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  1. #1

    Join Date
    May 2008
    Location
    West Texas
    Posts
    19

    Question 1999 xl1200 rebuild

    I'm just starting to rebuild a 1999 xl1200 that was given to me.... I originally posted this in Old School, but I got a PM suggesting that I post here in 2 stroke performance for better coverage. So, Here goes:

    The basics are, this is a completely stock 1999 XL1200. I've gotton the top end torn down. Cylinder three (the one at the back) has the most damage as you can see from picture of the piston and cylinder walls. It looks to me that the rings or maybe the piston itself melted and bonded with the wall of the cylinder. I don't see any gouges, other then one about the size of the tip of a ball point pen.

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    My friend that is helping me out says that it needs to be machined. I called around yesterday at our local shops, as it turns out only one cycle shop does any work on the yamaha pwc engines. But they don't re-nik, they send it to a company in Wisconson called US Chrome (http://www.usnicom.com/). Do ya'll know anything about this shop, or do you know of one that is cheaper? They charge about $207 per cylinder for striping, boring replating and honeing to standard size (matched to piston if it is sent in also).

    Also, cylinder 2 (middle one) has some vertical wear marks above and below one of the ports. Those marks are about an inch wide. It looks like someone marked on it with a pencil. It has one gouge that I can feel with my fingernail, but other than that its all smooth. I'm guessing that the plating has worn through, but don't know for sure since these are the first cylinders that I've seen. Same story with cylinder 1 (front one), however, I cannot feel any rough areas in the cylinder. Do you think that these needs to be re-niked also, or reuse as they are?

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    The other question that I have is that if I re-nik all three of them, should I stay with the same size as what's stamped in the top corner of the cylinder (18, 14 and 10 front to back), or replace with pistons of the same size and have the machine shop match the size?

    Thanks in advance for your help.


  2. #2

    Join Date
    May 2008
    Location
    West Texas
    Posts
    19

    Question Two questions

    I have two new questions that I can't seem to figure out. I've tried searching, but have had no luck in finding any threads.

    1: How do you remove the two center cylinder studs for exhaust so that I can send it in for re-nik? I don't want to mess them up.

    2. I've actually seen this before, but I cannot find the thread now... Whats the difference between the SBN44 and the BN44 carbs? How do I know which ones I have?

    Thanks in advance!

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