Blew exhaust rubber coupler
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  1. #1
    PWCToday Regular guy48065's Avatar
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    Blew exhaust rubber coupler

    Last weekend during a WFO run I blew a big hole in the rubber coupler closest to the water box. Should I source an "upgraded" coupler like a silicone boot that maybe can take the heat better?
    None of these parts are cheap & I don't want to waste $ on something unnecessary.
    96 & 97 1100Zxi

  2. #2
    PWCToday.com Is My Home Away From Home john zigler's Avatar
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    Re: Blew exhaust rubber coupler

    This usually happens from lack of water. IE you probably have some sand, or blockage in your exh somewhere, the pipe got hot, and blew the coupler.

    Go over all fittings on your pipe / cooling system, and make sure everything is clear.

    Check your hose from water box - out. Make sure this is not crusty inside.
    RCJS also doing business as WATCON
    608-743-1305 9am to 5pm CST m-f
    email watcon@watcon.com

    Please visit our web site

    new parts / products / services www.watcon.com
    thank you

    Please check out and like WATCON on Facebook

  3. #3
    PWCToday Regular guy48065's Avatar
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    Re: Blew exhaust rubber coupler

    The cooling system is very confusing and has dogged me all summer. This is the first jetski I've owned. I bought it from a man who only owned it a year and knew nothing of its history.
    It's overheated a couple times before but always gave me warning via the overtemp light. Not this time.

    Once I had it back in the driveway I disconnected the cooling hose from the pump and fed it with the garden hose so the entire cooling system could get water flow, and in the correct direction. It looks like the exhaust gets most of its water from a hose connected to the stator cover. With that hose disconnected there's a strong fountain of water spraying up from that fitting. From there it just drops into the expansion chamber. I removed the head pipe and stuck my hand in the expansion chamber and the water flow in through that nipple was strong.

    I haven't checked the flow from the head into the headpipe but that doesn't look like a big contributor to the water flowing into the exhaust bc only a small amount flows thru a small hole in the gasket--the rest flows past the temp sensor & out thru the pisser. Visible flow there seems weak but I have nothing to compare it to. The stream from the expansion chamber nipple & out the rear hull is strong.

    But all this was on the garden hose and the engine ran frosty cool then. I have no idea if the problem has cleared up, or if it will show up again the next time I put it in the lake.

    I'll add diagrams in the morning and hopefully someone experienced can tell me if I have the connections, path and flow directions correct.

    And BTW this machine is at my cottage 200 miles away and it's getting to be too cold in upper Michigan. Just a couple extra hurdles in trying to figure this issue out.
    Last edited by guy48065; 09-30-2020 at 10:35 PM.
    96 & 97 1100Zxi

  4. #4
    PWCToday.com Is My Home Away From Home john zigler's Avatar
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    Re: Blew exhaust rubber coupler

    Running on the hose is not always an accurate test.

    I suggest pulling ALL small hoses, and blow out with the air compressor both ways.

    We also pull all the brass fittings, and inspect. I cannot tell you how many times we find small rocks lodged in these.

    Then, be sure to KEEP your ski in deep water.
    RCJS also doing business as WATCON
    608-743-1305 9am to 5pm CST m-f
    email watcon@watcon.com

    Please visit our web site

    new parts / products / services www.watcon.com
    thank you

    Please check out and like WATCON on Facebook

  5. #5
    PWCToday Regular guy48065's Avatar
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    Re: Blew exhaust rubber coupler

    The diagrams in the factory service manual are confusing so I searched far & wide for better.
    Whoever did the block diagram didn't include the water path thru the stator cover so I made some changes to that diagram, and added direction arrows to the diagram based on the service manual. Can someone check these for accuracy?
    I'm still unclear if any water flows in the exhaust inside the headpipe, or if all flow is in the water jacket.


    1100zxi_cooling1.jpg

    1100zxi_cooling2.jpg
    96 & 97 1100Zxi

  6. #6
    Attention ***** PWCToday.com Is My Home Away From Home JonnyX2's Avatar
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    Re: Blew exhaust rubber coupler

    Add a little more water by opening the water screw(s) a 1/4 turn. It doesn't take much.
    Quote Originally Posted by Firebird A/C&Heating View Post
    OMG.....Rules for 550 vintage ski class...550 ski riders do not conform to any kind of rules. That is why you are riding a 550 ski in the first place. Rules suck....
    PS...the rule book will be in my 550 pump
    Quote Originally Posted by WB1994
    Listen , stop your cryin' , its only an X2.

  7. #7
    PWCToday Regular guy48065's Avatar
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    Re: Blew exhaust rubber coupler

    WHAT water screw?
    96 & 97 1100Zxi

  8. #8
    Attention ***** PWCToday.com Is My Home Away From Home JonnyX2's Avatar
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    Re: Blew exhaust rubber coupler

    Sorry misread your post I thought you had a Factory Pipe
    Quote Originally Posted by Firebird A/C&Heating View Post
    OMG.....Rules for 550 vintage ski class...550 ski riders do not conform to any kind of rules. That is why you are riding a 550 ski in the first place. Rules suck....
    PS...the rule book will be in my 550 pump
    Quote Originally Posted by WB1994
    Listen , stop your cryin' , its only an X2.

  9. #9
    PWCToday.com Is My Home Away From Home john zigler's Avatar
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    Re: Blew exhaust rubber coupler

    Quote Originally Posted by guy48065 View Post
    The diagrams in the factory service manual are confusing so I searched far & wide for better.
    Whoever did the block diagram didn't include the water path thru the stator cover so I made some changes to that diagram, and added direction arrows to the diagram based on the service manual. Can someone check these for accuracy?
    I'm still unclear if any water flows in the exhaust inside the headpipe, or if all flow is in the water jacket.


    1100zxi_cooling1.jpg

    1100zxi_cooling2.jpg
    Going by my memory, your diagram looks to be correct.

    Water is injected in the head pipe to the inner exhaust. THIS is what keeps your couplers, and rubber hoses cool.
    RCJS also doing business as WATCON
    608-743-1305 9am to 5pm CST m-f
    email watcon@watcon.com

    Please visit our web site

    new parts / products / services www.watcon.com
    thank you

    Please check out and like WATCON on Facebook

  10. #10
    PWCToday Regular guy48065's Avatar
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    Re: Blew exhaust rubber coupler

    Can anyone tell me the dimensions of the exhaust coupler (92190-3950)?
    I can get aftermarket and silicone couplers for less $$ than the OEM rubber part but I can't seem to find the specs or an interchange guide.
    96 & 97 1100Zxi

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