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  1. #1

    Join Date
    Oct 2011
    Bath, NC

    951 DI exhaust manifold failure - leads to engine lock-up

    After a great weekend ride, and one week in the garage, the engine in my 2001 GTX DI was locked up. This was very strange because the engine was running perfectly when I flushed it out just a week before. I could see cylinder rust and corrosion by removing the rave valves. Upon removing the tuned pipe, I found the rubber gasket melted on one side and then noticed the missing metal from the exhaust manifold flange. In the attached picture, the inner flange of the exhaust manifold is just plain missing from the 1 o’clock to the 8 o’clock position!
    No metal fragments were found anywhere in the engine. Presumably, the fragments were blown by the exhaust down into the muffler.

    My questions are: Has anyone else seen this type of failure? Anyone see a problem with using the exhaust manifold from a 2000 951 engine, which has the “old-style” flat paper gasket? I think SeaDoo changed gasket styles and went to the “machined groove” flange in 2001 – due to water leak problems at this junction.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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  2. #2

    Join Date
    Mar 2006
    The missing metal happens alot. No problem using a 98-00 manifold, just make sure to install everything correctly The paper gasket is a much better design...

  3. #3
    kecheme's Avatar
    Join Date
    Jul 2011
    Phoenix Az
    It happens. Do you ride in salt water?

  4. #4

    Join Date
    Jun 2012
    Forks Twp., PA
    Yes I had the same issue with my 03, replaced it and problem was solved. I think this is a common problem with the exhaust manifold on the 951 motor. Cheap fix, just replace it.

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