2003 Yamaha XLT1200 oil line problem - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts
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Old 03-24-2012, 11:41 AM   #1 (permalink)
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Default 2003 Yamaha XLT1200 oil line problem

Is there as way the make the oil injection system on these more safe to use? I have already lost cylinder 3 because of an oil line that fell off the carb. Premix looks like a hassle, is there a kit out there, or some way of making the oil injection system safe to use so this doesn't happen again?
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Old 03-24-2012, 02:45 PM   #2 (permalink)
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The failure point is the oil lines about 90% of the time. I guess there are other failure points, but you never hear about them. So, I'd say there are 2 ways to make the system safer:
1. Replace old worn, or brittle oil lines with new ones.
2. Make sure the lines are securely attached. Inspect the lines periodically. Yamaha uses zip-ties for the oil and fuel lines. I've never liked that system, since they can break or simply loosen and come off over time. You might want to consider replacing the zip ties with small hose clamps.
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Old 05-04-2012, 12:23 PM   #3 (permalink)
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I just found out about this problem, and would like to make sure my lines are secured. What do I have to take apart to inspect them? Does anyone have any pictures or guides, I want to take the time to inspect mine so that I dont have any damage done to the engine. Thanks
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Old 05-04-2012, 02:12 PM   #4 (permalink)
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Originally Posted by theroofable View Post
I just found out about this problem, and would like to make sure my lines are secured. What do I have to take apart to inspect them? Does anyone have any pictures or guides, I want to take the time to inspect mine so that I dont have any damage done to the engine. Thanks
I think you would have to remove the exhaust pipe to examine the lines coming off the carbs. thats the only way you can see them, but theyre in plain sight without the exhaust.
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Old 05-04-2012, 04:52 PM   #5 (permalink)
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I think you would have to remove the exhaust pipe to examine the lines coming off the carbs. thats the only way you can see them, but theyre in plain sight without the exhaust.
How involved is exhaust removal. Sectional or one piece? I guess ill have dive in and start removing some bolts.
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Old 05-04-2012, 05:20 PM   #6 (permalink)
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How involved is exhaust removal. Sectional or one piece? I guess ill have dive in and start removing some bolts.
some of the bolts are tough to get to but its not that bad. its sectional pieces.
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Old 05-04-2012, 06:06 PM   #7 (permalink)
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Which side will give the best access? In the seated position, looking down at the engine, the left side or right side with the plastic cover? Thanks for the help! Here is a picture I snapped.

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Old 05-05-2012, 10:03 AM   #8 (permalink)
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the carburetors are under the right side with the plastic cover. opposite from the exhaust manifold.
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