Waverunner rebuild 3 and start

The final rebuild video on this machine.

[@Altune45]

That wedge shaped piece in the cooling area of the cylinder is a sacrificial anode for corrosion control.

[@davidcornelison2460]

Great videos just rebuilt my 1999 Yamaha XL1200 NPV. The usual 3rd cylinder had low compression. After watching your three videos on your rebuild I felt confident to do the job. It turned out great. Luckily the cylinders were all good and just needed to be honed. By the way I did order the hone you showed in your video. Thanks Again for saving me a bunch of money not having to take it to a shop.

[@Jigsaw_knows]

Damn. Wow. 👍Your mom did a super cool seat!

[@ianamboy7254]

its an anode anti corrosion anode like what the outboard motor has..

[@mattc8821]

Did you figure out what caused the lean condition in the first place?

[@FranE.568]

Great job guys. I watched all 3 parts. These videos will help me if I have to rebuild mine, which I hope I don't have too.. Well done.

[@goringsotiri]

I agree with Michael's comment I have the same problem as it appears to be very common with the third cylinder the oil line came off and I fried it as I dug into the engine which was started as an easy project I found more and more problems as he stated small pieces from the piston head ended up in the crankshaft I would have never seen it if I didn't pull the engine out and I found a small crack on the crankshaft case so anyone trying to rebuild I strongly suggest you pull everything out or you'll be at step one put with a blown engine again after all the work you put inspect crankshaft change the seals rebuild carbs bypass oil pump bypass catalytic converter sensor

[@hoyay850]

Just an FYI, its been proven...adding an extension on the torque wrench doesn't affect torque numbers

[@jaycebough4882]

To add to that if your hand isnt perfectly centered on the grip ( further or closer to the socket ) you will get an innacurate torque. This is why those cheap beginner torque wrenches with the pointer have a handle that pivots on a fulcrum, when that handle is centered you are pushing in the perfect spot

[@MJCdoesstuff]

great videos!

[@shannonwilliams601]

You never jump start a jet ski with anything that has an alternator because if you do it will burn out the stator it has a sticker in set that says do not boost battery

[@montneymon-ta-knee6810]

did you have to hone the new cylinder

[@Timbo_tango]

Torquing up the head must be done with a beer in the left hand.21:22

[@paulhaines5755]

Nice vid, thanks! Not to be a know it all but one comment about torque wrenches: hand placement is important. Your hand needs to be on center the "rotating" portion of the handle. Also don't use your thumb. Your torque will likely be too great if you "choke up on it". If you don't believe this put one on a torque tester and see for yourself. This coming from someone who has broken bolts in a cylinder head and had to install heli-coils to repair them. You don't want to go there....

[@fitzsfixes]

Thank you for the tips! I'll keep that in mind for the next time. Thanks for watching

[@arteenpratt3166]

hey, That thing you mentioned is Anode, its made of softer material and protect the engine's part which is directly in contact with water, its very important to clean it and make sure it has clean surface specialty where it sets, basically its sacrifice itself to protect the engine, , if its in bad shape i always sugest to rep[lace it and it has to be replaced with original pic not after market

[@aaronhinojos1131]

Dude with the camera sounds like he needs to take a smoke break!, Lol!!

[@nguyen1424]

hi fit s fixes i got a yamaha 2000 waverunner xl how to adjust high and low speed

[@anthonypapa8676]

You went through all that why didn't you just take the battery out of the RV and put in the jet ski for a minute or one of the others jet skis and all the other stuff you have in the background lol

[@handyallaround5776]

i will be shocked that the pitting from the saltwater use let that cylinder slowly heat up and blow again,,,very sketchy looking , cant believe someone would rebuild a jug that is in that kind of shape, and sell it to someone,,,,but maybe it will not make a difference, im an outboard mechanic,, not a pwc mechanic , so i am learning , i hope it works great , because this is an awesome video!!

[@fitzsfixes]

So far so good. 2 seasons on the rebuild with no issues

[@tumnguyen1780]

I like work Ben

[@shannonwilliams601]

You forgot to put sealant on your gaskets you need to put form a gasket because it doesn't matter if they're crimp metal gaskets are not they can leak you always want to put either copper seal spray or form a gasket

[@Killian665]

Shannon Williams you never put sealant on metal gaskets

[@shannonwilliams601]

@@Killian665 you couldn't be more wrong you call any of the people that sell those metal gaskets they're called compression gaskets and you always want to put a light coat of either copper seal or a thin coat of spray sealant absolutely I build over 600 Motors a year trust me I know what I'm talking about

[@jbower4949]

So what was the culprit? No oil is what it looks to me

[@lonzo43379]

These engines require 3 things!!!! Power valve clips, oil lines replaced or pre mix, and d plate. After seeing these rebuilds without checking for what reason the motor failed is insane!!!! (Not just this clip) Engine should be completely out of ski to properly rebuild. Sure it runs..... but for how long. Feel free to question me about the 1200pv engine 800 as well.

[@scottw616]

I completely agree with you. On one hand, they give an in depth look at the thing which is cool for the novice, but needless tearing down of the engine and replacement of two of the good pistons. All it really needed was to repair the one piston which was a lean mixture causing the piston to flake off. I am surprised it did not all out detonate, but it was starting to which affected the compression. Normally I would just replace the one piston and find what caused the fuel mixture to go lean, but because it is a short living engine design because it is a 1200R, you really cannot be sure how much longer it will last. They are not known for reliability. They go really fast for a short time before they blow. It usually is best to replace it all if you can afford it because you won't get much time out of one any way. The 1200R is junk and yes put a D plate in it and go premix to give it plenty of lube.

[@lonzo43379]

Scott W Hey man thanks for the reply. I'm pretty much a yam fan. I know I will have my haters....lol but I have done a ton of these engines 66e 66v. I just finished a ski 2003 gp1200r. Looks amazing one owner. No compression pto cylinder. Pretty much was not surprised when I pulled the exhaust and looked at the oil injection nipple and of course it was popped off. Middle was about to pop off. So cooked it. Anyways complete breakdown crank felt good but pto bearing seemed lil loose so just ordered new crank. I had one cylinder done and others were perfect! So re used pistons as they were flawless! (New rings) but new piston in rear. I have right at 900 in it. I started ski. Had 286.4 hours. Ski is 1 owner. But here is the kicker..... it was taken care of. Yamalube. Cat delete. I cracked the engine it was clean and un touched. This was the highest hour yam engine I have done. (46) was losest. 10-12 oil line failure. 2-4 cat failure. 1-2 don't really know what happen motor just grenaded. In my honest opinion Yamaha should of went good for there faulty oil lines!

[@scottw616]

lonnie wilson I am a Yamaha fan as well. Sea Doo is just not reliable. I am not a fan of the 1200R and 1300R as they are pushed so hard. I tend to prefer reliable de-tuned motors, but I work in the rental business. I do jet ski tours traversing up to 40 miles to take people out to see dolphins in their natural environment as well as sightseeing of the area. We have 4 stroke motors 1100cc 110hp going a 1000 hours on original motor. We use to rent Sea Doo but they got ridiculously complicated. I was very entertained to watch people tearing down motors that had failed to troubleshoot the problem properly creating needless work for themselves. People watching these videos will follow suit. In the case of this 1200 R, I would simply have replaced the one piston and not have touched the others. I would have then run it until it blew the motor, then I would have replaced the crank and pistons in a complete rebuild. The cranks don't last long anyway so get out of it what you can, then start new. When the crank scatters it will take out the top end anyway.

[@DavidSmith-tc9yi]

I did the same overhaul and it lasted 12 hours due to the lower end having and air leak and causing a lean condition!!!! Always pull the engine and do it the right way and replace all seals and so on!!!!!

[@robertryan2228]

hey I have just got into owning a yamaha 1200 PV ski. I need a cylinder and a crankshaft I am going to weld the crankcase but the cylinder is totally wrecked, they are very expensive in NZ have you got a good second hand PV cyl I think 800 and 1200 look the same (66V)

[@Reservdansken]

could it be a sacrificial anode?

[@cenmike82]

Yes that's the name I was thinking off big guy

[@Lamai73]

Could you share the links for the parts please... I’m going through the same problem currently... thanks!!!!

[@adzythepwcblokeinaustralia5467]

Fuel pump pressure equalisation mod is must , blocking off the crossover ports under the carbs is a must do too . Power valve clips and replace the power valve joiners too . 1.5 needle and seat ,95 gram springs, 110 lows and 120 mains in the carbs . All these mods will make the engine reliable.

[@minibikemadman]

awesome info im going to put a non-pv triple into a 12ft alum jet boat..been trying to find info on what to do to make them reliable. Going to get it ported etc but trying to make over 200 on one.

[@Timbo_tango]

Also delte the oil injection and go back to premix. This will reduce the risk of piston seizure in the future

[@dominikatv4657]

hi, i have a mode yamaha waverunner 2004 xa800a i would like to remove the oil dispenser all you need to do?

[@4saleibuy]

Awesome videos. These engines are slowly becoming extinct as the whole marine community (except Evinrude eTec) has converted to 4strokers. You describe everything quite well in layman's terms. The Powervalves (Yamaha call this whole assembly "YPVS") is one of the achilles heels of these engines as the valve can dislodge over time and the valve itself can fall into the cylinder and oncoming pass of the piston, which could easily cause complete destruction of the engine parts. It's a good idea to clean and retighten all the remaining powervalves. I've learnt this the hard way having rebuilt 2 engines destroyed in this manner. The other achilles heel is the Wristpin on top of controd that rotates around gudgeon pin holding piston secure to conrod. Timely piston replacement every 100 hours or so eliminates this from self destructing and also causing catastrophic engine failure. Your Next improvement would be to replace catalytic with popular "D" Plate and chip. Hope it all goes well for you.

[@briantii]

Don't forget the crank snout the snaps, the oil lines that fall off, cat converter that clogs the exhaust, the carb throttle shafts that stick dangerously open, the carbs that need rebuilds every few years to make sure it doesn't go lean, cleaning the power valves every 100 hours, making sure the exhaust water jacket cuff is installed perfectly to avoid flooding, and installing Wave Eater Clips to ensure the power valves don't take out a cylinder. I eventually added reed stuffers too as they seemed to make it run better in general. I eventually got my 1200 to be pretty bulletproof and running great... just in time to sell it to a buddy who had to modify the carbs (against my advice) and caused a lean condition at mid throttle taking out a cylinder. I told him if he modified it I wasn't rebuilding it - and I didn't. I've since moved on to 4 strokes and have far less issues. :-)

[@travelguy1564]

@@briantii How about my 1996 Yamaha 700 2 stroke 2 cylinder Wave Venture? It doesn't have all the problems that you mentioned - right?

[@briantii]

@@travelguy1564 Nope. The 701 is one of the best PWC engines ever made. Those are great! It’s the later model “power valve” motors where they lost their way.

[@travelguy1564]

@@briantii OK - thanks for your quick reply. All I had to do was replace the carb diaphrams about 6 years ago and I took off the oil injection pump and just premix my oil and gas all the time. Should I check anything else out for preventive maintenance that you know of?

[@briantii]

@@travelguy1564 I’m not a 701 expert... but I’d just keep an eye out for the common 2 stroke stuff. 1) You may need to consider going through the carbs again at some point. All those diaphragms and check valves can wear out and still look good but not quite perform perfectly. Carb rebuilds are a maintenance item, 6 years is actually in the window where you may need to start thinking of doing it again. 2) Case leaks. Problems with idle or weird running that you can’t fix with carb tuning/ rebuilding could indicate a crank seal leaking. Given the age it’s certainly a possibility of something you could encounter. A case leak does typically involve tearing down the engine but it’s no where near as bad as it sounds especially with a simple one like that. Similar symptoms could also be caused by reeds which will wear out too, but are much easier to replace. 3) Spark plugs as needed, but you probably know that. Really though as long as it’s running good, not too much to worry about. Those are great engines.

[@bennyrosado5402]

awesome!!!

[@tommytwotoes3880]

The cyl torque is 16# and then 29#

[@Maxvett]

You guys in stall the head cover gasket wrong side hahaha

[@cenmike82]

small tabs inside jugs it's there stop salt water eating away metal when the water circulate though the jugs for cooling

[@matthewrobert2888]

Gave me hope on rebuilding one of these things

[@Jigsaw_knows]

You guys are awsome 👍

[@michaelbennett3989]

Ive been a waverunner tech for almost 20 years. I want you to go back to video 1 and observe how they found part of the piston skirt broken off and missing. Absolutley every time ive seen this, theres a crack in the crank case. Engine should have been removed at that point. Also, notice how dry the cylinder was. The oil line came off the rear cylinder. I bet this guy was pissed 30 seconds into his test ride when this machine dropped a cylinder again. And who doesn't rebuild the carbs while its down this far. Disappointed that these things were missed. Feel bad for the fella that owns it.

[@fitzsfixes]

MICHAEL BENNETT not all repairs were shown in the video. The only big issue we had after the rebuild was the new (used) just was from a saltwater machine. It was pretty corroded on the gasket surface. It developed a leak to the outside of the engine (not cylinder side) that still leaks to this day when running. The neighbor (new owner) still rides it most weekends. Also, the oil pump has been disconnected since the rebuild, and uses pre-mix instead.

[@swankster1966]

I have a 2001 XR1800, that I just bought. Took it out, everything worked fine up to 6000 rpm. Once I opened to full throttle (7000), 5 seconds later the left engine slowed down so I shut it off immediately. Took it apart, rear cylinder leaned out, and piston was melted onto cylinder. I drilled out the needle plugs, low speed jet was only 3/4 open from closed, high speed was 1 turn OFC. I set the low to 1 1/4 on all (factory says 1 1/8), and the high to 1 3/4 on all (factory says 1 1/2 on rear). New piston and cylinder, installed electric fuel pump, removed jets, blew out carbs, put back together. Took it out again, ran at 2K, 2.5K, 3K, 3.5K, 4K, 4.5K, 5K, 5.5K, 6K, 6.5K (all for approx 4-5 minutes each), no problem. As soon as I went full throttle again, same thing. Do I have to open my high speed needle even more? Any ideas? Thanks.

[@50mustangdrew]

Do you see the same with gp1300r as well?

[@johnpaulstez]

I would have pulled it after the skirt was found. I guess they can't show the whole rebuild, but I would of checked the deck and squish of the new rear one, or at least a comparative compression test against the others. Would have been a big bummer if the rear one ran hot due to higher compression. In terms of the parts upgrade, in particular the intake stuff, I would have stuck to OEM if possible. After a rebuild like this, if its not running right there are just too many gremlins to chase if its not back to OEM.

[@richardlamano1092]

Hi Michael, ive recently bought a wave runner xlt 1200 and although it started and ran at the time of purchasing

[@hoodboundstreetwear1570]

YOU GUYS ARE GREAT, YOU PUT ME IN THE DIRECTION I NEEDED TO BE...

[@upragu3]

Anode

[@xtune5731]

Spends 270 on jug but 9 dollars on keeping that jug alive, did your friend ever get it carbs rejetted? It probably didn't run too well, assuming its been sold soon after mods installed? Nevertheless pretty good informative video for those nervous about the task at hand.

[@fitzsfixes]

He sold it to his neighbor. As far as I know he still rides it. Pete, the guy here bought a new SeaDoo something. Not sure what kind, but hes hooked

[@xtune5731]

@@fitzsfixes Don't want to be biased but I love my old 2stroke seadoos, currently restoring a 96 hx I got for 300 bucks

[@fitzsfixes]

@@xtune5731 to be honest, working on them is fun. But I've never really gotten into them. I ride a friends seadoo sometimes. But I'm more of a boater. Unless the water is glass. Then I like to rip. But around here, that's usually only early mornings

[@xtune5731]

@@fitzsfixes I like the size and simplicity of the old 2strokes, not to mention the power!

[@Phils_Photos]

Its an Anode

[@fitzsfixes]

Phil B Vids yup. Thank you

[@Phils_Photos]

Loved the video and in the process of doing the same rebuild on my 02 XLT1200.

[@fitzsfixes]

Phil B Vids oh cool! Good luck with your project

[@gingerandreiovici1840]

You asked at 2:30 what that piece was with the flat screw it's called an anode.

[@gingerandreiovici1840]

I believe they are made of zinc and help to protect metals from galvanic corrosion

[@gingerandreiovici1840]

Salt water corrosion

[@majanovak8440]

that cylinder is no good. Head gasket will start to fail quickly due to the salty water corosion.

[@johna9841]

That was great!

[@Army_Of_Juan]

Where is the update of this wave runner

[@fitzsfixes]

Sold it to his neighbor shortly after the video. I haven't seen it in a while. Not sure if the neighbor still has it

[@Army_Of_Juan]

Fitz's Fixes , ohh but did it ran fine in the water?

[@fitzsfixes]

@@Army_Of_Juan yes. The owner ran it a few times before selling it. He said it ran great. And he's still friends with his neighbor. So I'm assuming it ran fine for him too, lol.

[@emersonc6443]

why didnt you buy from sbt, its much cheaper and they send every thing in one box

[@fitzsfixes]

emersonDAbeast I'd have to ask the owner that question. I don't own a waverunner. And I don't know what sbt is

[@emersonc6443]

Fitz's Fixes google it, but they sell jet ski parts as kits or separate. That is where me and my dad bought stuff for my grandpa jet ski that we rebuilt for him.

[@emersonc6443]

Fitz's Fixes i have a video of an over view of it and i will be starting it on sunday

[@fitzsfixes]

emersonDAbeast cool. I'll check it out

[@MrCpsloco]

Fitz's Fixes I loved following this rebuild, I was on the edge of my seat!!!! Sbt gets so flamed, but they warranty the work on the parts you buy from them!!!

[@2wheeltrafficbuster338]

could you do a video of it in the water ?

[@fitzsfixes]

2 wheel traffic buster machine was sold last summer. sorry

[@emersonc6443]

those things are like zincs or something like that

[@andreasmerletti]

Lol I live right on east river on gi

[@josmiantechsosa4217]

what website or where did you buy the sleeve or jug

[@fitzsfixes]

Josmiantech Sosa no idea. the owner got it online somewhere

[@Sanneti2012]

Hello, I'm about to buy one yamaha 120o with a blown engine, and such a coincidence is the same piston that you guys fix that is blown. so, how much guys did you spend in new parts? I didn't know you can change the jug by units so that will make it easier. great video by the way.