Polaris 1200 questions

M

marunr

Petty Officer 1st Class
Joined
Jul 11, 2004
Messages
225
Hi,
I'm a boat guy, but unfamiliar with PWC's. My son bought a 2000 model Polaris 1200 and the previous owner had apparently patched a hole in the hull. after riding it for several weeks, the patch job came undone and he sunk it far enough to get water around the engine, which cracked the "block". This what has me confused. In looking at it and the parts manual (he doesn't yet have a service manual) it appears that the 3 cylinders are individual, and not an actual block. It looks like he can unbolt and remove the busted cylinder and put on a new one.? There are aftermarket parts which include all three cylinders and the pistons, etc. Am I looking at this correctly? Can he just replace that cylinder and the piston?
 
R

Rob454

Chief Petty Officer
Joined
Oct 9, 2005
Messages
508
Re: Polaris 1200 questions

yes he can as long as he didnt hydro lock the motor and bent the crankshaft rod. the 3 cylinder motor is a 120* crank. basically do this
take 3 wood dowels that fit inside the spark plug holes not loose but not tight either. about 1 foot long.. take off the spark plugs. now insert a wood dowel in the #1 cylinder until it touches the piston top. turn the crank by hand at the rear coupler until the #1 piston is at TDC. youll know it because the dowel will stop moving and will want to start moving back down with the piston. take two more wooden dowels and insert them in the the #2 and #3 cylinder. the #2 and #3 wood dowels NEED to be at the same height. if theire off then you probably have a bent rod. at this point you probably would want to get a rebuilt crank or have yours rebuilt. if its ok and you pass this test then jsut replace the piston wrist pin and bearing and cylinder.

but if you had enough force to crack the cylinder then you most liekly have a broken crank.
jet ski motors are 3 major parts. the cases which are the lowest part of the motor and the crank sits in there. the cases are a two piece design. you split them to remove the crank.
the cylinders
the head.


i jsut got done rebuilding a 900 kawi and a 1200 yamaha motor for a couple of buddies of mine. the polaris is similar. You may find it cheaper to just get a rebuilt motor. also if the cases are cracked that will be a added expense.
Rob
 
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