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  1. #1
    dewzee1200's Avatar
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    2000 GP1200r rebuild after oil pump JOINT connector failure

    I will be rebuilding the GP1200r engine shown in the pics below after the joint connector [part #2 in diagram] came off oil pump with 26 hours on the meter. I am looking for a dependable ski not interested in major engine modifications yet.

    Work completed so far
    Complete disassembly
    Obtained used crankcase with matching top& bottom
    Obtained used cylinders
    Obtained WaveEater PV upgrade kit
    Clean-up of flywheel and stator
    Shipped carbs to OS Bill for rebuild and addition of primer ETC
    Oil pump block off planned AND will be running premix
    Obtained pressure test kit from Lowell Horning

    I would appreciate feedback on the following:
    What to do about crankshaft ? #3 cyl bearings and rod are not within specs
    Piston, rings, pins ETC - suggestions on best value ?
    Reeds ? - all appear undamaged but #3 is covered in grime

    Thanks in advance for assistance

    Click image for larger version. 

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    I also have another GP1200r under construction - more Holiday Fun !!


  2. #2
    Moderator OsideBill's Avatar
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    The crank is the heart of your system, this something you want to have right. My suggestion is send to Cranworks for evaluation and rebuild if it can be saved. otherwise a new OEM would the thing for reliability.

    Reeds can be cleaned, but if they are damaged they are very inexpensive used. I have seen lots of them on here, find a set from a 1300 if you can, they are compatible and flow better then the earlier 1200 ones.

    Pistons I like Pro-X they come as a kit and have the rings and pins all you need is bearings.

  3. #3
    dewzee1200's Avatar
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    I am sending Crankshaft to Crank Works Inc. for evaluation

    Crank Works Inc.

    http://crankworks.com/index.php/pwc/pwc-services

    5245 S. Kyrene Rd, Suite 32
    Tempe, AZ 85283
    Ph: 480-897-1746
    Fax: 480-897-1757
    Last edited by dewzee1200; 12-14-2010 at 04:51 AM.

  4. #4
    dewzee1200's Avatar
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    Has anyone used Langcourt LTD. for Nikasil replating and cylinder work ?

    http://www.langcourt.com/index.htm


    Auto Zone has the 12mm oil pan drain plugs for replacement of Cat Sensor for $2.99 each see pic
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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  5. #5
    dewzee1200's Avatar
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    I plan on cleaning up all the engine and exhaust system bolts prior to re-assemly with loctite--- a few questions in search of tipsWhat if any chemical spray can be used to get the thread-locker out of the threaded case holes ?
    Someone suggested cutting a pipe wire brush - I guess like the ones used for sweating copper -- I need something smaller in diameter
    Can I soak the bolts in Mineral Sprirts or ACETONE - WHAT is the universal solvent ??
    Hours at the grinding wheel with wirebrush attachment is no way to spent the holidays please advise
    Last edited by dewzee1200; 12-23-2010 at 03:31 PM.

  6. #6
    Superman! fivespeedsteed's Avatar
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    some will say to use a tap and dye set and use the thread cleaner to chase them. this was a scary thought to do, i just used acetone and got them as good as i can. the cleaner they are the more accurate the torque you get is however.

  7. #7
    agsbill's Avatar
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    Quote Originally Posted by dewzee1200 View Post
    I plan on cleaning up all the engine and exhaust system bolts prior to re-assemly with loctite--- a few questions in search of tipsWhat if any chemical spray can be used to get the thread-locker out of the threaded case holes ?
    Someone suggested cutting a pipe wire brush - I guess like the ones used for sweatig copper -- I need something smaller in diameter
    Can I soak the bolts in Mineral Sprirts or ACETONE - WHAT is the universal solvent ??
    Hours at the grinding wheel with wirebrush attachment is no way to spent the holidays please advise
    Someone suggested cutting a pipe wire brush - I guess like the ones used for sweating copper -- I need something smaller in diameter

    Take that wire brush to your grinder and make the diameter smaller.

    Or, go to WalMart and get a gun barrel cleaning brush.

    Bill

  8. #8
    Moderator OsideBill's Avatar
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    I have found that chasing the threads with a tap and wd-40 is the quickest easiest way.

  9. #9
    Ouch, I've got the same ski hope mine doesnt come off, pulling carbs off mine now may have to find a better way to secure hoses. goodluck

  10. #10
    I had the oil pump joint connector go out on my XR1800 jet boat and it filled my engine bay with oil. I had a bolt stripped out on my flywheel that took weeks to get off.

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