2004 15F Kawasaki: To replace the blue exhaust coupler and exhaust pipe rings...
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  1. #1
    PWCToday Newbie lafox56's Avatar
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    2004 15F Kawasaki: To replace the blue exhaust coupler and exhaust pipe rings...

    ...does the exhaust pipe and/or exhaust manifold have to be removed? Looked at manual and various posts but still unsure.
    Thank you

  2. #2
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    Re: 2004 15F Kawasaki: To replace the blue exhaust coupler and exhaust pipe rings...

    No. After loosening the blue coupler and the output hose to the 2nd water box, you can pull the primary water box back to clear the manifold extension. Will be a PITA to change out the rings, but can be done.

    Only concern is the possibility of major corrosion at the rings on the bottom of the manifold extension. Unless it's off, it's very difficult to see it inspect and decide if the extension should be replaced due to corrosion. If you put new rings on a badly corroded extension, it's time / money wasted as it will not seal properly.

  3. #3
    PWCToday Newbie lafox56's Avatar
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    Re: 2004 15F Kawasaki: To replace the blue exhaust coupler and exhaust pipe rings...

    Thank you so much for the info. Looks like I better remove the manifold and check out everything properly.

  4. #4
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    Re: 2004 15F Kawasaki: To replace the blue exhaust coupler and exhaust pipe rings...

    Quote Originally Posted by lafox56 View Post
    Thank you so much for the info. Looks like I better remove the manifold and check out everything properly.
    To me, you made the correct choice. Only takes about 20 minutes to pull the manifold. Just be sure to get a new graphite gasket for it for reinstallation. While it's off, you can also check the water ports for corrosion, too. Those brass fittings can clog up w/ crap pretty easily.

    When cleaning the ring groves up, be sure to not use a steel brush to do it. Use a S/S or brass one, because the residue from a steel one can cause accelerated corrosion. Some hi temp grease on the part that goes into the water box / rings can help preserve the aluminum. Clean the inside of the water box neck, too, while it's easily accessible.

  5. #5
    PWCToday Newbie lafox56's Avatar
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    Re: 2004 15F Kawasaki: To replace the blue exhaust coupler and exhaust pipe rings...

    Really appreciate the tips! : )

  6. #6
    PWCToday Newbie lafox56's Avatar
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    Re: 2004 15F Kawasaki: To replace the blue exhaust coupler and exhaust pipe rings...

    Should the manifold and manifold extention both be removed and separated or only remove the manifold extention?

  7. #7
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    Re: 2004 15F Kawasaki: To replace the blue exhaust coupler and exhaust pipe rings...

    Quote Originally Posted by lafox56 View Post
    Should the manifold and manifold extention both be removed and separated or only remove the manifold extention?
    If it were me, I would just pull both off, inspect everything, clean what needs to be cleaned, replace what needs to be replaced and be done with it. Piece of mind is priceless.

  8. #8
    PWCToday Newbie lafox56's Avatar
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    Re: 2004 15F Kawasaki: To replace the blue exhaust coupler and exhaust pipe rings...

    Thank you

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