Section 03 ENGINE
Sub-Section 08 (EXHAUST SYSTEM)
03-08-6
SPX Model Only
Move tuned pipe cone
no. 12
in front of bilge be-
tween body and fuel tank.
Open storage cover and remove basket. Then,
pull out tuned pipe cone
no. 12
through storage
compartment opening.
XP, GSX and GTX Models
Remove tuned pipe cone
no. 12
from engine
compartment.
EXHAUST MANIFOLD REMOVAL
SPX, XP, GSX and GTX Models
Remove air intake silencer and carburetors. Refer
to FUEL SYSTEM 05-03 for proper procedure.
All Models
Remove eight screws
no. 14
and lock washers
no. 24
then withdraw exhaust manifold.
MUFFLER REMOVAL
All Models Except the HX and XP
Disconnect hoses from muffler.
Disconnect hoses of the water flow regulator
valve (787 engines).
Disconnect retaining strap
no. 2
of muffler.
Pull muffler
no. 13
out of bilge.
HX Model Only
Loosen exhaust hose collar
no. 1
at tuned pipe
cone outlet (only if tuned pipe cone is not re-
moved).
Remove rear access cover from body.
Disconnect upper exhaust hose
no. 25
in front of
muffler.
Disconnect both water injection hoses and both
water drain hoses from muffler.
Disconnect retaining strap
no. 2
of muffler.
1. Strap
Pull muffler
no. 13
out of bilge.
NOTE:
Lower exhaust hose of muffler may be
disconnected or left with muffler.
TUNED PIPE REPAIR
This procedure is given to repair tuned pipe cracks
using T.I.G. welding process.
Procedure
– Sand the cracked area to obtain bare metal.
– Perform a 1.50 mm (1/16 in) depth chamfer
over crack.
– Use pure argon gas with 5.55 mm (3/32 in)
tungsten electrode (puretung “green”, zirtung
“brown”) and AC current.
– Use a 5.55 mm (3/32 in) aluminum welding rod
(no. 4043), to fill crack.
– Sand welding slightly to remove material sur-
plus.
Test
– Use compressed air at 124 kPa (18 PSI) to pres-
surize tuned pipe.
F01D7JA
F05D07A
1
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