2000 GP1200r rebuild after oil pump JOINT connector failure

[dewzee1200]

I will be rebuilding the GP1200r engine shown in the pics below after the joint connector [part #2 in diagram] came off oil pump with 26 hours on the meter. I am looking for a dependable ski not interested in major engine modifications yet.

Work completed so far
Complete disassembly
Obtained used crankcase with matching top& bottom
Obtained used cylinders
Obtained WaveEater PV upgrade kit
Clean-up of flywheel and stator
Shipped carbs to OS Bill for rebuild and addition of primer ETC
Oil pump block off planned AND will be running premix
Obtained pressure test kit from Lowell Horning

I would appreciate feedback on the following:
What to do about crankshaft ? #3 cyl bearings and rod are not within specs
Piston, rings, pins ETC - suggestions on best value ?
Reeds ? - all appear undamaged but #3 is covered in grime

Thanks in advance for assistance



I also have another GP1200r under construction - more Holiday Fun !!

[OsideBill]

The crank is the heart of your system, this something you want to have right. My suggestion is send to Cranworks for evaluation and rebuild if it can be saved. otherwise a new OEM would the thing for reliability.

Reeds can be cleaned, but if they are damaged they are very inexpensive used. I have seen lots of them on here, find a set from a 1300 if you can, they are compatible and flow better then the earlier 1200 ones.

Pistons I like Pro-X they come as a kit and have the rings and pins all you need is bearings.

[dewzee1200]

I am sending Crankshaft to Crank Works Inc. for evaluation

Crank Works Inc.

http://crankworks.com/index.php/pwc/pwc-services

5245 S. Kyrene Rd, Suite 32
Tempe, AZ 85283
Ph: 480-897-1746
Fax: 480-897-1757

[dewzee1200]

Has anyone used Langcourt LTD. for Nikasil replating and cylinder work ?

http://www.langcourt.com/index.htm

Auto Zone has the 12mm oil pan drain plugs for replacement of Cat Sensor for $2.99 each see pic

[dewzee1200]

I plan on cleaning up all the engine and exhaust system bolts prior to re-assemly with loctite--- a few questions in search of tipsWhat if any chemical spray can be used to get the thread-locker out of the threaded case holes ?
Someone suggested cutting a pipe wire brush - I guess like the ones used for sweating copper -- I need something smaller in diameter
Can I soak the bolts in Mineral Sprirts or ACETONE - WHAT is the universal solvent ??
Hours at the grinding wheel with wirebrush attachment is no way to spent the holidays please advise

[fivespeedsteed]

some will say to use a tap and dye set and use the thread cleaner to chase them. this was a scary thought to do, i just used acetone and got them as good as i can. the cleaner they are the more accurate the torque you get is however.

[agsbill]

I plan on cleaning up all the engine and exhaust system bolts prior to re-assemly with loctite--- a few questions in search of tipsWhat if any chemical spray can be used to get the thread-locker out of the threaded case holes ?
Someone suggested cutting a pipe wire brush - I guess like the ones used for sweatig copper -- I need something smaller in diameter
Can I soak the bolts in Mineral Sprirts or ACETONE - WHAT is the universal solvent ??
Hours at the grinding wheel with wirebrush attachment is no way to spent the holidays please advise

Someone suggested cutting a pipe wire brush - I guess like the ones used for sweating copper -- I need something smaller in diameter

Take that wire brush to your grinder and make the diameter smaller.

Or, go to WalMart and get a gun barrel cleaning brush.

Bill

[OsideBill]

I have found that chasing the threads with a tap and wd-40 is the quickest easiest way.

[jaxterra]

Ouch, I've got the same ski hope mine doesnt come off, pulling carbs off mine now may have to find a better way to secure hoses. goodluck

[jetboatdave]

I had the oil pump joint connector go out on my XR1800 jet boat and it filled my engine bay with oil. I had a bolt stripped out on my flywheel that took weeks to get off.

[dewzee1200]

After the damage to the engine shown above I am not surprised at the evaluation from Crank Works - my crankshaft is trash.

Since reading the post by OsideBill --> http://www.greenhulk.net/showthread.php?t=119173

I will be shopping a new OEM crankshaft -- I will see if Brandon Poynor at Boats.net will match the www.yamahasportsplaza.com $591.55

Price with free shipping.

I will update the thread with results of my crankshaft price inquiry.

[dewzee1200]

Thanks to OsideBill's Post - I ordered my GP1200r OEM Crankshaft from Boats.net for $591.51 Free Shipping
I spoke with
Brandon Poynor
Customer Service Representative
Boats.net
877-512-6287 x210
Fax: 801-881-1039

http://www.boats.net

Customer Service Hours:
Monday - Friday 8:00 am to 9:00 pm (EST)
Saturday 8:00 am to 4:00 pm (EST)

[dewzee1200]

REBUILD Questions for the veterans:
1. "True & Weld " ETC and other upgrades to NEW OEM Crankshaft - what do I need to know ? Can I install "as is" from OEM box ?
2. I have read where rebuilders use either 3M 1211 or Marine Grease on the outer edge of Crankshaft oil seals during crankcase reassembly - what is the best ? Any discussion ?
3. Flywheel installation on crankshaft - Lapping or No Lapping - I have read strong thoughts on each side - Leaning toward --> wiping both surfaces with anti-seize then wipe clean and bolt up to spec's.
----------
Update
NO PREMIX: I am staying with oil pump since - I cannot watch or worry about all the other riders refilling gas tank and not adding oil.
CRANKCASE - ALL bolts holes run in with matching tap and WD40 then degreaser and case was washed with soap and water -- C AIR dryed and wrapped up clean
CRANKSHAFT - I got the word from Crank Works - Corey called me and said Crankshaft was TRASH - new OEM crank is on the way from Boats.net see FAQs
CYLINDERS - Must decide on who to use for replate work
PISTONS - Ordered PRO-X Kits
CYLINDER HEAD - I want to set up for 87 octane -

[OsideBill]

REBUILD Questions for the veterans:
1. "True & Weld " ETC and other upgrades to NEW OEM Crankshaft - what do I need to know ? Can I install "as is" from OEM box ? Yes, but true and weld will add another level of robustness. If your ski unhooks a lot while riding the crank takes all the punishment, I always plan for the worse. Saves money in the long run.
2. I have read where rebuilders use either 3M 3 Bond 1211 or Marine Grease on the outer edge of Crankshaft oil seals during crankcase reassembly - what is the best ? Any discussion ? I use a little grease to aid in assembly and seal, OEM is dry. You want to be careful on the two rear seals, as they are designed to allow oil to flow between them to lube the rear shaft seals.
3. Flywheel installation on crankshaft - Lapping or No Lapping - I have read strong thoughts on each side - Leaning toward --> wiping both surfaces with anti-seize then wipe clean and bolt up to spec's. Lapping merely insures they mate properly, it cleans any high spots that may have occured from handling. It also cleans the flywheel side more then anything if you look inside a used one you will see the pressure marks from use. this is a ten minute job worth doing.
----------
Update
NO PREMIX: I am staying with oil pump since - I cannot watch or worry about all the other riders refilling gas tank and not adding oil.
CRANKCASE - ALL bolts holes run in with matching tap and WD40 then degreaser and case was washed with soap and water -- C AIR dryed and wrapped up clean Have you cleaned all the bolts? did you check all the mating surfaces for any raised metal?
CRANKSHAFT - I got the word from Crank Works - Corey called me and said Crankshaft was TRASH - new OEM crank is on the way from Boats.net see FAQs
CYLINDERS - Must decide on who to use for replate work Millenium has never done me wrong
PISTONS - Ordered PRO-X Kits
CYLINDER HEAD - I want to set up for 87 octane - Leave it alone then stay stock on the head-

See answers above.

[dewzee1200]

Have you cleaned all the bolts? did you check all the mating surfaces for any raised metal?.

I do not have access to a surfacing stone so I would love to find a sheet of 600 - 1000 grit 18inches by 30 inches to use on top of granite counter top to gently wet sand mating surface - any Ideas ?

I will be at the grinder with wire wheel this weekend - cleaning all the bolt threads