Exhaust installation

[stevepaulus]

I'm in the process of re-installing my exhaust in a 97 XP. There are 3 parts in the fron hull that come off the engine. The header pipe, the middle one and then the stinger pipe that connects to the rubber coupler. For the life of me i can not get this sh** to line up. What order do i re-install this to make it easy? I have the installation guide but it don't help much, and what ft lbs to i torque the header pipe and carbs?

[ April 25, 2003, 06:28 AM: Message edited by: stevepaulus ]

[Bill O'Neal]

By "header pipe", I'm assuming you mean the exaust manifold. The 97XP has a two piece exhaust pipe. Headpipe and chamber. The complete exhaust system consists of an exhaust manifold, headpipe, tuned chamber, coupler, tube, coupler, muffler, exhaust hose and exhaust thru-hull fitting.

Bolt the exhaust manifold to the motor and torque to 30ft/lbs.

Place the tailcone into the hull and slip it into the rubber coupler of the exhaust tube leading to the muffler, loosely. Do not install any bolts into the cases at this time.

Put the headpipe into place, but do not install any bolts or nuts just yet. Being very careful, align the center pipe joints together and tighten the big clamp. I use orange high temp silicone on this joint. Once you have the center joint put together, you can start all of the mounting bolts and nut. Leave the monuting bolts of the center brace on top of the mag housing loose. Once all of the fastners are started, you can begin tightening the fastners on the headpipe to exhaust manifold joint. Once that is torqued, tighten the rest of the mounting bolts, starting with the chamber to case bolts , then the center mount bolts, last.

Torque to 18-22 ft/lbs on the 8mm bolts, and 30 ft/lbs on the 10mm fastners. Use Blue Loc-Tite on all fasteners.

[stevepaulus]

Thanks Bill, them instructions will work great [img]/graemlins/winkanim.gif[/img]