Exhaust leak

[99seadoogtxltd]

I recently rebuilt my carbs and replaced all fuel lines. Upon test riding I noticed I had a exhaust leak at the manifold. So, I have replaced the gasket, applied sealant on both sides and I am let it dry over night. But after I tightened everything back up, When I hit the gas on the water hose, I noticed that the band where the head pipe meets mid pipe is leaking also. Some smoke came from the band area. How do I fix that? I tightened it down almost as tight as I could get it. Im no expert, rather new to the whole jet ski world. Any help would be much appreciated!

 

[Spimothy Leary]

I recently rebuilt my carbs and replaced all fuel lines. Upon test riding I noticed I had a exhaust leak at the manifold. So, I have replaced the gasket, applied sealant on both sides and I am let it dry over night. But after I tightened everything back up, When I hit the gas on the water hose, I noticed that the band where the head pipe meets mid pipe is leaking also. Some smoke came from the band area. How do I fix that? I tightened it down almost as tight as I could get it. Im no expert, rather new to the whole jet ski world. Any help would be much appreciated!

take band off, your probably not fitted just right, the band should tighten down quite a bit ! and its a major PITA to get it just right.

 

[RebuiltSeadooBaffles]

take band off, your probably not fitted just right, the band should tighten down quite a bit ! and its a major PITA to get it just right.

^This, it needs to be put together just right or it will not seal properly, a second set of hands will help

 

[99seadoogtxltd]

Thanks fellas. Ill give it a shot tongiht!

 

[SabrToothSqrl]

the 951 pipe is nothing short of an art.

the threads should stick out past the nut 22-25 mm and it should go on smooth an easy. Bolting it down will NOT help the situation.

read some pages on this forum; you have some research to do!

 

[Britrick]

Pain in the butt that clamp , take the large copper washer out clean it up and clean both faces of the pipe , then put it back together with high temp sealer and make sure the clamp is seated correctly .

 

[summer]

You also want to loosen all the bolts on the exhaust pipe. Including the bracket bolts and the pipe to manifold bolts. Start your reinstall by getting everything a little more than hand tight, then slightly tighten each manifold bolt a turn or so. Then go to the hanger next to the mag cylinder and tighten each of those slightly, then do the same to the big clamp then the rear bracket. Go back to the manifold and repeat until everything is tight. This is the key to getting that big clamp joint sealed correctly. If you tighten it or any other bolt completely first, it will not allow enough movement for it to all settle together. I have removed and reinstalled mine three times and never had a problem. Would do it again tomorrow if I had to and not thing twice about it. And yes I recommend a second set of hands as well. At least until you get all the bolts started.

 

[99seadoogtxltd]

Wow. Sounds like I have opened up a can of worms. This might be a project!

 

[AdamXP800]

Yep! I have heard nightmare stories that will keep you up all night on this subject!

 

[99seadoogtxltd]

Finally got the manifold sealed up. Thank goodness. Now it is time to start my way down the exhaust, this should be interesting. I have had so much practice taking the carbs off i can tear them off and have them back on in 5 mines

 

[SabrToothSqrl]

It takes you 5 min?! Keep practicing! Lol.

 

[99seadoogtxltd]

I figured that was pretty good, being that i had to pay someone two weeks ago to show me how to do it. And I have only owned 1 jet ski and only had it 3 months. Good in my book anyways!

 

[summer]

Finally got the manifold sealed up. Thank goodness. Now it is time to start my way down the exhaust, this should be interesting. I have had so much practice taking the carbs off i can tear them off and have them back on in 5 mines

Are you saying you have torqued all four manifold bolts down without installing the rest of the pipe and bolts? If so you may still have trouble getting the clamp joint to seal.