Gp1200 Problems

[bassfisher74133]

I have a Gp1200 that had the starter go out in it, so I took it in and they said with the starter going out it might have messed up stater clutch and they also said the honey comb stuff in my cat converter is broke, so basically how hard is this to fix on my own, because they are wanting 2000 to fix the problems , I have the basic knowledge because I have a 1970 chevelle ss that I have overhauled on my own.

Also if the honey comb filter is broke then why cant I just bust that stuff out of the cat converter, I did that on truck and now it sounds sweet with my flow master

[PWC-abuser]

Re: Gp1200 Problems

I assume this is a gp1200r year 2000 or newer?

Removing the cat is not a big deal .... simply take off the exhaust part that is above the flame arrestor, and replace the broken cat with a D plate (I think $45). Don't even bother looking at new cat prices, they are very expensive. As for gutting the cat, if you want to fool with altering your engine's performance that is your choice, but I would suggest keeping the exhaust back-pressure stock with the D-plate so that you don't have to alter anything else to compensate.

The starter stuff might be more challenging. I never did it on my R. By looks at my service manual, you might have to remove most of the exhaust starting from the exhaust manifold and on to get to the starter and generator cover plate. If you can get that far, taking the generator plate off should uncover the starter bendix which should be easily removed and replaced (call a salvage yard). I imagine the starter will be a challenge to pull out but it shouldn't be impossible.

The marina likely will charge you for the analysis anyway, so if they have things apart already it might be easier for you to have them give it back to you apart (the only disadvantage being you didn't see how it came apart).

Overall if you don't know what you are doing, replacing the cat is probaly a 3-4hr job and can be done with simple hand tools. I don't have an estimate on the starter and bendix.

The R hull is very tight to work in, try not to get too frustrated, and work on the ski in a place where it can be apart for several nights.

[skraggy]

Re: Gp1200 Problems

I agree with abuser...dont alter the cat...Remove it and replace it with the D-plate.As for the starter...Make sure it is indeed bad before you go and buy one.The bendix does not usually go bad just because the starter did.What is it doing exactly to make you(them)think the starter is bad ?

As far as the ski in general and access to the starter...if it is a 2000 or later...Once the exhaust is off,most things are pretty accessable.

Make sure the PV upgrades have been done also.

[bassfisher74133]

Re: Gp1200 Problems

Well basically when you push the button to start the ski the engine wont crank and starter makes a buzz sound, so I took the ski in for the dealer to check that problem along with a vibration sound that my ski makes every now and then off a cold start, there response was the starter clutch has gone out and it could have messed up my stater and as far as the vibration goes they said it’s because of the honey comb stuff in my cat converter how the heck does that just brake.

The cost for them to fix these problems $2000.00 so I told them no thanks and the guy in the service place hung up on me (how nice of them to try and earn my business) oh well

I need to find another service place in Tulsa that can fix waverunners

[skraggy]

Re: Gp1200 Problems

First off...what year is it ?

Maybe someone will ring in with a service shop near you that does good work and is not out to rip you off.If not,maybe put up a post in the general discussion forum asking for a shop near you.I try and stay away from dealers and thier service shops.

On the cat...they just come apart,all of them do eventually.And alot sooner than one would think.There are many threads on this site that address this subject as well as the pv problems.Do a search for 1200pv or something similar....it will bring up lots of stuff for you to read and learn.

On the starter.A click and a buzz huh ? That sounds like something is bound somewhere.Assuming that everyone made sure the battery was fully charged...The buzz is most likely the starter,trying to turn.I would first look at the jet pump...remove the intake grate(careful not to break the bolts),and try and turn the impellor shaft.If you cannot turn it,it is not the starter.Try and slide a piece of paper between the impellor and the impellor housing.I have seen a few housings swell around the impellor,causing it to lock up and not allow the motor to turn over.If you have clearance around the impellor and cannot turn the shaft,then something else is bound...possible motor from pv dropping into motor...I still doubt that the bendix went bad and is causing this...but it is slightly possible.They are the most common things to check first...let us know what you find out,and we'll go from there.

[PWC-abuser]

Re: Gp1200 Problems

The cat is problem in the 2000 and newer gpr's .... even if it isn't broken, replace it with a D-plate if you take the exhaust apart. I do a lot of jumping, any mine self destructed around 70 hours or so. If you do take the cat out you can run $8/gal tcw-3 instead $21/gal yamalube 2w.

I agree with skraggy ... take your plugs out and see if you can spin the shaft by hand; hopefully nothing is stuck/fused in the pump or engine.

Take care if you decide to take off the intake grate. The nuts on the inside of the hull aren't very sturdy. If you strip them on the inside, you'll be in for a real treat in dismembering most of your boat to replace them.

Also, make double-sure that your battery is good and that your battery terminals and wires are clean. I've had all sorts of starting troubles, and it's usualy because the battery connections are bad. Whenever I have trouble I take the wires off and sand all the terminal contact areas with 220 grit sand paper.

[1fastski.com]

Re: Gp1200 Problems

first starters dont buzz , relays buzz when they dont have the power to connect check for a dead battery or bad ground, if the starter is bad the relay will CLICK and thats it . to test the starter open the electric box and jump the relay , very easy . the starter is not a hard job , if you need a starter buy one from SBT and go at it , other then that ill a D plate or a used cat . then get out and ride .

[skraggy]

Re: Gp1200 Problems

Buzz...Humm...I couldnt tell the exact sound from this thread... :) But when the starter tries to turn a frozen motor or pump,it makes noise...more like a low pitched humming sound and possibly some chattering.If this is the case,discontinue trying to start it and find what is locked up...or you will fry the starter.

I would hope that if it were only the battery or the relay...that the dealer would have found that...but whether or not they tell you is a different story I guess.

You know anyone in his neck of the woods Chris ?

[1fastski.com]

Re: Gp1200 Problems

Oklahoma? no i dont know anyone there , i do know ive got a few machines in my shop here from dealers with est in hand saying they need starters and none did , iam not sure if people in the dealers are crooks or just dont have a clue what there doing . i dont see many yamaha starters go bad unless the ski was sunk . but if the start buton is pushed and hes getting a steady buzz and not a firm CLICK then i would say a bad connection or relay or battery . if you want feel free to give me a call and i can walk you though figuring it out , just call when your ready to work on it , 609 926 5100

[bassfisher74133]

Re: Gp1200 Problems

My ski is a 2000 and the best way to describe the sound would be if your starter was working but you had no gear to catch the engine to crank, I had the same problem with my boat engine a couple years back and basically on the starter you had to push the gear up and then try to kick the engine over, for some reason the gear would not lift on it’s own, you had to push it up yourself then it would work.

ill try the things you guys said to try, I appreciate all your help