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  1. #1

    2003 XLT 1200 Rebuild

    So i have pulled the exhaust and head on a 2003 XLT 1200 that i just bought. Attached are pictures, cylinder #1 had 0 lbs on compression test and as the pictures show #1 is shot. I was wondering if this looks like oil starvation? i have not gotten past pulling the head to check the oil line yet. So i am going to pull the the engine out and i am thinking replacing the crank. I am thinking going OEM for pistons or pro-x, and going to millennium for re-plating of the cylinder but i don't want to fork out for an OEM crank where is the best place to get a replacement crank or should i have it rebuilt? Also what should i be checking i just got this ski about 2 weeks ago and when i pulled the exhaust it had some frozen water like 1/4 inch in the gasket to the stinger i don't know if it was winterized buy the previous owner but what should i check to be sure before i rebuild the motor so i don't find any surprises when the motor is rebuilt and i stick it in the water for the first time? This will be my first rebuild so i what to say thanks in advance for all the help and advice i know i will be provided.
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  2. #2
    Also I forgot to ask if the head can be ported to smooth the bad dome from #1 and if so where is the best place to send it or should i just look for a new head.

  3. #3
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    That looks like damage from debris. Im thinking you either broke a ring or lost a rod bearing on the crank.

  4. #4
    powerstroke specialist mikegp's Avatar
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    Quote Originally Posted by aloosen View Post
    Also I forgot to ask if the head can be ported to smooth the bad dome from #1 and if so where is the best place to send it or should i just look for a new head.
    that head has seen the last day, I will not use it , regarding the crank , pm WFO , couple weeks ago he had a rebuild crank for sale.
    you need to check if the cat/con still on the exhaust , needs to be out and replace with dplate , also carbs need rebuilt to be safe, once back together it sucks if they need to be out ,better do them now.

  5. #5
    powerstroke specialist mikegp's Avatar
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    forgot to mention you will need new crank seals ,head gasket , and a new set of rings for the remaining cylinders , I will only use OEM parts on this items. but again WFO will guide you in the right direction.

  6. #6
    Thanks for the opinion bryanp and i will be pulling the whole motor shortly and splitting the case to check out the crank. I appreciate the advice mikegp now the motor has 170 hours on it i was thinking about replacing all 3 pistons not just rings on the 2 that are still good. Is it best just to do new rings or replace the pistons as well?

  7. #7
    WFO sold the crank they had so I am looking at sending the crank to crankworks for a rebuild, i see they have a rebuild option and a rebuild with balancing which would i need? also i have seen alot of places offering welding the crank too is that something that should be done?

  8. #8

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    If you are going to keep the ski, consider buying the best/newest parts possible that you can afford. Take everything apart and clean/inspect well. If you are so inclined, new crankcase seals, new oem crank, new reeds, new gaskets all round, 1211 or similar to seal crank cases and pro-x pistons and rings, hone/replace cylinders, flame arrestors, aftermarket ride plate, aftermarket intake grate. If the 2003 xlts have carbs, then carb rebuild and proper jetting are a good start. good luck. michael

  9. #9
    Ok so I have the motor disassembled down to now I need to split the case. The #1 crank bearing is gone, what should I be looking for to diagnose what the cause the bearing to fail I am prepared to check the seals what else should I be looking for? I have ordered a oem crank and I am going to replace all 3 pistons all gaskets professionally have the carbs rebuilt, dplate and chip. Anything I am overlooking? Also should I replace all three piston side rod bearings 1 is shot but the other 2 still look very good.

  10. #10
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    Rust is usually what kills crank bearings.

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