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  1. #1

    Join Date
    Sep 2012
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    gresham, oregon
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    14

    2004 yamaha xlt 1200 top end rebuild

    Hey everyone, Im a newbie on here and over the last few months have gained priceless info on my ski on here so I first thank you all.

    Im rebuilding my top end of my yamaha 1200 xlt 2004 waverunner. My question is now that I have the cyclinders off and have access to everything what else should I do besides rebuild carbs(which im going to do), I installed the d plate, and I ordered the oil block off kit. I would like to know which pistons I should replace the OEM ones with? Any advice? I just wonder if its worth the extra money for the Pro-X pistons. Im a guy that just wants my ski to run at stock speeds and power. 2 of my cyclinders were in great shape and the 3rd had a scratch in it from the top of the piston breaking off so I got lucky and only had to replace one. Any and all advice is appreciated. Im a newbie to rebuilding a 2 stroke and want to do it right. I have plenty of experience wrenching on old straight 6's and chevy 350's but this is all new to me so Im asking for advice. And again, without these forums I wouldnt have been able to get as far as I have without paying a shop top dollar just to pull the exhaust out. Me and my brother spent 4 hours figuring it out the first time and now I can pull it all out in about 30 minutes. Thanks ahead of time.


  2. #2
    Banned User
    Join Date
    Aug 2011
    Posts
    5,049
    +1
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    oem pistons or pro x pistons. both work great
    buy the wave eater clips for the power valves if you have them
    runs amsoil(or a good syn oil)
    use only oem gaskets
    clean pvs if its a pv motor

    geeze 4 hours to yank the single pipe. id hate to see you with triple pipes! lol ..good luck and stay thirsty my friend

  3. #3

    Join Date
    Sep 2012
    Location
    gresham, oregon
    Posts
    14
    4 hrs was in the water at the lake on vacation!!! I was so pissed that the exhaust temp warning was going off I said Im tearing into this thing now I found the cat had separated and got plugged in the exhaust just like I read on here. Anyway that parts easy now. Im going to pull the carbs off today and give a look at them. Do I need to do any adjustments after installing the D plate? Ive read both arguments, that I need to and that I dont. Either way they need to be cleaned and inspected. If the carbs should be modified or rebuilt who is the guy to go to on that? And yes I ordered the wave eater clips. Those power valves were so dirty and gummed up it was nasty. Should I replace the crank shaft housing seals as well? And thanks thatdude596,just reading your post have helped me alot. I just have to be careful at work reading your stuff cause the blonde with the big boobs on your profile photo might mislead some of my coworkers. Thanks man.

  4. #4
    srjrinc's Avatar
    Join Date
    Aug 2012
    Location
    Sun Valley, CA
    Posts
    122
    I don't think you should have to replace those crank seals, you basicly have to tear down the entire case to do that.... ( wich i'm doing right now to my 03 xlt....) how many hours you got on this thing?

  5. #5

    Join Date
    Sep 2012
    Location
    gresham, oregon
    Posts
    14
    This may sound dumb but what about timing? Is it set by the factory in which not something I need to set?

  6. #6
    there is no timing in this engine.
    its all done on the keyway on your flywheel, thats it my friend!

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