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  1. #1

    XLT 1200 Need Advice on ignition or carb issues. Rough running

    Hello friends,

    I live in El Salvador and have a Yamaha 2003 XLT 1200.
    that needs advice on ignition or carb issues.
    The 1200 was in storage for almost a year
    and upon starting it for the 1st time, new fuel, as tank had been drained,
    it hesitated, changed plugs + poured some gas in the cylinders.
    It started, ran ok for a minute, then back to two cylinders.
    I am returning tomorrow to the lake and would really appreciate your input.
    I have the feeling it is the carbs that are probably in need of a rebuild, yet
    would prefer less drastic measures to start, and possibly solve the issue.
    Thank you and Happy New Year!

    Regards, Alberto


  2. #2
    mudslanger's Avatar
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    It sounds like carb issues and needs to be repaired witch means removing the carbs and cleaning and installing carb kits. I would NOT ride it if it is running only on 2 cylinders as serous engine failure could result.

  3. #3

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    I agree, very likely at the very least one carb internal fuel filter is clogged, not uncommon on todays gas. I have seen it on my own boat that has always been taken close care of and had top tier fuel in it. I also agree DO NOT continue to run it, or you will damage the cylinder that is not getting emough fuel.

  4. #4
    Thank you for the suggestions, they make sense.
    I had also another incident, but ignore if any bearing in this issue.
    Just before being put into storage, the battery was installed perhaps with the negative ground not tight enough
    (forgot the loctite!) and the terminal melted down with the consequent stalling of the motor.
    Could this have caused an electrical issue that might also be influencing the carb problem?
    Short of checking for spark, grounding the plugs, any other test that I should perform
    before carb removal?
    Thank you.
    Regards, Alberto

  5. #5
    Finally brought the XLT back home were work can be performed properly.
    Following the friendly advice, we started removing the carbs. We discovered that the oil feed line to carb #3 was disconnected, so now I have another problem on my hands, as you may imagine.
    Do I remove the head and inspect the bores? How can I ascertain if the piston is shot?
    The engine ran badly due to the carb issues, but that was cylinder # 2, not #3, and the ski was not run long, although I am well aware that lack of oil is not a good thing
    Any other suggestions?
    Thank you in advance for the kind help.
    Regards, Alberto

  6. #6
    mudslanger's Avatar
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    post some pics of the head combustion chamber and piston/cylinders.

  7. #7

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    I would not panic until I looked inside cyl #3. Many times I have knocked the #3 oil line off when accessing the carbs the first time because that original tie wrap isn't very tight, and that line is the longest but a bit on the short side for #3. It can come off real easy when working near it. Was there a good deal of oil on the bottom of the boat in that area? If a quick compression test looks good, look down inside #3 with a flashlight or borescope to see if there is any damage or aluminum on the cyl walls. You may still just have a carb problem.

  8. #8
    No, not much, a couple of tbsp. that's all, as it has not been run due to the carb issues.
    What should compression be at?

  9. #9
    Pulled the head and Piston # 3 has a melted chunk on the exhaust side, to the extent that both rings are visible.
    The other pistons, 2 and 3 feel rather loose in the cylinders.
    We are pulling the engine out.
    Thoughts?

  10. #10
    Moved on and pulled cyl. 1 and 2. No issues here. 3 Does not want to slide up...

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