coffmansexhaust

"Lightning Series" Kawasaki Ultra 150 Triple Exhaust

PLEASE READ ALL INSTRUCTIONS PRIOR TO INSTALLING!!

The following are parts mandatory to run with the "Lightning Series" Ultra 150 exhaust system from Coffman's.

1. Aftermarket carbs (We have run the Buckshot 47 and 50's and they have performed well with the Coffman set up)

2. Aftermarket prop (Suggested at this time to run the 16-20 Solas)

3. Remove foam from sides of your personal watercraft.

Parts Included

3ea. Chamber Bodies(labeled F (front)C(center)R(rear 2 billit flanges with O-Rings installed

1 billit flange with rubber mount ,flat washer & nut (install) 3ea. exhaust manifold gaskets

9ea. 8mm x 30mm Allen Bolts 6ea. Stainless Springs

2ea. 1 1/2 x 5" Hose 1ea. 1 1/2 x 2 1/2" Hose

6ea. #28 Hose Clamps 24ea. 3/8 Hose Clamps

3ea. 3/8 Water Bypass 3ea. 3/8 x 24" Hose

3ea. 3/8 x 7" Hose 3ea. 1/4 x 20" Hose

1ea. 3/8 x 56" Hose 1ea. 3/8 x 45" Hose

1ea. 3/8 x 36" Hose 3ea. 3/8 x 1/4 x 3/8 "T" Fitting

10ea. Zip Ties 2ea. 5" x 9" Rubber Pads

1ea. Oil Cable Bracket with 8 x 15 bolt & washer 6ea. 1/4 x 3/8 90 brass fitting installed on pipe

3ea. 1/8 x 1/4 90 brass fitting installed on pipe 1ea. 3" x 4" silicone hose

1ea. 3 into 1 collector Decals

Installation Instructions

1. Remove the stock exhaust system and studs from cylinder.

2. Remove the stock carburetors.

3. It is at this time that you will want to do cutaways on the foam in your boat for pipe installation. It is easier to remove the pump and loosen the motor and slide toward the rear of the boat for this procedure. Using a hacksaw blade, remove the foam from the front of the waterbox and cut around the coil box approx 1" past. (leaving the foam in place on the coil box) This will be relocated back WITH THE FOAM next to the battery. On the carburetor side of the ski, remove the foam the length of the motor and carbs. This section pops out and can be determined how much foam you want removed after the pipes are installed.

Installing the pipes

1. Install the exhaust flange with the rubber mount attached and exhaust gasket with the 3ea.

8 x 30mm allen head bolts to the center port on cylinder.

2. Install the remaining 2 flanges with O-Rings on the left and right ports on cylinder utilizing the remainder of the 8 x 30mm allen head bolts. Install small amount of grease to O-Rings at this time.

3. Take the front pipe (as marked) and slide into boat (with the motor pushed back toward the back of the boat-easier with a friend) Once the pipe is in the hull l , slide the motor back into the stock location. Install the pipe onto the front flange. Take the rubber pad and slide under the chamber body, so that the pipe is sitting on the pad. Remove the pipe again, and glue the pad down to the bottom of the hull in same location. (We reccommend you run epoxy paste for the pad. Reinstall the pipe back in and put the motor back in place and tighten everything down.

4. Slide the center pipe (as marked) into the opposite side of hull onto CENTER flange. With the second rubber pad, locate where the pipe and pad would meet in hull. Remove the pipe again, and epoxy the rubber pad onto bottom of hull. Reinstall the pipe onto flange.

5. Install your aftermarket carbs at this time. MAKE SURE that the throttle cable linkage clears the chamber bodies. If they do not, you MUST modify the linkage on the carbs to accommodate. Otherwise it may dent the pipes. VERY IMPORTANT!

6. Install the 3" x 4" silicone hose onto your stock waterbox and slide your STOCK clamps onto this hose, but do not tighten yet.

7. Install the oil cable bracket (if you are running your stock oil injection) supplied onto the stock bracket located above the oil tank with the 8 x 15 bolt and washer. Make sure that the cable does not touch the pipe or any of the oil lines. VERY IMPORTANT!!

8. Determine at this point where you would prefer the water bypass fittings to be located. We located ours at the rear of the boat. This is your discretion. Make sure that the water is not directed directly at you. Install these now.

9. Take the 3 into 1 collector and slide it onto the 3" silicone hose installed on the waterbox, and align the collector to the chambers in the boat using the front and center pipes as your guide. Take the two 1 1/2 x 5" hoses and connect the chamber bodies to the collector. (Slide the hose clamps over the hoses prior to installing). Install the 1 1/2 x 2 1/2" hose onto the remaining collector bend. Push it all the way on until it is FLUSH with the tube.

10. Referring to your water diagram at this time, install the waterlines leading from the head to the exhaust chambers.

11. Install the REAR chamber body onto the exhaust flange lining up the rubber mount to the bracket on the pipe. Slide the 1 1/2 x 2 1/2" hose over the stinger end of chamber approx. 1 inch. Tighten the rubber mount onto the bracket and install all springs on all 3 chamber bodies.

12. Check to make sure that the alignment is good on all collector points to pipes. If it is, go back and tighten all clamps.

Waterline Installation

1. Take the 3/8 x 56" waterline and install on the front of the head to the front of the FRONT chamber .

Clamp down.

2.Take the 3/8 x 45" waterline and install on the center of the head to the front of the CENTER chamber.

3. Take the 3/8 x 36" waterline and install on the rear of the head to the front of the REAR chamber.

4. The remaining waterlines will lead from the 90 degree brass fitting on the stinger of the tail pipe to the waterbypass. The 3/8 x 3/8 x 1/4 T-Fitting will be used to "T" into these lines leading to the 90 degree 1/4" brass fitting on the tail section of pipe. (Make sure to match up the 1/4 to 1/4 and 3/8 to 3/8).

All three chambers will be run in the same manner.

Tuning

If using the Buckshot 47's with stock porting and stock head, use the following jetting specs as a GUIDELINE.

120 Pilot

150 Main

2.0 Needle & Seat

80 Gram Springs

2 or 3 fuel pumps

1 1/2 turn on high speed

1 turn on low speed

150 return jet

If using the Buckshot 50's with stock porting and stock head, use the following jetting specs as a GUIDELINE.

110 Pilot

180 Main

2.3 Needle & Seat

80 Gram Springs

120 return jet

2 or 3 fuel pumps

2 turn on high speed

1 turn on low speed

VERY IMPORTANT: Nothing is written in stone if using aftermarket head and/or porting, elevation, heat factor, These jetting are to be used as a GUIDELINE ONLY.

Note from the manufacturer

We would like to take this opportunity to say THANK YOU for purchasing the new "Lightning Series" Ultra 150 Triple Exhaust System. For close to 30 years, we have been manufacturing high performance parts for the motorcycle/ATV and personal watercraft marketplace. Your support through the years has helped us achieve what we are today, and for that we are sincerely grateful. Should you have any questions or comments, please do not hesitate to contact us at the following address and phone.

Coffman's Exhaust Systems, Inc. 181 Wabash Ave. Ukiah, CA 95482

(707)462-7881 or (707)462-9369 (fax )or coffmans@pacific.net (e-mail)