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  1. #1
    XLTNoob
    Join Date
    Jul 2007
    Location
    Baytown, TX
    Posts
    400

    XLT 1200 lean seizure rebuild (With Pics!)

    Okay guys, this is becoming an issue, so I'm taking the time and the money to do it right!

    Finally finished recieving my three carbs, all three pistons and my replacement cylinder in the mail today.

    So far, this is the work plan:

    Step 1: Take my pistons down to a local industrial valve remanufacturing place, and have them mic my pistons. DONE

    Step 2: Take my cylinders to a friendly local PWC enthusiast, and refresh the hatching. (Any takers? should take but 10 mins.) DONE

    Step 3: Re-Ring the pistons with new rings. DONE

    Step 4a: Verify and set jetting on replacement carbs. DONE

    Step 4b: Clean up mating surfaces of: reed stuffer backing plate, reed stuffers, case where cylinders mount.

    Step 4: Pressure test the crankcase. (Will also need help with this one)

    Step 5: Remove old carbs, pull old reeds and inspect

    Step 6: reinstall reeds.

    Step 7: Verify jetting on new carbs, and reinstall


    So far, that's all I've got. Anyone have a little bit of time to spare local to Baytown, TX that can help me with step 2?
    Last edited by Jolly Roger; 07-05-2010 at 08:55 PM.


  2. #2
    XLTNoob
    Join Date
    Jul 2007
    Location
    Baytown, TX
    Posts
    400
    Pics as promised.



  3. #3
    XLTNoob
    Join Date
    Jul 2007
    Location
    Baytown, TX
    Posts
    400
    Got the last of my parts in today - WFO did a great job refreshing the hatch on my cylinders.

    Pics coming soon - BUT
    Reeds look great. Only one with a small chip in the corner. I will need a new intake gasket (the one that goes behind the carbs). While I'm at it, I'll probably go ahead and order a few base gaskets.

    And my old tube of Yamabond is hard. Will need a new tube of 1211 to replace it.

  4. #4
    XLTNoob
    Join Date
    Jul 2007
    Location
    Baytown, TX
    Posts
    400
    Pulled and verified my jets out of the old carbs.

    Stock 1200 PV engine - D-Plate, & Flame Arrestors, choke plates intact:
    125 Mains
    110 Pilot
    1.5 Needle & seat
    95g spring
    (FYI, these mods with choke plates intact should have been 120 mains)

    OsideBill's suggested jetting (new carbs do not have choke plates):
    125 Mains
    110 Pilot
    1.5 Needle & seat
    95g spring


    Looks like my new carbs are good to go!

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