Leaking exhaust

[Minnetonka4me]

The biggest thing is replacing the bushings, bolts, and using the correct washers. The washers have a little concave to them which would act like a lock washer.

They did switch in 2002 to bigger bolts and hardware, gotta use a 2002 pipe and mani though.

I do have plenty of manifolds in stock and ready to ship.

 

[Mickirig1]

When I had mine fixed at my machine shop, he heated it up with a torch. Said with an easy out, the broken bolt came right out. He did a chase with a tap and it was good to go. I just figured the manifold being part of the engine. It would be impossible to get. I kinda get great prices at my machine shop. Been going there for 30 years. I walk in and he says: " Oh God What Now? "

 

[racerxxx]

When I had mine fixed at my machine shop, he heated it up with a torch. Said with an easy out, the broken bolt came right out. He did a chase with a tap and it was good to go. I just figured the manifold being part of the engine. It would be impossible to get. I kinda get great prices at my machine shop. Been going there for 30 years. I walk in and he says: " Oh God What Now? "

Some shops love the odd ball job to break up the daily grind.

 

[jwall116]

New bushings ordered as well as gaskets. Will attempt to remove using extractor, if i'm unsuccessful I will be replacing the manifold. Local machine shop told me $20 a bolt to remove, but if I attempt myself, not to even bring it in and it would take a week to get it back. NO THANKS! Challenge accepted

 

[mikidymac]

I say $20 is money well spent. They are a PITA in my experience. Drilling, heating, soaking you name it I have tried it and still never had one just magically unscrew as others have.
I wish you the best of luck and hopefully yours just spins out.

 

[jwall116]

The other two bolts came out without any big effort and had what appeared to be grease on the threads. Leading me to believe the broken bolt also had this treatment.

It's not the $20 charge, it's the keeping of my part for a week that is throwing me off.

Will post my luck in this

 

[mikidymac]

Sometimes left hand drill bits are a good shot too.

 

[jwall116]

Victory !!!

Had to remove manifold to get a strait shot at bolt. Used center punch and dewalt black oxide drill bits with cutting oil. Took my time and gave bit multiple cool downs. Came right out without any trouble.

What goes into the gaskets ?

 

[mikidymac]

That is awesome. So glad it came out easy for you.
The paper gaskets go on dry.

 

[jwall116]

POS stripped the threads upon install, same bolt hole! Heli-coil kit was $40 local, forget that. I am getting a used manifold from Minitonka

I really hope this ski does not keep up with issues keeping me off the water. :cuss:

 

[mikidymac]

That sucks. They are $25 from Amazon but I would just get a good manifold from Minnetonka too.

 

[racerxxx]

Wow, so close to throw in the towel now? Personally I'd fix the one you have but that's me. Ebay has heli-coil kits for $25

Here it is:

http://www.ebay.com/itm/HeliCoil-55...151837?hash=item3f2bf0f71d:g:AGEAAOSw3mpXEApz



Here is my thread on the thread repair of your exact manifold.

http://www.seadooforum.com/showthread.php?61936-717-720-Exhaust-manifold-repair-with-HeliCoil

 

[jwall116]

One way or the other I'm off the water due to me waiting on a part. That alone has ruined my days off. I work 12 hour shifts. 60 hours a week.

I will sell this manifold cheap to recoup some cash

 

[racerxxx]

One way or the other I'm off the water due to me waiting on a part. That alone has ruined my days off. I work 12 hour shifts. 60 hours a week.

I will sell this manifold cheap to recoup some cash

You could hit a local machine shop and they'll probably do it for $20 and you could be back on the water tomorrow.

 

[mikidymac]

Wow, so close to throw in the towel now? Personally I'd fix the one you have but that's me. Ebay has heli-coil kits for $25

Here it is:

http://www.ebay.com/itm/HeliCoil-55...151837?hash=item3f2bf0f71d:g:AGEAAOSw3mpXEApz



Here is my thread on the thread repair of your exact manifold.

http://www.seadooforum.com/showthread.php?61936-717-720-Exhaust-manifold-repair-with-HeliCoil

Thanks a lot Racer...... info that would have been helpful a week ago, LOL. I have been installing heli coils for 25 years now and never realized they had deeper ones. Those would have been better on my cylinders. I knew they had deeper time serts.

 

[racerxxx]

I posted that a few years back, sorry. Next time just ask, lol.

 

[jwall116]

I asked! And I've already ordered the manifold.

 

[mikidymac]

I asked! And I've already ordered the manifold.

Sorry, Jwall that last post was directed to me by Racer in good fun.

 

[jwall116]

I know. All is well !

I started out really enjoying messing with this ski, but once the weather is good and im stuck waiting on a part... my entire mood changes.

Heading out to the lake on the big boat for lunch! Must recover my personality lol

 

[mikidymac]

Well, you could be like the rest of us desperately waiting for it to either get warmer or the lakes to fill :facepalm:

 

[jwall116]

Lol

I bought this as my winter project. Houston had other plans.

 

[poinddexter]

I had the same issue on a 580 this past summer. Once i got the broken bolt out (and then stripped out the new one) i oversized the 8mm threads to 3/8" and it worked perfect. Its just slightly bigger so i didn't even have to open up the pipe holes.