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  1. #1
    PWCToday Guru E350's Avatar
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    '88 x2 650cc What's the size of the oem Exhaust Manifold Bolts?

    So I got my Mitivac MV8510 from Amazon to do the vacuum test and pressure test on the 650 in the X2 (and I can also use it for other things like the Cody test on the 7.3L PSD in my van).

    So I remove the bolts, make my block off gasket for the exhaust side and start to reinstall the bolts with the block off gasket and ...

    1. All of the bolts are socket heads which makes no sense given the fact that one of them sits directly underneath a pisser port which makes it nearly impossible to remove and reinstall (I cut a #8mm allen wrench to 3/4" long and used an open end wrench on the allen wrench to remove it. The person who installed socket heads instead of cap heads should be flogged 30 times; and

    2. WTF !!!!! One of the three manifold bolts is ~1.25" x 10mm 1.50 while the other two bolts are ~1" x 10mm 1.25.

    The bolt is shown on the attached 1988 JET SKIŽ X-2 Muffler(s) - Parts Diagram as part number 130, but it does not list its size.

    I am buying stainless steel replacement cap heads tomorrow morning.

    WHAT IS THE OEM MANIFOLD BOLT SIZE?

    P.S. If the person who chose socket heads over cap heads is the same person who decided that a 10mm 1.5 would work in place of a 10mm 1.25, then he or she should be taken outside and summarily shot. Let me repeat that with emphasis.

    Do it right or don't do it at all guys and gals! This ski is 29 years old this year and still runs like a raging bull! Your ski will likely outlive you. Think about the people who will be owning it after you! Show some respect for your equipment!

    Grumble, mumble, grumble, mumble ...

    Any help would be greatly appreciated.
    Attachment 530919
    Attachment 530920
    Last edited by E350; 09-25-2017 at 12:35 AM.
    Learning Slowly...

  2. #2

    Re: '88 x2 650cc What's the size of the oem Exhaust Manifold Bolts?

    I thought that they were studs?

  3. #3
    I dream skis JC-SuperJet's Avatar
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    Re: '88 x2 650cc What's the size of the oem Exhaust Manifold Bolts?

    I would say 8mm diameter x 30mm Stud because Kawasaki Exhaust Stud Size.jpg.

    If the nomenclature is similar to Yamaha's, then 172R0830 BOLT-STUD would signify 08 mm x 30 mm.

    If you study the photo and compare the ruler marks to the stud length, looks to be just over an inch, which is 25 millimeters.
    Last edited by JC-SuperJet; 09-25-2017 at 12:02 PM.

  4. #4
    I dream skis JC-SuperJet's Avatar
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    Re: '88 x2 650cc What's the size of the oem Exhaust Manifold Bolts?

    Part #130 = Exhaust Manifold to Head Pipe are 92150-3819 BOLT,10X50 = 10mm diameter x 50 mm Bolts
    Last edited by JC-SuperJet; 09-25-2017 at 12:08 PM.

  5. #5
    PWCToday Guru E350's Avatar
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    Re: '88 x2 650cc What's the size of the oem Exhaust Manifold Bolts?

    JC SuperJet: Thank you. I know that took a lot of work to photograph! Are my attachments not opening you guys?

    1988 JET SKIŽ X-2 Muffler(s)_Page_1.jpgDSC03681 - lq.jpg

    They are the three "MANIFOLD-EXHAUST (Ref # 59081) 59081-3702" hex cap head bolts that attach to the pipe that I am looking for the dimensions for. (No. 130 on the attached diagram.)

    Please let me know if the photo and the parts diagram attachments are not opening and I will try to repost them.

    By the way, it looks like the 89-95 exhaust manifold has through holes for the these bolts, while the 1988 has "blind" holes that the bolts thread in to. (Which means that using a bolt which is too long will also strip the manifold...)
    Last edited by E350; 09-25-2017 at 12:23 PM.
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  6. #6
    PWCToday Guru E350's Avatar
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    Re: '88 x2 650cc What's the size of the oem Exhaust Manifold Bolts?

    JC SuperJet: Dude you are being really helpful, thanks! Thank you for providing the length! But what is the thread count?

    One of my three bolts is 10mm 1.50 (metric course) and the other two are 10mm 1.25 (metric fine).
    Last edited by E350; 09-25-2017 at 12:22 PM.
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  7. #7
    I dream skis JC-SuperJet's Avatar
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    Re: '88 x2 650cc What's the size of the oem Exhaust Manifold Bolts?

    Not sure what the OEM pitch is but maybe the threads were re-tapped or repaired with Helicoils, Timeserts or other type of insert?

  8. #8
    Top Dog bandit88's Avatar
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    Re: '88 x2 650cc What's the size of the oem Exhaust Manifold Bolts?

    M8x1.25, not sure of the length of the OEM bolt, Factory pipe bolts are 50mm long, I want to say OEM is 40mm long
    -95 750SXI
    -86 440 with PJS800 conversion
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  9. #9
    PWCToday Guru E350's Avatar
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    Re: '88 x2 650cc What's the size of the oem Exhaust Manifold Bolts?

    JC-Superjet: I just spent about $20 at our best hardware store which has an incredible fastener selection, Emigh Hardware in Sacramento. Just by chance the owner of the fastener supply company which sells to Emigh Hardware was there. And he looked at my three bolts and determined that two of the three socket heads were 1.5 pitch (course ~16 threads per inch) and only one was 1.25 pitch (fine at about ~20 threads per inch), and at my photo, and surmised that since the manifold is made out of aluminium that the course thread was likely the OEM pitch because aluminum holds course threads better than fine threads.

    So, I bought new stainless 10mm socket heads in both 25mm and 30mm lengths and hex cap heads in the same lengths and some zinc 10mm in both lengths and some new 10mm stainless steel washers and will gently try them. I may even run a tap down them first.

    He pointed out that the 1.25 pitch was somewhat "worn" likely because it was forced into a 1.5 thread pitch hole.

    Finally, because the stainless aftermarket pipe (Coffman ?) I have has a shorter shoulder than the OEM aluminum pipe, the OEM bolt length of 50mm would be way too long for my application.

    I assume that people were stripping their manifolds on the 1988 manifold and earlier by using too long bolts and bottoming them out. So, that is why the 1989 to 1995 manifolds have through holes in the manifolds instead of the blind/closed-end bolt holes.

    Anyway, I will know how it works this evening after work and post up the results.

    Thanks for your interest and all your help.
    Last edited by E350; 09-25-2017 at 04:45 PM.
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  10. #10
    Resident Guru still standin's Avatar
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    Re: '88 x2 650cc What's the size of the oem Exhaust Manifold Bolts?

    The bolts you want are M10 x 1.25 pitch x 40mm long. Hard to find in stainless. The Rad Dudes sell them.

    McMaster Carr has them but not in stainless.
    Last edited by still standin; 09-25-2017 at 05:11 PM.
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