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  1. #1
    mr. happyfunbear tenjuna's Avatar
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    HELP! Exhaust leak in 2002 Virage 1200?

    So I finally got around to pulling my Virage out of storage this past weekend.

    Got it put back together, started her up, and the expected volume of smoke except a lot of it was coming from inside the engine compartment. It seems to billow out from the exhaust side of the engine, but I could not pinpoint it.

    I had no problems at all with this ski when I put it away.

    I took her out, left the seat off, and it ran just fine at WOT for a good long while.

    Did I do something wrong, or did I blow a gasket maybe???

    Any ideas?

    Cain


  2. #2
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by tenjuna View Post
    ...Got it put back together, started her up, and the expected volume of smoke except a lot of it was coming from inside the engine compartment. It seems to billow out from the exhaust side of the engine, but I could not pinpoint it...

    ...I took her out, left the seat off, and it ran just fine at WOT for a good long while.

    Did I do something wrong, or did I blow a gasket maybe?...
    You ran it without the seat on the water at full throttle, or on land?
    Just recently, or last year?

    Check the exhaust hoses for damage, especially the huge, stubby hose (Item 13 in diagram) that links the two big sections of the exhaust pipe, down low on the left side of the engine.

    Use an inspection mirror to see underneath.

    Check the large U-shaped hose (item 2) for softness. If not sure, remove the hose and inspect the inside.

    Also check the exhaust water injection for clogs - items 9 & 10, which are linked with a small diameter hose. If the water injection into the exhaust is blocked, it will allow the rubber hoses to overheat and melt.
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    Last edited by K447; 05-24-2010 at 11:33 AM. Reason: Corrected item numbers

  3. #3
    mr. happyfunbear tenjuna's Avatar
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    I took her out yesterday on the water. Once the de-winterizing smoke cleared, that's when I ran WOT.

    Thanks for the advice...the part blowout you posted does not match the numbers you stated but I think I get what you are saying.

    Thanks again for your help, I will check it out and report back.

    Cain

  4. #4
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by tenjuna View Post
    ...the part blowout you posted does not match the numbers you stated...
    Now corrected - working too fast here

  5. #5
    mr. happyfunbear tenjuna's Avatar
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    Quote Originally Posted by K447 View Post
    Now corrected - working too fast here

    I finally got a chance to take things apart last night, and everything looked good to me.

    I didn't take the exhaust manifold off due to gaskets being $75, so the leak is either the gaskets or the hose coming off the fitting on the bottom of the manifold (I suspect this hose is melted and that is where the leak is coming from due to how the smoke comes off the engine, it is part #11 in the picture). either way cannot go any further without new gaskets.

    anyone know where I can get a set of gaskets for way cheaper? I r the broke.

    J

  6. #6
    Click avatar for tech links/info, donation request K447's Avatar
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    Part 11 is leaking exhaust fumes?

    Am I looking at the wrong diagram?

  7. #7
    mr. happyfunbear tenjuna's Avatar
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    Quote Originally Posted by K447 View Post
    Part 11 is leaking exhaust fumes?

    Am I looking at the wrong diagram?
    More specifically the hose that attaches to 11, I believe this is the water intake for the exhaust cooling? I don't know for sure, but I suspsect the hose is melted.

  8. #8
    mr. happyfunbear tenjuna's Avatar
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    found the hose thanks to zig, now just need to find a reasonably priced set of exhaust gaskets and I am back on the water!

  9. #9
    Click avatar for tech links/info, donation request K447's Avatar
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    Try to check that large diameter, very short coupling hose section (Item 13) located in between the heavy exhaust manifold sections. See first attached photo.

    That would be where I would think exhaust would leak out from if the exhaust was overheated.

    I think you can remove the lower section of the exhaust manifold without touching the upper exhaust manifold bolts.

    You would need to remove the water box to give yourself room to work. Then undo the rubber mountings that hold the lower exhaust section in place.

    Loosen those huge hose clamps around that stubby rubber section, and watch for the smaller water cooling hoses that attach to that lower rear manifold section. You may need to undo them, or you might get away with just sliding the lower manifold section back with them still attached.

    With some swearing, you should then be able to slide that exhaust section rearwards.

    Now you can remove and inspect that large diameter stubby hose piece. My suspicion is that you have melted that hose too.

    The rest of the photos show details of where that medium sized cooling hose actually connects to the bottom of the exhaust manifold/pipe.
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  10. #10
    mr. happyfunbear tenjuna's Avatar
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    I tore down the exhaust system down to and including the large stubby hose and it looked fine it was very pliable had no cracks or holes. I can't see the medium hose underneath but that's all that's left so it either that or a blown gasket.

    Ordered the hose from zig just in case and once I find gaskets I will redo it and get back out there.

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