xl 1200 non pv starter change - PWC Forum: The best hang-out for Personal WaterCraft enthusiasts
 
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post #1 of 6 (permalink) Old 08-06-2019, 08:43 AM Thread Starter
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xl 1200 non pv starter change

Anyone changed a starter on an xl1200 recently with engine in place? I think I need to remove the exhaust but hoping I can do it with exh manifold in place. I have done plenty of them with engine out as I always put in a new starter before installation but engine on this ski is in good shape just stuck/corroded starter.

Hol
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post #2 of 6 (permalink) Old 08-06-2019, 04:49 PM
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Originally Posted by ugmw177 View Post
Anyone changed a starter on an xl1200 recently with engine in place? I think I need to remove the exhaust but hoping I can do it with exh manifold in place. I have done plenty of them with engine out as I always put in a new starter before installation but engine on this ski is in good shape just stuck/corroded starter.
Yes, they can be changed without taking the exhaust off. It may not be easy, but it can be done. You definitely don't have to remove the motor.
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post #3 of 6 (permalink) Old 08-06-2019, 06:31 PM
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It is a bear with the exhaust on. Try to get a "mental picture" and feel around for the bolts that hold it to the case. On my XLT 800 (PV) they were different sizes. Try to get at it from all the angles to see what works best. An army of long, short, wobble, and U joints should help you attack it without removing the exhaust. If you get stuck, have a beer, then comeback at it, worked for me, found an angle that worked for me. Follow Dave's advice, he is the resident Yamaha Wikipedia.
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post #4 of 6 (permalink) Old 08-07-2019, 01:11 PM Thread Starter
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Thanks. I think I will remove the stinger...hopefully that will make it easier...adds extra $25 for the gasket where the u and the manifold meet but worth it I think. At least I have the bolt sizes ect. memorized. I recall just getting the hot attached to the starter lug was a big enough pain last time I changed one.

now just hope that the starter is not "stuck" in the hole...corrosion and swelling o ring tend to make these things fun to pull.

Hol
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post #5 of 6 (permalink) Old 08-12-2019, 09:38 AM Thread Starter
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Just to follow up. I pulled the U pipe and upper exhaust. [that was fun]. It was still an exercise in reaching around and feeling my way to the bolts but since I knew what to feel for it was much easier. Anyhow, pulled and replaced it in about 30mins. The exhaust r&r was probably 2-3hours. I then replaced the starter relay as well. [another hour just due to the location of the box and corrosion on the securing bolts for the cover. Buttoned it up and started it up.

Thanks for the tips. BTW, not sure how anyone could do the starter on this boat without removing the exhaust.

Hol
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post #6 of 6 (permalink) Old 08-12-2019, 10:14 AM
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Glad you got it done. That's great. You can replace starter without exhaust removed but it's not easy. You cuss a bit walk away for another beer 😂😁 that sort of stuff.
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