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  1. #1

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    98 XL1200 motor removal & replacement

    Both rear seals blown out. Removed motor today. Took off exhaust, exhaust manifold, carbs, airbox first, starter as motor was coming up. Pushed and pulled & finally came out coupler and starboard rear bracket first, then port rear bracket. Harbor Freight 1 ton chain hoist is on sale for $44.99, use your 20% coupon and you have an invaluable tool for motor removal for $36.
    Was thinking about leaving head & head cover on, leaving motor upside the whole time. Remove flywheel, with flywheel puller, & coupler, probably with a Harbor Freight 36" pipe wrench (thanks for the four-year-old tip Zmann), then remove bottom case. Pull crank "up" just enough to slip on new seals, leaving pistons in cylinder body. Will that work or am I missing something?
    Found two shims in bottom of hull. Front mounts had no shims, back mounts each had one.
    Will use WFO's method to align.


  2. #2
    Yamaha artisan Cutlass's Avatar
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    Yes that should work as long as you don't pull a piston too far out and as long as you have enough room to clean everything that needs to be cleaned. Also make sure you can get all the bearing locating pins lined back up. I'd recommend OEM crank seals as well.

  3. #3

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    All 3 OEM seals in hand.

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