March 1999

The following are requirements and recommendations that must be done prior to running the above named system. Upon purchase of the enclosed system, it is agreed by you to do the following:

1. You must utilize an aftermarket rev limiter (NOT INCLUDED) with the "Signature Series" XP951 Ltd. Exhaust. Any warranties on the rev limiter purchased are to be addressed to the manufacturer of sold product. (Please note: The '98 and '99's are different! Make sure that you have a rev limiter that is adaptable to your year boat)

2. This system is not adaptable to the 2000RX model boats.

3. It is extremely important to note that you are installing a high performance exhaust system that increases your horsepower substantially as well as a RPM increase. these boats have been known to have crank failures and seizure problems in STOCK FORM, let alone adding other performance accessories. Further performance products can place your boat at a higher risk, and should be taken into consideration PRIOR to installing your new exhaust, etc.

3/1999

1ea. Expansion Chamber 1ea. Exhaust Flange

1ea. 3"OD x 1 3/4 Silicone Hose 1ea. 1/2"OD x 5" Waterline

2ea. 1/4" OD x 22" Waterline 1ea. 3/8 x 5" Waterline

1ea. 3/8 x 3/8 x 1/4" Nylon "T" Fitting 2ea. 70-90 Norma Clamps

2ea. 1/2" Clamps 8ea. Zip Ties

1ea. Exhaust flange gasket 1ea. 1/8" Brass pipe plug

1ea. Micro-Touch Water Controller 1ea. Solenoid

1ea. Weather Pack Connector 2ea. Female Electrical Connectors

2ea. Rubber Seals 1ea. 1/8 x 1/4" Straight Brass Fitting

1ea. 1/8 x 3/8 Straight Brass Fitting

1ea. Aluminum Tray Cover Plate 2ea. 3/32 Screws

4ea. 3/32 Nuts

1. Remove stock exhaust system, leaving exhaust manifold and stock waterbox hose in place.

2. Clean exhaust manifold gasket surface good. (Very important)

3. Take the stock 1/2" waterline that was connected between the stock expansion chamber and then ran out the boat, and run this line under the motor tot he right side of the hull. (so instead of it being on the front of the motor, it will then be on the right side of the motor)

4. Take and install the new head pipe gasket (supplied) onto the exhaust manifold (no sealant required as these gaskets are pre-dipped for sealing) and install flange (supplied). Tighten evenly with stock bolts (28 ft. pounds).

5. Loosen the 3ea. 8mm bolts that hold the front stock exhaust mounting bracket.

6. Take the Coffman pipe making sure that the 3" silicone coupler is FLUSH with the collar on the chamber. (You'll move this forward later) This is very important.

7. Slide the pipe onto the flange aligning the bracket and the waterbox hose. Push the silicone hose down onto the flange and install the stock bolt onto chamber body, and tighten chamber body.

8. Tighten the 3ea. 8mm bolts that held the mounting bracket in place. Make sure that the pipe is secure in the stock hose between pipe and waterbox. If it's not, you'll want to push the waterbox and the tube forward onto the chamber, and then tighten the clamps down.

9. Install the 70-90 hose clamps (supplied) onto the 3" silicone coupler and tighten. Make sure these clamps are straight. Do not over tighten.

1. Take the 1/2" x 5" waterline (supplied) and run from the 1/2" 90 degree brass fitting on flange to the 1/2" 90 degree brass fitting on top of the expansion chamber. Tighten with supplied 1/2" clamps.

2. Take the stock 1/2" waterline that you installed underneath the motor to the right hand side of the boat and hook up to the 1/2" 90 degree brass fitting on the bottom of pipe and tighten with stock clamp.

3. Take the stock 1/4" water bypass line and hook up to the straight 1/4" brass fitting on the flange and zip tie secure. IMPORTANT....You will only be running 1 of the 1/4" bypass lines. Make sure you plug the second line!! This is extremely important! Water will fill your hull unless the process is completed!

4. Remove the water valve on the top of the waterbox and the waterline connected to it from the hull. Plug this hole with 1/8" pipe plug (supplied).

IMPORTANT NOTE: The following steps 1 and 2 should be assembled prior to installing on hard parts. This will make it much easier to secure later. Please refer to water diagram for guidance.

1. On the stock 1/2" incoming waterline, there is a 1/2" T. You need to hook up the waterlines starting from this point.

2. Referring to diagram, lay out your waterlines and solenoid. Secure all in place with zip ties on each of the waterlines.

VERY IMPORTANT Make sure that the solenoid "in" and "out" are installed in the correct direction!!!

Go back and make sure that each line is secure before proceeding to the next step.

3. Locate a desired location for the Micro-Touch module to secure MAKING SURE that it is not located next to the coils!!! Secure in place by either using zip ties or double sided sticky tape, etc.

4. The RED wire connects to the POSITIVE on the battery.

5. The BLACK wire connects to the NEGATIVE on the battery.

6. The BROWN wire does not hook up to anything.

7. The YELLOW wire should be wrapped around the spark plug wire at least 3 times and secured. (On the 1999 models, you will need to wrap this yellow wire around BOTH spark plugs 3 times).

8. Hook up the weather pack connector assembly to solenoid.

9. Plug in the Micro-touch module to solenoid.

10. Preset module to 2000 "On" and 6750 "Off". OR 2000 "On" and 6400 "Off". On a completely bone stock boat, the 6750 seems to work the best. If you utilize an aftermarket head, etc. the 6400 setting for "off" seems to work better.

You MUST utilize an aftermarket rev limiter (such as the Micro-Touch) installed prior to running this exhaust system. (AGAIN... the 1998 and 1999 rev limiters are DIFFERENT!)

1. If utilizing the Micro-Touch Rev limiter, set it at 7750 and the timing retard at 1/2 degree. (1998 Model). When the 1999 models become available, we will be able to give you further specifications.

Install aluminum tray plate cover (supplied) on left hand side of storage tray. Trace with a market on the bottom of the tray around plate. Using a hack saw blade or drummel tool, etc. (CAUTION IS REQUIRED!), trim along bottom 1/2" IN FROM YOUR TRACING so that the tray CLEARS THE EXHAUST PIPE. You can always go back later and trim a little extra if you need it for clearance. A small portion will need to be cut around the corner of where the fire extinguisher is located to clear the brass fitting on pipe.

When everything has clearance, bolt down the aluminum plate to plastic OEM tray (with bolts supplied), and silicone around all edges.

Jetting recommendations with a completely stock boat run at sea level should remain at stock settings. It is highly suggested to make sure that your boat is running rich enough, and perform a plug test prior to running extensively. This is YOUR RESPONSIBILITY!

For the knowledgeable personal watercraft enthusiast, we encourage you to experiment with water flow and jet sizes with this system to give you the maximum performance benefit with YOUR PARTICULAR SET UP. (This is do be done at your own discretion.) On a stock boat, the way we have the waterlines and jets set up initially for you creates the maximum OVERALL benefit. However, depending upon your application, you may want more bottom end torque or top end speed gain. Also keep in mind that running a different prop or repitching your stock one will effect how much water pressure will be delivered to the pipe for tuning purposes. You may need to adjust your water directly to the pipe to accommodate for this.

COFFMAN'S EXHAUST SYSTEMS

181 Wabash Ave. Ukiah, CA 95482 USA (707)462-7881 or (707)462-9369 fax

e-mail: coffmans@pacific.net

web site: www.coffmansexhaust.com