Post Your Technical Information Here "NOT A QUESTION SECTION"

[ph2ocraft]

If you have any information you'd like to post in the technical section, please post it here and I will move it to its appropriate location.
I will remove the post once it's dropped into its new location.

JPEG and Word is better than PDF as I want to install the document so that you see your document and not a file or attachment. I can easily convert it, it's just easier.

Thanks to ALL that have and will participate in this section!!!

[Hydrotoys]

How to search

Sometimes the search function up top isn't as friendly as you would hope. So, to help out on these tech articles, I've arranged them by model type first (ultra150, ultra250, kawasaki general etc...) Use the "Thread" button (located under threads in forum) as it is pointed out in the picture to organized alpha-nuemeric. As the post count grows this might not be very friendly, but it does offer an alternative to the search engine.

[Beagleman62]

Mark,
Thanks for the help. I agree that a section just for tech issues will help clean up the forum. Most of the time, a thread's title has absolutely nothing to do with what has been posted under it. At first, it usually has a few posts relating to the title then after that it winds up being something totally unrelated to the original post.
Jimmy

[Hydrotoys]

Well,
unfortunately, not very much info is here. I'm catching hell just trying to fine a concise thread on how to change the oil or something as simple as prop inspection.

Skip has tons of good info, but he chooses to put it offsite (his choice.) So, we can't really use that. I've stickied a post to his work as well as a lot of his answers are just re-directs, so at least that is covered.

It's just going to take time, to allow the first wave of folks to blow over, as info trickles in, eventually.

I KNOW that we are all open to organizational ideas as well as actual tech articles. If you know of any, or have any....no matter how trivial they seem to YOU, please feel free to post them up.

[Hydrotoys]

Also,
if you see missed info, that needs adding to existing thread, just shoot me a PM.

[Wildxard215]

I have an technical issue and need help please

[blakegjones]

Hi. I have a 2007 Ultra Lx and have had huge corrosion problems with my exhaust manifold, exhaust pipe, spigot of first/left/port side muffler, exhaust rings and blue silicone hose.

Let me explain each one individually.

Exhaust manifold
Pin hole corrosion towards the 4 to 1 join and mostly prevalent in one of the cylinder outlets, probably the one lowest to the hull. When I bought it I found someone had done some weld repair work on it. Seems like they welded a hole close from the inside to the outside of the manifold. Skimmed both manifold faces, pressure tested the manifold at at about 2 bar and no leaks. So far so good.

Exhaust pipe
Same corrosion symptoms as manifold. The grooves for the exhaust rings near non existent on the bottom quadrant. I got someone to build up the missing aluminin and re-machined the grooves for the rings. Not perfect but much better than it was. I am concerned about the free play of the rings in the grooves. Not sure what the OEM specification is for the groove width.

Port Muffler
On the inside of the spigot there is also pitting corrosion. Along the internal length of the exhaust pipe as it projects into the muffler, there is pittting corrosion. I did some tests with air and water and it seems the holes go right through to the cooling jacket/annulus where the water is fed from the water cooling system.

Conclusion
My blue exhaust hose had a hole in it one day. I stripped the exhaust system and found everything above. What I think has happened is the following;
1. Someone used ski in salt water and didn't flush it properly/at all
2. Overtime the pinhole corrosion in the muffler made it through to the annulus jacket. At this point water was being pumped into the exhaust pipe and would fill up the exhaust pipe after engine shut down
3. This in turn corroded the inside of the manifold and the exhaust pipe and eventually the grooves for the rings
4. Absent grooves caused the rings to move and eventually break and then exhaust gas burnt hole in blue exhaust hose

It would be great if someone could post the OEM dimensions of the grooves to help those that need to get grooves remachined.

[steve45]

I would suggest you read the title of this thread.

[blakegjones]

The dimensions of the grooves are technical pieces of information that may benefit some users. That's why I posted here.

If not here then where should it be posted steve45?

[sirbreaksalot]

The dimensions of the grooves are technical pieces of information that may benefit some users. That’s why I posted here.

If not here then where should it be posted steve45?

Open discussion as that's all it is .

the dimensions are easy once you have new rings in his hand....just measure them
any competent machinist will know what clearance to give them...….. no different to a piston ring to piston clearance.

[blakegjones]

That's a very simplified answer. The OEM may have machined the ring grooves to be slightly bigger to allow for movement or to allow for thermal expansion of the ring. The exact dimension of the groove (depth and width) is necessary. I have created a new topic/thread elsewhere. Hopefully someone will answer.