Fuel / Exhaust
4.44
Exhaust System -- Inspection
A complete inspection of exhaust components is critical to proper operating performance. Inspect all hoses for
cracks, pinholes, swelling, tears, discoloration, air bubbles, and fatigue. If any of these are evident, the hose
MUST be replaced.
NOTE: A hole in an exhaust hose no more than a pin head in diameter can cause significant power loss and poor
runability.
S Cracking can occur at the bends in the hose and undersides due to normal wear and tear. Inspec-
tion of hoses involve the entire hose.
S All worm gear clamps must be in good working condition. Replace if rusted, stripped, or
stretched.
S Check the condition of each PLANETt acoustic resonator. Replace if damaged. Check each
resonator for impasses due to carbon deposits or foreign material. Replace if material cannot
be removed.
S Inspect each exhaust hose for signs of internal melting or foreign material. Replace hose if lining
are melted.
S Drain the water from the exhaust resonators. Inspect the inside of the resonator for signs of burn-
ing and cracking. Verify that the downpipes inside the resonator are not clogged with carbon or
foreign material. If any cracking is evident, replace the resonator.
NOTE: Burned or bubbled exhaust components are signs of extreme exhaust temperatures. When found, the
cooling hoses should be checked for proper operation. Check the condition of the water inlet fitting located at
the top of the exhaust pipe. For more information on cooling systems, refer to the chapter three, cooling section.
Ex haust System T r oubles hooting
Pr oblem
Possible Cause
Poor Performance Exhaust leaks: Operate watercraft with seat off. If
performance improves, inspect exhaust hoses and
connections. T ighten worm gear clamps.
Exhaust Flow Obstructions: Check inner linings of
hoses for signs of melting. Inspect resonators for for-
eign material and signs of overheating.
Exhaust leaks at manifold: Replace exhaust manifold
gasket(s), re--torque manifold.
Resonator Leaks: Check resonator for holes. Replace
if holes are found.
Overheating Exhaust Components Obstructed cooling hoses: Refer to cooling section in
chapter three.
Obstructed inlet grate: Check for foreign material in
and around the inlet grate and pump.
Fuel and ignition problems: Refer to this chapter’s
Lean Fuel Mixture troubleshooting guide and chapter
seven for ignition troubleshooting.
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