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  1. #1
    PWCToday Newbie
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    '99 Yamaha XL1200 Ltd coupler

    Hi all,
    I will shortly come into possession of a '99 Yamaha XL1200 Ltd. that has a couple of issues.
    The main issue is it is leaking water from the bearing assembly(?) when lowered into the water. (The piece below with the hose coming off.)
    Coupler.JPG

    Once I remove the pump, does the engine have to be pulled to replace that part? What failed to cause it to leak water?
    Does the spline of the pump shaft fit into the back side of this?

    Thanks-
    Dshow
    Last edited by Dshow; 09-22-2017 at 07:55 PM.

  2. #2
    resident guru JetEd73's Avatar
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    Re: '99 Yamaha XL1200 Ltd coupler

    Ive had this same issue with my 99. The engine wont have to be 'removed' but you will have to loosen the engine mounting bolts and slide the engine forward a bit to remove the coupler. The mounting bolts have shims under them that line the engine and coupler up. You'lll have to re-align the engine and coupler left-to-right, but not up-and-down. Yes the pump shaft fits into the backside of the bearing. If the seals arent blown from the bearing there is a chance that the coupler is cracked or broken in the center. thats what happened to mine. Had to replace the coupler.



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    99 Yamaha XL1200 Limited
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  3. #3
    PWCToday Newbie
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    Re: '99 Yamaha XL1200 Ltd coupler

    Thanks! I am wondering if improper alignment may have caused this issue.

    A little history if your interested...
    I bought the ski back in ‘99 with 7 hours on it. I rode it for several years and did lots of upgrades. ~2006, wife wanted a boat, so we sold the ski to my brother. They rode it and ended up blowing the engine in ~2015 and replaced the engine. Now this issue so as opposed to him just giving it away, I told him I wanted it back... I look at this as something to tinker with in the winter months...

    Second issue it has after I fix this is that it bogs at a certain RPM spot when cold... I figured the carbs need tuning?

    Thanks again!

  4. #4
    PWCToday Regular Dave in DE's Avatar
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    Re: '99 Yamaha XL1200 Ltd coupler

    Dshow,
    The pump does not need to be removed just the motor slid forward to remove coupling. No need to do all the extra work of removing the pump. Unless the pump shaft splines are rusted into the coupling shaft. Then you may need to remove pump. But you should be able to work the coupling off just as easy as removing the pump in that situation.

  5. #5
    PWCToday Newbie
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    Re: '99 Yamaha XL1200 Ltd coupler

    Good to know...

    Thank you!

  6. #6
    PWCToday Regular Dave in DE's Avatar
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    Re: '99 Yamaha XL1200 Ltd coupler

    Oh. Be sure to put plenty of Marine grease on the splines before you reinstall the coupling. Will help next time you need to remove pump or coupling.

  7. #7
    PWCToday Newbie
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    Re: '99 Yamaha XL1200 Ltd coupler

    Finally getting around to working on this. Question on getting to the motor mounts... I have the rear exhaust pipe out to get to the coupler. Does the front half of the pipe need to come out to get to the front motor mounts?

    Thanks!

  8. #8
    PWCToday.com Is My Home Away From Home freekstyle's Avatar
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    Re: '99 Yamaha XL1200 Ltd coupler

    Pull the exhaust and rebuild the carbs while you are at it. If done correctly that should cure your bog.

  9. #9
    PWCToday Newbie
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    Re: '99 Yamaha XL1200 Ltd coupler

    Thanks. Is there a rebuild kit to get for each carb?

  10. #10
    PWCToday Regular Dave in DE's Avatar
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    Re: '99 Yamaha XL1200 Ltd coupler

    Quote Originally Posted by Dshow View Post
    Thanks. Is there a rebuild kit to get for each carb?
    yes, you need to order one kit for each carb.

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