2004 XLT 1200 rear cylinder dropping out - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts
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post #1 of 20 (permalink) Old 05-07-2019, 10:20 PM Thread Starter
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2004 XLT 1200 rear cylinder dropping out

Purchased a 2004 XLT 1200 in February- had been winterized, power valve servo recently replaced, and cat d-plate kit installed, new spark plugs.

Ran great first two weekend outings, then this past weekend while running at speed RPM drops to 4000 rpm at WOT. Back at the dock a simple feel of the cylinder head indicated that rear cylinder had dropped out- it was warm while others were hot to the touch.

Pulled the spark plug and it was wet. Cleaned and dried the plug, back on the water and all was good for about 100 yards of running and then same thing. I have repeated this twice now.

Servo is actuating the power valves during cranking and power valve on rear cylinder is ok.

Suspicion at this point is coil pack, but would a coil pack fail intermittently? Any suggestions on what to check next?
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post #2 of 20 (permalink) Old 05-08-2019, 03:45 PM
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How many hrs on the ski or motor?
Have you checked compression on that cyl?
Is it still oil injected? If so check around in the bottom of the hull for oil. The line to the rear carb may have come off.

With this being an 04, I'm just betting the oil lines have never been replaced. And are quite hard and shrunk up and pulled off.
Of course this is just theory at the point based on experience.
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post #3 of 20 (permalink) Old 05-08-2019, 05:02 PM Thread Starter
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Thanks Dave for the reply.
I should know the hours, but I'm going to have to check to be sure. The ski is at my weekend place and I'm nowhere close for the next few days.
Compression on that cylinder is 120psi- consistent with the other two.
Still oil injected.

I'm new to PWC's so I welcome info on things such as brittle oil lines, etc. I know engines in general but the nuances of oil injected 2-strokes are new to me.
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post #4 of 20 (permalink) Old 05-08-2019, 11:45 PM
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The oil injection is pretty much bullet proof if properly maintained. That maintenance includes replacing the hoses from the pump to carbs every couple years. This is the systems weak link. As I said they get hard and shrink and break.
The pump is a variable ratio pump. Connected to the carbs by cable. At idle it's around 200/1. Helps keep from fouling plugs in low speed zones, and saves oil. At wot it's around 30/1. It also has a safety feature if the cable fails it opens up and over oils to save the motor and make you aware of issue.

Last edited by Dave in DE; 05-09-2019 at 12:05 AM.
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post #5 of 20 (permalink) Old 05-09-2019, 12:03 AM
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What's the compression on all 3 cyl's?
There's two possablities for your issue if that cyl is ok. It's either spark related or fuel. Fuel over delivery could be clogged fuel return orifice in carb, stuck needle valve. Or carb pop-off set wrong. Electrically it could be the ignition coil. Or the lighting coil that signals your ignition coil.
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post #6 of 20 (permalink) Old 05-09-2019, 05:07 PM Thread Starter
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I will definitely inspect the oil injection hoses first chance I get.

All 3 cyl show 120psi. I feel pretty good about the condition of the rear cylinder because just before that cylinder starts dropping out the ski runs like a scalded dog.

Can you get to the coil signal wire connectors from outside the electrical box? If so and the #3 hi-volts wire will reach to #2 cyl I thought I would try to swap #2 and #3 coils and see if the problem moved to #2 cylinder.

If not I guess I remove the electrical box to get to the coils? Can you pull the electrical box without removing other parts (exhaust, etc.)

I figure this will be an easier check than the carbs so do it first.
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post #7 of 20 (permalink) Old 05-10-2019, 06:34 AM
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Dock
Just for giggles, try a new plug, and trim the plug wire about 1/2".
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post #8 of 20 (permalink) Old 05-10-2019, 10:18 AM Thread Starter
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Quote:
Originally Posted by rodsatheart View Post
Just for giggles, try a new plug, and trim the plug wire about 1/2".
Quick and easy- I'll give it a try.
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post #9 of 20 (permalink) Old 05-10-2019, 10:16 PM
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Quote:
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Quote:
Originally Posted by rodsatheart View Post
Just for giggles, try a new plug, and trim the plug wire about 1/2".
Quick and easy- I'll give it a try.
Good thought Rods.
Yes, you can access the E box without removing the exhaust. And yes the coil charge wire connections are inside.
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post #10 of 20 (permalink) Old 05-21-2019, 09:51 PM Thread Starter
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Sorry for the delayed response. I have this pesky distraction called my job that has kept me away from troubleshooting.

My 2004 XLT is equipped with the crimp-terminal plug wires- not the type with screw-on boots. Since changing the plug wire required removal of the electrical box anyway I changed both the rear cyl plug wire and coil pack. Took the ski out for a test run- some warm-up laps around the cove and then WOT in the open water. For about 1 mile all seemed good at 7000rpm then when blasting back into the cove the RPM drops to 5000 rpm. Problem is back. I did notice that during half-throttle running there seems to be some "skipping" heard in the exhaust.

I can get WOT 7000rpm momentarily if I idle, move the fuel valve to OFF, let the engine starve and shut off, then move valve back to RUN, start the engine and go.

I'm thinking at this point I have fuel delivery or contamination (water) issue. Maybe siphon the fuel in the tank, replace with fresh, and replace the fuel filter?
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