1].jpg 
Views:	121 
Size:	51.3 KB 
ID:	405067  

  10. #10
    Ok, I have just received my engine back from being rebuilt. Just downloaded the service manual & now see that it states that all the exhaust gaskets are not reusable. Do I need to buy all these gaskets or am I ok to reuse them? If reuse, do I need any sealant, if so what do I use?
    Thanks

  11. +1 by:


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. 98 GP1200 Engine rebuild questions
    By smitch in forum Yamaha PWC Performance (2-stroke)
    Replies: 8
    Last Post: 10-02-2017, 08:05 PM
  2. gp1200r engine rebuild , need help/advice
    By m4c13k in forum Yamaha Projects & Build Threads
    Replies: 5
    Last Post: 04-23-2013, 07:53 PM
  3. 03 GTX SC engine Rebuild Need Some Advice
    By vdiddy95 in forum 4-Tec Performance
    Replies: 2
    Last Post: 06-13-2012, 09:35 PM
  4. 97 Gp1200 Engine Rebuild
    By CDW78 in forum Yamaha Old School Skis
    Replies: 7
    Last Post: 04-18-2011, 09:57 AM
  5. Engine rebuild advice needed FX HO
    By xRXPMike in forum Yamaha PWC Performance (4-stroke)
    Replies: 1
    Last Post: 08-03-2008, 06:15 AM

Posting Permissions

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