Exhaust Manifold - Sea-doo 2005 4-Tec models Shop Manual

Section 03 ENGINE SYSTEM
Subsection 04 (EXHAUST SYSTEM)
1. Exhaust pipe flange
2. Exhaust clamp
3. Engine manifold
Apply a soapy solution on inner side of muffler
strap no. 5 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 inlet hose no. 8.
Care must be taken not to induce strain on hose
to avoid muffler movement.
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Reconnect cooling hoses to the exhaust pipe and
torque clamps to 8 N•m (71 lbf•in).
54
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.
CAUTION: Never run engine without supplying
water to the exhaust cooling system when wa-
tercraft is out of water.

EXHAUST MANIFOLD

Removal
Disconnect the cooling hoses from the exhaust
pipe no. 1.
Remove the exhaust clamp no. 6 and detach the
muffler from its support. Move the muffler no. 4
rearwards to separate the exhaust pipe from the
manifold. See above in EXHAUST PIPE.
Disconnect the cooling system supply hose under-
neath the front part of the exhaust manifold no. 7.
NOTE: On inter-cooled engines, the hose comes
from the intercooler.
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.
NOTE: On RXP models, move the manifold rear-
wards to remove it from vehicle.
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