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  1. #1

    xl1200 rebuild issues

    Hi Guys,

    I bought a 98 xl1200 with a blown 65u engine and have been reading lots of threads on here which has been awesome in helping with me pulling it apart and ordering bits. Ive got new piston kit coming and mikuni carb kits and full gasket kit. I have some issues that im not sure what to do with.
    1. see photo, the barrell has a piece missing out of the inlet side. How much is this going to affect things? I noticed that theres a mod that removes a fair bit ofd metal from that side of the barrel anyway, should i do that ? is it ok to use ? In an ideal world i should replace the barrel but im trying to not let this thing cost too much.

    2. see other photo. theres some very small damage in the webbing between cylinder 2 and 3. what should i do with this ? JB Weld? the block is still in the ski. The bottom end had new seals done before i bought it so i wasnt planning on pulling the cases out.

    cheersClick image for larger version. 

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  2. #2
    Yamaha artisan Cutlass's Avatar
    Join Date
    Oct 2010
    Madison, WI, USA
    I'd clean up the skirt on that broken cylinder a little bit but I think you'll be ok. The case...I'm not sure. you might be able fix the case with JB weld. Get it clean so it'll stick. You don't want chunks of JB weld breaking off and floating around.

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