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  1. #1

    Join Date
    Jun 2008
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    St Augustine, FL
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    xlt 1200 problem/question

    I've been having some trouble with my ski and after reading up on it here it seems I may have a cat converter problem. Problem is I can't find it in the manual. Can someone point me in the right direction and maybe a little help with the D plate as well.

    Thanks a bunch


  2. #2
    quadzilla's Avatar
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    Lightbulb ?

    Hey Chuck

    Welcome to the forum..

    First things first...

    If you've not already done so then download the workshop manual from...
    Here:.http://www.hydrotoys.com/gpr/tuners/...ce/XLT1200.pdf

    What you're looking for is in section 5, page 8,

    The Dplate should come with some basic fitting instructions..

    If not the plate goes in with the opening (D) at the bottom..

    Gerry

  3. #3

    Join Date
    Jun 2008
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    St Augustine, FL
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    Thanks for the welcome and the info! One more question - do these ski's actually have an air filter? I looked at the manual but can't make out an actual air filter. Thanks for your help.

    Chuck

  4. #4
    Moderator OsideBill's Avatar
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    No air filter, just a flame arrestor

  5. #5
    OLD # 7 IEGPR's Avatar
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    post up your local and I know there is someone close to you who might be willing to help out

  6. #6

    Join Date
    Jun 2008
    Location
    St Augustine, FL
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    To those of you who have done it - do you have to remove the whole muffler assembly to get to the catalyst?

  7. #7
    There is no winter in Hawaii! tnerb's Avatar
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    Dec 2007
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    Hawaii
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    154
    To get to the D plate you only have to remove the stinger. The hardest part to get out of the boat! Allow about 30 minutes of solid wrestling time to get it out, the second time it is easier. I made a little notch to clear the cooling line fitting on the top. seemed like the only way to get it out.

    Getting it back in is easier but you just have to wrestle it. don't tighten any bolts until you have them all started. I made that mistake and the last bolt was about 1/16" off and ther was no way to get it in without loosening all of them and moving it.

    Good luck, if you decide to do it and you run into problems post it up, there are some great minds on this forum.
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  8. #8

    Join Date
    Jun 2008
    Location
    St Augustine, FL
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    Thanks for the info. I pulled mine out and removed the catalyst, it looked fine. Real sooty but no pieces missing. Could it just be plugged up and causing problems? I've been getting the exhaust overheat after 10 minutes or so and only about 60% performance. From what I have read there could be other things causing the performance issue, but was wondering if anything else would give the exhaust overheat message. I haven't checked hours lately, but I think mine has about 75 hours.

    Thanks for all your help.

    Chuck

  9. #9
    so far every link ive found for the shop/service manual has been bad.
    can noone help me?

  10. #10

    Join Date
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    Bossier City, LA
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    135
    http://www.cajundude.com/stingerremoval.htm
    try this page for help with stinger.

    http://www.mediafire.com/ServiceManuals
    try this for manual

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