rebuild or not - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts

Scott1200 · 01-06-2012, 12:20 PM

I have a 2003 Yamaha xlt 1200 with 270 hrs, my question is, a Yamaha mechanic said the motors usually get ~250 hrs before they go. My pwc has some pretty hard hours on it, kids pulling tubes, etc. Am I on borrowed time, should it be rebuilt and what needs to be done?

Ernest T · 01-06-2012, 03:48 PM

Check the compression and rpms the engine is running at. Ideal would be: 120 psi per cylinder and running at 7080 rpms. If you are close to those numbers, then pat youself on the back, because you are in a relatively small group of people that can get close to 300 hours on a 1200 without a rebuild. If you are close to ideal numbers, forget the rebuild and keep doing whatever you have been doing.

The further the compression numbers are from ideal on one or more pistons, the closer you are to a rebuild. Good news is that if you do need a rebuild, it will only require a top end kit at this point, so not too expensive.

98yota · 01-06-2012, 05:46 PM

Once you verify compression is good and you still have good hard pulling motor it's best to just let it go and ride the thing. I usually go by "if it works, don't fix it." once your in the high hours, habitually check the compression, and as stated before once the numbers fall and performance is noticeably reduced, then you can rebuild the top end.

Scott1200 · 01-09-2012, 07:31 AM

Thanks, I checked the compression in mid summer when the converter was pulled out and it is 107 in two cylinders and 110 in the third. Looks like I should start shopping for a rebuild kit. Any suggestions for a kit?

Ernest T · 01-09-2012, 03:59 PM

Those numbers are not bad. I'd say you still have some time on that engine before a rebuild in mandatory. SBT is probably the biggest seller of kits: Model: XLT1200 -- SBT Jetski Engines, Parts & Accessories:

WSM also sells a kit. You can find them at a number of places including Ebay. When you get ready to do it look at the cylinders. I doubt you need to replace or re-plate them at this point.

There are other kits out there. I don't know that there is a big difference until you get to the point that you have to replace a cylinder. Then my recommendation is to send the cylinder off to have it re-plated rather than replacing with an aftermarket.