Sea-doo GTX Limited iS 255 2009, Shop Manual

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Section 02 ENGINE
Subsection 06 (EXHAUST SYSTEM)
3. Disconnect the exhaust manifold water outlet
hose.
smr2009-016-023_a
1. Water outlet hose
2. Exhaust manifold
4. Disconnect exhaust manifold water inlet hose
from exhaust manifold.
smr2009-016-024_a
1. Exhaust manifold water inlet hose
5. Unscrew the exhaust manifold beginning with
the bottom screws. This will help holding the
manifold while you remove the screws.
6. Move the manifold rearwards to remove it from
vehicle.
Exhaust Manifold Inspection
Inspect exhaust manifold condition paying atten-
tion for cracks or other damage. Check contact
surfaces and hose. Replace any defective part.
Inspect plane surfaces for warpage. Small defor-
mation 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.
Exhaust Manifold Installation
Installation is essentially the reverse of removal
procedures. However, pay particular attention to
the following.
NOTE: There is no gasket between cylinder block
and exhaust manifold.
Apply
LOCTITE 243 (BLUE) (P/N 293 800 060)
on
threads of screws.
To help holding the manifold while installing
screws, first insert the exhaust manifold into the
exhaust pipe then, install the upper front screw.
Continue with the remaining screws.
Torque screws to 9 N•m (80 lbf• in ) as per follow-
ing illustrated sequence. Repeat the procedure,
torquing screws again to 9 N•m (80 lbf•
in ).
R1503motr152A
7 5 1 3 9 11
8 6 4 2 10 12
After installation, ensure there is no water or ex-
haust gas leak when the engine is running. Test
run the engine while supplying water to the flush-
ing connector.
NOTICE
Never run engine without supplying
water to the exhaust system when watercraft is
out of water.
RESONATOR
Resonator Removal
Remove engine from vehicle. Refer to ENGINE
REMOVAL AND INSTALLATION subsection.
Remove battery and battery holder. Refer to
CHARGING SYSTEM subsection.
Loosen clamp securing rear exhaust hose to res-
onator.
Remove the front exhaust hose from resonator.
Remove resonator from vehicle.
Resonator Inspection
Inspect parts condition paying attention for defor-
mation, cracks or other damage. Check hoses.
Replace any defective part.
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