Section 05 ENGINE (4-TEC)
Subsection 03 (EXHAUST SYSTEM)
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F18D0XA
23
1. Exhaust pipe flange
2. Exhaust clamp
3. Engine manifold
Apply a soapy solution on inner side of muffler
strap no. 7 to prevent muffler rotation at strap in-
stallation.
Reinstall muffler strap using the spring installer/re-
mover (P/N 529 035 989). Care must be taken not
to induce any rotation of the muffler.
Tighten the bottom clamp of the muffler. Care
must be taken not to induce strain in the flexible
joint of the exhaust tube.
Reconnect the water lines to the exhaust pipe and
torque to 8 N•m(71lbf•in).
CAUTION: Never run engine without supplying
water to the exhaust cooling system when wa-
tercraft is out of water.
After installation, ensure there is no water or ex-
haust gas leak when engine is running. Test run
the engine while supplying water to the flushing
connector.
EXHAUST MANIFOLD
Removal
Disconnect the cooling hoses no. 2 and no. 3 from
the exhaust pipe no. 1.
Remove the exhaust clamp no. 4 and detach the
muffler from its support. Move the muffler no. 6
rearwards to separate the exhaust pipe from the
manifold. See above in EXHAUST PIPE.
Disconnect the cooling system supply hose no. 8
underneath the front part of the exhaust manifold.
NOTE: On inter-cooled engines, the hose comes
from the intercooler.
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R1503motr151A
2
1. Exhaust manifold
2. Cooling system supply hose location
Unscrew the exhaust manifold beginning with the
bottom screws. This will help holding the mani-
fold while you remove the screws.
Remove the manifold and move it out toward the
front of the watercraft to withdraw.
F18D0LA
Inspection
Inspect exhaust manifold co
ndition paying atten-
tionforcracksorotherda
mage. Check contact
surfaces and hose. Repl
ace any defective part.
smr2004-Complete Line Up 213
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