Page 1 of 2 1 2 LastLast
Results 1 to 10 of 15
  1. #1

    Cylinder Installation

    I bought a 1998 XL1200. It was leaking between the bottom of the cylinders and top of the crankcase. I bought new gaskets and tore it down inside the hull. The cylinders are all one solid piece, instead of a different one for each cylinder. I've had other people help me, I've tried zip ties, hose clamps, and anything else I can think of to compress the piston rings, but I can't get all 3 pistons in and get the cylinder installed. Are there any tricks I should try, or should I just pull the whole engine out of the hull to put it back together? It seems like it would be so easy to do, but I've wasted several hours just trying to get it back together.

    Thanks in advance.


  2. #2

    Join Date
    Nov 2009
    Location
    NC
    Posts
    782
    +1
    29
    Just did this a couple weeks ago. Use zip ties & set the pistons so the back one is at top dead center, center piston will be next and front piston shortest. Get a friend to hold the cylinder body while you hold the pistons/rods and slowly work the cylinder down.
    Patience, grasshopper.

  3. #3
    I'll give this another go and see what I can figure out. I tried the pistons in several different places, but never could get it to work out.

    Did you find some zip ties that were large enough to cover both rings with one, or use two separate ones? Also, did you get them as tight as you could. It actually seemed to work better with hose clamps, but I was afraid of scratching the pistons.

    Thanks!

  4. #4
    Yamaha artisan Cutlass's Avatar
    Join Date
    Oct 2010
    Location
    Madison, WI, USA
    Posts
    2,500
    +1
    55
    Its a pain. I had to have my wife help me, which BTW is a great way to start a yelling match.

    Use paint stir sticks to hold the number 2 piston from moving.




    http://www.greenhulk.net/forums/show...op-end-rebuild

  5. #5

    Join Date
    Nov 2009
    Location
    NC
    Posts
    782
    +1
    29
    Find 16" or 18" zip ties. Pull them tight by hand, do not use pliers as they will be too tight to slide down. (Ask me how I know!)

  6. #6
    Ok, I'll give that a shot. The stir sticks might be a big help too.

    Thanks!

  7. #7
    I found big zipties at home depot if your still looking lol

  8. #8
    I just used my fingers to compress one ring at a time and slid it into the jug, took 15 seconds a jug and i have never done it before this, make sure they are both lubed well with 2st oil before you try to install it.

  9. #9
    Yamaha artisan Cutlass's Avatar
    Join Date
    Oct 2010
    Location
    Madison, WI, USA
    Posts
    2,500
    +1
    55
    Yeah, individual cylinders is easy, but the old GP1200 (not GPR) has a all 3 cylinders in one mono-block. Holding that up, while compressing rings and trying to keep the crankshaft from spinning around is a challenge.


  10. #10
    Lol Agreed! I didnt even notice it said XL1200 my bad!

Page 1 of 2 1 2 LastLast

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Similar Threads

  1. 1200 Cylinder installation tips?
    By Jamescmei in forum Yamaha PWC Performance (2-stroke)
    Replies: 3
    Last Post: 06-20-2016, 04:37 AM
  2. Gpr cylinder install help
    By quinton in forum Yamaha PWC Performance (2-stroke)
    Replies: 11
    Last Post: 05-11-2016, 07:17 PM
  3. Cylinder Install Tricks?
    By Zazoos2 in forum Polaris Open Discussion
    Replies: 11
    Last Post: 03-21-2009, 07:20 AM
  4. 750 SS Re-installing with new cylinder - couple of questions!
    By stephenson in forum Kawasaki Open Discussion
    Replies: 3
    Last Post: 08-21-2008, 08:49 PM
  5. 750 cylinder install
    By buck0123 in forum Polaris Open Discussion
    Replies: 2
    Last Post: 06-12-2008, 04:23 PM

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •