1200pv rebuild tips?

[Jolly Roger]

Okay, I've never rebuilt a high-performance 2stroke before, so...
Could you guys give me some tips?
2001 XA1200A (it's an XLT 1200pv)

I know I should be /very/ concerned with the lower crankcase seal being air tight.

What about bearings, etc? Should I be generous with the assembly lube, or just squirt them with a shot of 2 stroke oil?

Any other tips here and there you guys have for me, let me know

[RX951]

Hello, welcome to the forum. sorry for the late reply. I'm heading off to work, this thread below will save me alot of typing.

http://www.hydrotoys.com/gpr/tuners/...neAssembly.pdf

All I can say is be very meticulous when reassembling the motor.

* when assembling the cases, clean the curfaces very well with acetone or with alcohol. Use 1211 to seal the cases. Make sure you don't plug the oil return holes with 1211 when assembling the crank seals.

* Also use a childs medicine syringe or turkey baster to apply 2 stroke oil in the oil holes in the case after the case halves have been assembled. Also squirt liberal amounts of oil in the bearings all thru out the crank to ensure good lubrication is coating the bearings upon assembly and on the first crank.

again, read that link I posted, very good info !

gotta run...

[Jolly Roger]

those are good pictures, but it's not very well written. I'll take what I can from it..

Anyone else have any suggestions?

[jeffsntx]

those are good pictures, but it's not very well written. I'll take what I can from it..

Anyone else have any suggestions?

It doesnt get any clearer than the link that RX951 posted. Fercho knows what he is doing.

And like he said CLEAN CLEAN CLEAN is the key.

[RX951]

those are good pictures, but it's not very well written. I'll take what I can from it..

Anyone else have any suggestions?

Also look in my signature and download you a copy of the SERVICE MANUAL to your harddrive. There are important torque specs that are necessary when reassembling the motor.