2002 Yamaha 1200 XLT Known Problems? - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts

ZARDOZ · 09-01-2011, 03:05 PM

Hello. Recently purchased a used 2002 Yamaha 1200 XLT after my 2006 Sea Doo died when its timing chain broke. Sold the Sea Doo as-is and put the salvage value into the Yamaha.

My question relates to preventative measures. What are the known issues as to the 2002 XLT's performance and longevity? The known problems as I understand them to be are:

1. The oil lines are only held on with zip lines, and are prone to come off.
The prior owner of my XLT replaced the zip lines with metal clamps and then secured the clamp bolts with aircraft cable so they could not back out.

2. Power valve dropping into a cylinder. Is this when valves that are in the exhaust line protrude too far into the cylinder chamber and collide with the piston? The prior owner informed me that he had put limiters in valves in the exhaust line (power valves?) which prevented them from protruding too far into the cylinders. Is this a correct fix and something that Yamaha added after 2002?

3. Carb problems. Of an unknown nature to me. I would appreciate any additional information anyone may have on how to treat and prevent carb problems.

Are there any other problems/conditions I should be looking for, or any other preventative measures I should take?

Also, without a manual I cannot be sure, but would this machine want/crave synthetic oil? I'm considering switching to synthetic oil, however, I would like to know if synthetic oil is a must with this machine.

I appreciate any help anyone out there can provide. I hope this PWC will give me better service than the Sea Doo, which only gave me 17 hours of use before dying.

Ernest T · 09-01-2011, 05:14 PM

Sounds like the previous owner fixed 2 of the 3 problems (oil lines, and power valves). The fix for the powervalves involved putting a clip on the top of the valve to keep it from falling into the cylinder. You can remove the covers on the power valves and easily see if the clip has been installed. WaveEater Products

The other potential problem for that ski is that the catalytic converter tends to fail at around the 10 year point. You definitely want to stay with Yamalube oil if it still has the cat/con., because other oils will speed the failure. You should consider removing the cat/con and replacing with a "D" plate (this is how Yamaha sells the skis to overseas customers). Even with the "D" plate I recommend sticking with Yamalube oil. Their engines are designed to run on that oil, and I've seen enough problems with other oils used in their skis to advise guys to stay with the Yamalube.

Best preventative for carb problems is running non-ethanol fuel if available. I'd also recommend running Yamaha Ring Free Plus fuel additive. Other guys like Seafoam, etc.. Even with that you will still need to take the carbs apart, clean and rebuild them periodically. Stuff (varnish, etc.) will eventually build up in the carbs despite doing the above, plus the little springs, seats, needles, gaskets, and other parts in the carbs eventually wear out and need to be replaced.

You can download an owner's manual here: http://www.yamaha-motor.com/waverunn...r_manuals.aspx

ZARDOZ · 09-02-2011, 05:38 AM

Thank you Ernest T (is your last name "Bass"?). I really appreciate the information and will go out and buy some Yamalube today!

Could you direct me to any additional information about the "D" plate? The 10 year anniversary of my "new" PWC is here and it's about time for a cat/con replacement. Also, are there any sites which give directions as to the carb overhaul? I am somewhat mechanically inclined, and I do have a close friend who is a great mechanic, but directions are definitely a help.

I appreciate the link to the owner's manual. Is there any similar link to a shop manual? If I can't pick up a shop manual for free, are you familiar with a site where a shop manual can be picked up for a small fee?

Thank you again and your kind response is an example of the reason why these sites exist, so information and kindness can be exchanged. Have a great weekend, I hope to do so with my "new" 1200 XLT.

Ernest T · 09-02-2011, 10:10 AM

D plate: YAMAHA XLL / XLT (scroll down to Riva D plate and chip)
You may also need to install the chip on the exhaust sensor wire to prevent getting an overheat alarm. Here are the installation instructions: http://www.atlanticjetsports.com/ins...iva/ry1819.pdf

Here is where you can get carb rebuild kits and other parts: Model: XLT1200 -- SBT Jetski Engines, Parts & Accessories:

Here is a carb rebuild guide: http://www.shopsbt.com/pdfs/mikunisbn.pdf

I've got a 1997 service manual, but the ski changed so much between then and 2002 you are better off getting one for your model year. I've had pretty good luck with this guys manuals: Yamaha XL1200 LTD Waverunner Service Shop Manual PRO | eBay Just be sure it covers your model year.

Good Luck!