Yamaha XLT1200 User Manual download pdf (Page 8)

Engine Removal / Installation

Yamaha 1200 pv

v 1.0 © 2001 Short Block Technologies

8

Follow the removal steps in reverse order

to install your new SBT short block

assembly:

5.14 Place the bendix assembly in the

case.

5.13 Using a new flywheel key, place the

flywheel on the crank and tighten the

retaining bolt.

• Torque to 54 Ft. Lbs.

5.12 Using a new o-ring, install the

flywheel cover and bolts.

• Torque to 11

.

5.11 Replace the pulse lines.

5.8 – 5.10 Install the reed cage assemblies

as shown in the picture.

5.7 Install the intake manifold.

• Torque to 9 Ft. Lbs.

5.6 Install the front exhaust bracket.

• Torque to 28 Ft. Lbs.

5.5 Install the starter and the bottom

mounting bolt.

• Torque to 28 Ft. Lbs.

5.4 Install the rubber PTO cover mounting

studs.

5.3 Install the PTO coupler.

• Torque to 54 Ft. Lbs.

5.2 Install the rear exhaust bracket.

• Torque to 28 Ft. Lbs.

5.1 Install the top exhaust brackets, and

leave out the rear-most bolt.

• Torque to

4.6 Spin the engine mount bolts into the

mounts, and rock them back & forth with

your hands; try to break them. If any

mount(s) fails, replace it before installing

the new engine. Place the engine in the

hull and slide it back onto the driveshaft

coupler.

Your new engine may require re-

shimming. Shims are necessary between

the engine mounts and brackets to properly

align the engine and pump shafts. If you

do not have enough factory shims with

your hull, very thin, wide washers may be

substituted.

Take a small straight edge and place it on

the coupler. You are looking for an even

match all the way around the coupler.

Place shims where necessary to align the

couplers.

4.5 Install the ground cable and remaining

starter bolt. Make sure the connection

surface is sanded and clean.

• Torque to 28 Ft. Lbs.

4.4 Install the power valve cables and

bracket.

• Torque to 7.2 ft. lbs.

4.3 Plug in the three electrical harnesses.

1 2 3 4 5 6 7 8 9 10

Yamaha 1200 pv 1
Engine Installation 7

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