Please read all instructions PRIOR to installing your Coffman exhaust system!INSTALLATION INSTRUCTIONS
(e-mail) coffmans@pacific.net
"Signature Series" SeadooÒ 800 Race Exhaust SystemTHANK YOU FOR CHOOSING COFFMAN'SInstallation Instructions
Parts Included
1ea. Chamber Body 1ea. Exhaust Flange
1ea. Head Pipe Gasket 1ea. 2"ID x 4"L Black Exhaust Hose
1ea. 3"ID x 1 3/4"L Silicone Hose 5ea. 3/8" Norma Clamps
2ea. 70-90 Norma Clamps 4ea. 1/2" Clamps
11ea. Zip Ties 1ea. 65 Main Jet(Installed in 1/4" T-Fitting)
2ea. 90 Main Jets(Installed in 2 of the 1/4" T-Fittings)
1ea. 1/8" Brass Plug 2ea. 1/8 x 3/8 90 degree brass fitting (on pipe)
1ea. 1/8 x 1/4" straight brass fitting (Installed on flange)
2ea. 1/2" x 3/8 x 1/2 T-Fitting 2ea. 1/4" T-Fitting
1ea. 1/2 x 5 1/2"L Waterline 1ea. 1/2 x 7"L Waterline
1ea. 3/8 x 4 1/2"L Waterline 13a. 3/8 x 12"L Waterline
1ea. 1/4 x 12"L Waterline
Water Injection Components Included:
1ea. Microtouch Water Controller 1ea. Solenoid
2ea. 1/8 x 1/4" Straight brass fitting 1ea. Weather Pack Connector
2ea. Female Electrical Connectors 2ea. Rubber SealsInstallation Procedures:
1. Remove the stock exhaust system including the mounting brackets, the hose from the head to the stock exhaust, and the water valve that is mounted on the top of the stock waterbox. Leave the stock exhaust manifold in place.2. Clean the gasket surface on the stock exhaust manifold.
3. There are 2 ways you can install this exhaust system. The first method can be used on the '95-96 XP's, or SPX's. Drain the gas completely out of the gas tank, and remove from ski. Please use caution when doing this! Loosen up the electrical box. Slide the pipe into the front of the boat into place.
The second method, you need to undo the electrical wire from the motor to electrical box.
Remove the grey cover on the PTO, and undo the clamp on the drive shaft to the rubber seal.
Remove the two lower 8mm bolts on the front engine mount to the hull. (IMPORTANT! FIRST MARK THE BOTTOM OF THE ENGINE MOUNT TO THE HULL WITH A MARKER! THIS WILL MAKE IT MUCH EASIER TO REALIGN MOTOR LATER)
Remove the back top 8mm bolts to the engine mounts using the above described method of marking the washers on bolts PRIOR to removing.
Slide the engine forward off of the drive shaft, and shift it towards the carburetor side of boat while pushing the motor towards the back of the boat, lifting up on the front of the motor. It is best to use the BUDDY SYSTEM when doing this so one person can shift the motor, and the second person can slide the pipe into position.
Reinstall the motor onto the drive shaft aligning up the bolts in the original position where you previously had marked. Make sure you reinstall the original clamps on the drive shaft (or zip tie), and stock bolts to motor mounts.
At this point, you now have the pipe within your hull!
4. Install the new gasket (supplied) on to the exhaust manifold
5. Install the exhaust flange (supplied) with the alloy spicket facing the bottom of the boat. Using all the stock bolts and washers, install on Coffman flange, and torque to SeadooÒspecs.
6. Install the 2" x 4"L black exhaust hose onto the waterbox. Slide the STOCK clamps onto hose, but do not tighten yet. (On some model boats, this hose might need to be shorter!)
7. Take the 3" x 1 3/4"L silicone hose and install onto the exhaust flange. Tighten with one of the 70-90 clamps. Slide the other 70-90 clamp onto opposite end of hose.
8. Install the stock mounting bracket onto magnito cover, and leave loose.
9. Undo the waterbox strap.
10. Slide the exhaust system onto silicone hose, pushing it tight against exhaust flange.
11. Align STOCK exhaust bracket onto the Coffman exhaust system, and install the stock 8mm bolt.
Use LOC-TITE on this bolt.
12. Tighten all the clamps and bolts on the chamber and stock exhaust bracket.
13. Slide the waterbox hose onto the exhaust system, and tighten it with stock clamp.
14. Reinstall the STOCK waterbox strap over waterbox.
The following are waterline installation procedures. IT IS IMPERATIVE THAT YOU HOOK ALL THESE LINES UP ACCURATELY. PLEASE REFER TO THE WATER DIAGRAM! HOOKING THE WATERLINES UP OTHER THAN WHAT WE SPECIFY CAN AND WILL ALTER PERFORMANCE!
15. Waterline installation:
PLEASE REFER TO THE PAGE WITH THE WATERLINE DIAGRAM!
A. Take the 1/2" x 5 1/2"L Hose and the 1/2 x 7"L Hose and the 3/8" x 4 1/2" Hose and install on the 1/2 x 3/8 x 1/2" T-Fitting. (Of course the 3/8" hose goes on the 3/8" end of "T"). Tighten with hose clamps supplied.
B. Take the 1/2" x 5 1/2" Hose and hook it up to the spicket on the exhaust flange and clamp down.
C. Take the 1/2" x 7" Hose and connect it to the head and clamp.
D. Take the 3/8 x 4 1/2" Hose and lead it to the 90 degree brass fitting on the top of the chamber body. (Just like in diagram), and clamp.
E. Locate the STOCK 1/2" waterline that exits the head going out the boat. Cut this line to a 2" length from where it comes out of the head and install the 1/2 x 3/8 x 1/2" T-Fitting. Take the other end of the hose that you just cut, and install on the second 1/2" end of the T-Fitting and clamp. F.Take the 3/8" x 12" hose supplied and hook to the 90 degree brass fitting on the lower end of the exhaust system and clamp with 3/8" hose clamp. Connect the opposite end of this hose and attach it to the 3/8" part of the T-Fitting, and clamp.
G. Install the 1/8" brass plug into the waterbox where the water valve was removed earlier.
H. Install the 1/4 x 1/4 x 1/4 T-Fitting into the stock waterline from pump that was hooked up to the water valve (SEE DIAGRAM). IMPORTANT! THIS T-FITTING WILL HAVE A 90 MAIN JET INSTALLED ON THE STEM PORTION! LOOK FOR THE SIZE OF JET STAMPED ON THE END OF THE MAIN JET!
I. Take the 1/4" x 12"L waterline (supplied) and hook it up from the T fitting (the side with the 90 MAIN JET INSTALLED) to the 1/4" water spicket on the lower portion of chamber body, and tighten with clamp.
J. On the other end of this 1/4" "T" will be the STOCK 1/4" line that lead to the stock exhaust system.
This line will go to straight brass fitting on exhaust flange.
K. On this line that just installed, take and measure back 2" back from the brass fitting, and cut.
L. Install the 1/4 x 1/4 x 1/4 "T" (the side that does not have a jet installed!) onto this hose. IMPORTANT!
M. On the other end of this 1/4" T that has the 90 main jet installed, hook up the other end of the line you just cut.
N. From the stock exhaust manifold, there is a 1/4" waterline that exits out the boat. From the start of this waterline, measure 7", and cut hose. (You will no longer be using a water bypass out the boat)
O. Install the opposite end of this 7" waterline onto the 1/4 x 1/4 x 1/4 T-Fitting on the stem portion of this T (with 65 Main jet installed).
Go back and make sure that all waterlines are connected correctly. If so, zip tie all lines in place with zip ties provided.
Installation of Water Injection
Take the Microtouch water control module and set to the following (See Microtouch instructions how to do this)
500 - ON
6900 - OFF
Install the module in the boat per the Microtouch instructions.
Take the solenoid and install the two 1/8" x 1/4" straight brass fittings. Take the two green rubber seals that are supplied, and slide onto each of the electrical wires on solenoid. Take the two female electrical connectors and crimp onto wires. Make sure that they are snugged down good!
Install the two wires into the weather pack connector, and snap close. Plug this connector into the Microtouch Module.
Locate the stock waterline that goes to the "T" that leads to the exhaust flange (in step M of the waterline installation procedures), as this line runs along side of the boat, cut this line approximately half way from where it begins at the flange, and goes back to the pump.
Install the solenoid into this line, making sure that the "OUT" side of the solenoid FACES THE EXHAUST SYSTEM. Zip tie both ends of these lines.
JETTING PROCEDURES
STOCK '95-98 XP, 96-98 GTX, GSX, SPXis as follows with stock flame arrestors:
USE STOCK JETTING. (Based at sea level)
STOCK 800 boats as listed above with flame arrestors:
1.5 Needle & Seat
80 gm springs
90 Pilots
145 Main (front)
150 Main (rear)
1 turn High (Turn all the way in and back out)
1 turn Low (Turn all the way in and back out)
EXCEPTION TO THE RULE: Any of the boats that run accellerator pumps, must have this disconnected.
IMPORTANT NOTE: Any other engine mods/air temperatures/altitude can and will change our jetting reccommendations. Our jetting specs are to be used as a guide line only. If you are not familiar with tuning your carburators, please contact a professional.
Controlling the water into the exhaust system by using the pre-installed jets:
You will notice that there are preinstalled jets located in the T-Fitting next to the flange (ONCE AGAIN...LOOK FOR THE SIZE JET ENGRAVED ON THE END OF THE JET!) This controls the how much water is injected into your pipe, thus creating a strong and even powerband. With other aftermarket performance enhancers available, you may decide that you might want more bottom end or more top end. By changing these jets, it enables you to do this. Use the following as a guideline in changing these jets. The bigger the jet size, the more torque you achieve, but less top speed. The smaller the jet size, the less torque, and more top end you MAY achieve. The jets that controls the top end, is the 65 main jet that is installed in the stem of the "T" fitting to the top of the exhaust manifold. This already is a very small jet, and you can only plug this line so no water goes into the jet. We find this to work on Superstock/Mod applications. If you want to increase the torque of the boat, you can increase the jet size in increments of 5 (Do this slow, and do not increase by larger amounts all at once). The other jet that leads to the solenoid, can be increased/decreased to achieve better bottom end/mid range response.
PLEASE NOTE: In the summer time when the air and water temps rise, the air becomes less dense. You may need to run bigger jets to accommodate for these changes.
REGARDING IMPELLORS: When running aftermarket props, the taller the pitch, the more water pressure is put through the waterlines, and a reduction in jet size may be warranted.
IN ADDITION TO: The waterlines supplied and their routing are set up for stock heads. The stock head has 1 inlet and 2 outlet water fittings. Some aftermarket heads may only have 2. It is imperative that the waterline orfices of the incoming and outgoing have the same diameter as stock.
You can install your aftermarket rev limiter at any time of installation.
1. Install a digital tack on your boat to get a correct rpm reading on the water as you are riding the boat.TUNING INSTRUCTIONS
2. Remove your air filters so that you can easily access your jets and make tuning easier. (Later you will reinstall these to do the final tuning)
3. Warm up your boat by riding it a good 10 to 15 minutes. Turn your rave valves clockwise so that the small red nob bottoms out against the black cap.
4. To figure out maximum performance gain with your valves, do the procedure as follows:
A. Run your boat for 3 consecutive full throttle runs counting to 30 on each run. Check to see what your rpm reading is on each run.
B. Turn your valves counterclockwise 2 full turns and go out and run your boat for 3 more consecutive full throttle runs. (Once again counting to 30 on each run).
C. DID YOU SEE A CHANGE IN THE RPM'S? You may see the RPM's rise.
D. Turn your valves counterclockwise 2 full turns and go out and run the boat for 3 more consecutive full throttle runs (counting to 30 on each run). This will be the last time you have to do this.
E. Did your RPM's rise again? If they did, leave your valves at this point. If they did not rise at all, go back to the FIRST or whatever setting was your highest RPM level.
F. Your rave valves should now be set.A. Turn your main jets out (counterclockwise) 1/4 turn and check your RPM's. Did they rise or fall from the last test eprformed? If they increased, turn them out 1/4 turn again, til they begin to drop off. When this happens, go back to the prior setting. If they decreased, turn them IN 1/4 turn to see if they come back up.Fine Tuning your Carburator
We would like to thank you for purchasing a Coffman exhaust system. For many of you, we know you have used our products for many years and are grateful for your continued support. We hope that you are once again completely satisfied with our product and enjoy your personal watercraft even more with the Coffman exhaust system installed.Note from the ManufacturerFor those of you who are just entering the sport of personal watercrafts and have purchased a Coffman exhaust for the first time, we would like to welcome you into the "Coffman experience" and hope that you are happy with the performance and fit of your "Signature Series" Seadoo 800 Race exhaust system.
Should you have any questions, comments, or problems, please do not hesitate to contact us.
Coffman's Exhaust Systems, Inc.
181 Wabash Ave.
Ukiah, CA 95482
PLEASE MAKE SURE TO FILL OUT YOUR WARRANTY CARD AND TURN BACK TO COFFMAN'S AS SOON AS POSSIBLE!(707)462-7881 (707)462-9369(fax) coffmans@pacific.net (e-mail)