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  1. #1

    Yamaha 1200 XL Limited (1999) Rebuild

    I am rebuilding a Yamaha 1200 XL Limited with Powervalve Engine. I purchased it with a blown engine with 130 hours total on the ski. I think it had a oil system failure. The piston closest to the starter dropped a skirt and it blew a hole in the side of the upper crank case. The cylinder was damaged beyond repair. All 3 pistons showed scarring on the sides. One cylinder looks fine, I had to buy two re-plated cylinders and a crank case.
    Here is my plan:
    • Replace crank case with used one.
    • Replace all 3 pistons with cast pistons and new wrist pin bearings.
    • Rebuild and clean all power valves and install keeper clips.
    • Rebuild all 3 carbs with genuine Mikuni carb rebuild kit.
    • I am not replacing needle valves since it is such a low time ski.
    • Block off oil system and go with pre-mix.
    • Install new top end gasket kit.

    Right now I am at about $1000 in parts. I really don't want to spend much more. Is there anything else I should do while I have the engine out? Any advice on parts. Here are some pics of the damage:
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  2. #2
    Here are the pistons I am looking at. Anyone have experience with these? The seller says he sold hundreds without complaints.

  3. #3

    Yamaha Piston Kit on Ebay.


  4. #4
    jeffg426690's Avatar
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    I'd strongly recommend getting your cyclinders in your hands first, getting them mic'd by a shop (local bike shop can do it), and then order pistons accordingly. There are 4 OEM piston sizes (A,B,C,D) that vary a few hundred thou from each other.
    D/l the service manual and you'll find the specs your looking for.
    Would also consider rejetting the carbs via the OsideBill recipe in the how-to's. At the very least do the return mod

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  6. #5
    butterbean_29512's Avatar
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    I ordered a WSM Platinum complete top end kit from Jet.com for like 240. Some don't like them, but I personally like the WSM products. Have not had any problems with them, I have rebuilt 2 66v's using them. Both run great.

  7. #6
    Quote Originally Posted by butterbean_29512 View Post
    I ordered a WSM Platinum complete top end kit from Jet.com for like 240. Some don't like them, but I personally like the WSM products. Have not had any problems with them, I have rebuilt 2 66v's using them. Both run great.
    I wanted to get those, but they only come over bored. It looked like a great value kit.

  8. #7
    What is the return mod? Also some bypass the cat for better performance, but I don't need that, is there any other reason to bypass it? Mine apparently was rebuilt before because the power valves have the lever links installed. I am a very experienced wrench turner, (former Jet Engine Mechanic), but 2 stokes are new to me, so I don't understand a lot of the lingo on this site yet. I am using the service manual from 1997.

  9. #8
    jeffg426690's Avatar
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    The return mod is in the How-to's stickies along w explanation of what and why, very easy to anytime you are in the carbs.

    The Cat removal is not a performance thing at all, it's PM. They tend to break apart and clog up the exhaust causing all kinds of issues, one of the first things to be done if it has not already been done. Cat gets replaced w a D plate to maintain the same back pressure as w the cat, the 'chip' goes where the exhaust temp sensor plugs in to fool the CDI with a resistance that keeps it happy and from alarming w the cat removed.

  10. #9
    butterbean_29512's Avatar
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    Quote Originally Posted by egraffius View Post
    I wanted to get those, but they only come over bored. It looked like a great value kit.
    Dig a little....both of mine were standard size.

  11. #10
    What 2 cycle oil is best to use for this machine and what grease do I use when assembling the engine. I see blue/green looking grease on some of the pics of rebuilds, what is that and where do I get it?

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