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Hello from the NJ shore. I am new ( and I mean new, like I rode a jet ski about 20 years ago new) but not new to being on the water.
My years of tuna fishing has been put on hold, with family commitments but I recently picked up a 2003 Yamaha XLT 1200 for the price of gas to pick it up. It is going to be a winter project that my kids can get some use out of next summer

I was told that the starter was bad, but after an afternoon of digging in, naturally the engine is locked up. I plan to pull the engine in the next couple of weeks.


My initial questions concern reputable companys that rebuild engines.

Also the reliability of the oiling system. What are it's shortcoming if I was to keep it intact?

Thanks in advance for what I am sure will be the first of many stupid questions.
 

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Hello from the NJ shore. I am new ( and I mean new, like I rode a jet ski about 20 years ago new) but not new to being on the water.
My years of tuna fishing has been put on hold, with family commitments but I recently picked up a 2003 Yamaha XLT 1200 for the price of gas to pick it up. It is going to be a winter project that my kids can get some use out of next summer

I was told that the starter was bad, but after an afternoon of digging in, naturally the engine is locked up. I plan to pull the engine in the next couple of weeks.


My initial questions concern reputable companys that rebuild engines.

Also the reliability of the oiling system. What are it's shortcoming if I was to keep it intact?

Thanks in advance for what I am sure will be the first of many stupid questions.
Hello Chris996, welcome aboard.

Have you considered rebuilding it yourself? Not the difficult if mechanicly inclined. with a factory manual.

One word of advice steer clear of sbt's motors. There Parts are ok but there motor quality is not there.
Pwcengines is much better. Same basic pricing/warranty as sbt. A much better option and quality.

The oil injection system is pretty much bulletproof if it's maintained. Basically replacing the pump to carb lines every few years. The hoses are the weak link not the pump. The nice thing about keeping the injection system in tact is you'll use less oil as they are a variable ratio pump. 200/1 at idle, saving fouled plug. Up to 30/1 at full throttle. needing to carry oil separately is messy. A tank of oil will last for 5 to 6 fuel tanks. Allowing for fill ups at a marina without needing to add oil.
I would pull and clean the oil tank once the motor is out. The sending unit is also the filter and should be removed, cleaned and new seal installed. Quite a bit of sludge and debris end up in the tanks after all these years.

No such thing as a stupid question.

You can find new factory parts and schematics at Babbittsonline or Partszilla. Select OEM parts, Yamaha, pwc's, year, model.
After market parts at Riva racing, wsm, sbt, and a slew of others.
 

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Discussion Starter #3
Thanks Dave in DE for the welcome.


I have thought about doing the rebuild myself. Besides time, my concern is the shape of the cylinders themselves. They are in rough shape with no deep gouging but assuming they are Nic coated, I cant hone them.


The least expensive cylinders that I have found are roughly $500 a piece. 3 of them puts me close to the pricing I have seen for a rebuild? Unless I am not looking under the right rocks?


Thanks for the info on the oiling system. Sounds like what is in the Yamaha HPDI outboard.
 

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Thanks Dave in DE for the welcome.


I have thought about doing the rebuild myself. Besides time, my concern is the shape of the cylinders themselves. They are in rough shape with no deep gouging but assuming they are Nic coated, I cant hone them.


The least expensive cylinders that I have found are roughly $500 a piece. 3 of them puts me close to the pricing I have seen for a rebuild? Unless I am not looking under the right rocks?


Thanks for the info on the oiling system. Sounds like what is in the Yamaha HPDI outboard.
Chris,
Rather than repair that cyl, you can buy an entire top end exchange kit from wsm performance. It's 3 sleeved cyl's, pistons, and gaskets. I think around $700/800.
If the base is solid I'd go this route. Just need to flush out the base with mineral spirits to get any alluminum from pistons/cyl out.
 

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Ha! I was just going to ask about the cylinder exchange. Dave, you’re the best.

Looks like you keep some pretty late hours. I’m a UPS tractor trailer
driver. Hope it’s not work keeping you up this late
 

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Ya, I'm up late getting into my night shift work mode. Starting my night shift tonight. I'll sleep in a bit this am. I work a weird schedule. 2 on 2 off. 13hr shifts. Switching back and forth, days/night when you go back.

SBT also sells a top end exchange kit. I've used them there about the same price range. I prefer Wsm you can select different piston brands, like wisco, and proX or wsm witch is basicly OEM.

Again, I won't used sbt motors but there parts aren't bad. There cyl's are decent and I haven't had any issues with them. They only offer there brand of OEM pistons though. Happy Driving.
 

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Ha! I was just going to ask about the cylinder exchange. Dave, you’re the best.

Looks like you keep some pretty late hours. I’m a UPS tractor trailer
driver. Hope it’s not work keeping you up this late
DAVE IS THE MAN!!!!

Chris, Dave and I are actually rebuilding same year XLT's just 800's (one less cylinder). I have a build thread around here somewhere if it helps you any. If you have the time, rebuild yourself, it is a ton of fun and with guys like Dave in this forum, they are worth their weight in gold when it comes to knowledge and helping. I'll be happy to assist in any way I can. Welcome to the club!
 

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DAVE IS THE MAN!!!!

Chris, Dave and I are actually rebuilding same year XLT's just 800's (one less cylinder). I have a build thread around here somewhere if it helps you any. If you have the time, rebuild yourself, it is a ton of fun and with guys like Dave in this forum, they are worth their weight in gold when it comes to knowledge and helping. I'll be happy to assist in any way I can. Welcome to the club!
I appreciate it T-Bones

I will look over your rebuild, thank you.

As luck would have it, seems as though I will be picking up another XLT 1200 in need of an overhaul, because I guess one just isn't enough?:dunno:
 

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Chris, misery loves company so they say. I did the same bought an 01 grp that needed full overhaul. Lost an oil line. Was still working on it and bought an 02 that needed a lot of TLC. That was 3 years ago haven't looked back yet.
So I say, go for it.
 
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