Section 05
ENGINE (4-TEC)
Subsection 04
(EXHAUST SYSTEM)
SMR2002-068_05_04A.FM
05-04-5
Rotate (axially) and move (longitudinally) the muf-
fler (LH) so that the exhaust pipe flange makes
perfect contact with the engine manifold. A maxi-
mum gap of 1 mm (3/64 in) is allowed.
Torque the exhaust clamp
no. 4
to 11 N•m (97
lbf•
in
) while maintaining the exhaust pipe in the
proper position.
Reinstall the muffler (LH) strap
no. 11
using the
spring installer/remover (P/N 529 035 559). Care
must be taken not to induce strain in the flexible
joint of the exhaust tube.
Torque the two clamps located in the upper part
of the muffler (LH) hose to 8 N•m (71 lbf•
in
). 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 (71 lbf•
in
).
CAUTION:
Never run engine without supplying
water to the exhaust cooling system when water-
craft is out of water.
After installation, ensure there is no water or exhaust
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 (LH) from its support. Move the muffler
(LH)
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.
1. Exhaust manifold
2. Cooling system supply hose location
Unscrew the exhaust manifold
no. 9
beginning
with the bottom screws. This will help holding the
manifold while you remove the screws.
Remove the manifold and move it out toward the
front of the watercraft to withdraw.
Inspection
Inspect exhaust manifold condition paying attention
for cracks or other damage. Check contact surfaces
and hose. Replace any defective part.
Inspect plane surfaces for warpage. Small deforma-
tion can be corrected by grinding surface with a fine
sand paper. Install sand paper on a surface plate and
rub part against oiled sand paper.
Clean all metal components in a solvent.
1
R1503motr151A
2
F18D0LA
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Summary of Contents for GTX 4-TEC 5573 2002
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