WetPipe Manifold Gasket Problems

I have had a 2nd hand Wetpipe on my 2007 Kawasaki 800 X2 for the last year and LOVE IT!!!!!!!!!. AWESOME in the SURF!!!!!

I got it 2nd hand off TradeMe and had to "Helicoil" repair the Factorypipe manifold threads due to damage before I got it.
8)
I have tried a couple of different high temperature gasket materials from metal reinforced exhaust sheet to fibre HIGH PRESSURE / TEMPERATURE boiler joint sheet, but have found that the gasket fails after a few months causing a severe undesired shift in the power band due to a water leak.
:cry:
I have now re-faced the manifiold and head pipe YET AGAIN!! by draw filing both faces to match perfectly and I am now trying it with NO gasket to see how that performs. :cry:

Each time I have repaired it I have re-faced the castings and torqued and re-torqued the bolts to DOUBLE the suggested torque. (due to the helicoils being MUCH stronger than the original aluminium threads).

There is only around 3mm between the malifold exhaust port and the manifold water jacket which is rather annoying and STUPID considering the head pipe simple blanks off the TOP of the manifold water jacket anyway! - STUPID DESIGN really!!! :roll:

I appreciate that ANY performance MOD is bound to add reliability issues, but there MUST be a way to achieve GOOD reliability. In all other ways the ski has been TOTALLY FLAWLESS!!

Has anyone else has similar issues on their head pipe??????? :?:

On a different note - IT IS SOOOOO disapointing that The 2010 superjet has NOT gone to 760cc yet, considering it is so close being the the LAST days of the two stroke!!!!
I wonder what 2011 will bring???

Can't help you on your prob but i'll be fuckin' gutted if the 2011 superjet has a 760 as I just recently bought a 2010 !

It is just my daydream... a 760..

Just fit a B pipe and you will be sweeeet

It'll never happen. The exhaust chamber for a 760 will never fit in a superjet and they are not likely gonna supply them with b-pipes standard.
Thing is, and argue this all you want, but the dif between a 701 with a b-pipe vs. a 760 with a b-pipe is negligible, maybe a couple of hp and having 44's on it may give you a couple more again, that's all..

Well then that just means yet ANOTHER year will pass without any change. (other than the recent hull change with the pump set further back than the old beastie. The new hull may hang on in the corners, but I find it like rollerskating on ice on GLASSY WATER!!).

As I understand it, the 2006 Superjet RR (Europe Only) was apparently 753CC 100HP. (According to THIS website)
Why not go out with that for 2011????

I would be suprised if they ever put the 62t cylinder as std on a superjet
the 61x has smoother power and suits there target market better

To be fair with ya. Your a muppet. Dont slag the mighty Super jet when ya Kwaker is stuffed. Insure it and sink it and buy SJ. Fag

lol..

I dont know why you would have to machine the faces?
Use a green gasket, get one off Roger, dont torque them over 30 ft/lbs.
0211489711

I have never had a problem with that gasket are the bolts coming loose or gasket just blowing? you can weld the top of the madifold and machine it flat but shouldnt need to.
I have always used a fp or a 650 gasket not a home made one.
if the bolts are coming loose check engine alignment etc causing vibration.
If all else fails I will take it off your hands wish i never sold my old pipe I brough new and ran for a while.

I have seen people use bolts that have the thread all the way down as opposed to bolts with a shank
because of the threads it allows the pipe to move a bit where a shanked bolt would hold it better
The result of this was the gasket blowing all the time

Hears my two cents worth. I have found in the past that if you over tention manifold bolts it causes the gasket to over squash and split. This may be the cause. Other than that how hot is the pipe running.

Good point, it will also bring the threads up and make them sit slightly proud on the manifold which release the tension on the gasket

SO, the short answer is obviously NO - This is not a problem ANYONE has EVER had with a SJ B pipe or a Kawa Wet Pipe.

That is all I really wanted to know. If it is NOT a common problem then it is obviously a problem specific to mine, probably due to being so old and abused.

I DID NEED to machine the faces originally BECAUSE the faces became BADLY PITTED due to the MESH inside the gasket PITTING the faces once a bolt loosened.

I may have to put some of my issues down to the fact that it appears that the MANIFOLD was cast with the core slightly off centre which would not help the problem as the wall thicknesses are not even. I think this is 50% of the problem really.

Good thinking Waxhead, the style of bolt shank may be contributing to movement.

I definitetly KNOW it is NOT an issue with vibration or pipe temperature.
I also know that it is not an issue of the threads pulling up and reducing tension on the gasket due to ALL 3 threads having been RECOILED in such a way as to be 1 to 2 mm BELOW the face of the casting.

No Flan, I am NOT slagging the MIGHTY SJ, no way.
I am just echoing comments from some of my SJ owning friends. I am just hoping that Yamaha WILL PUSH the limits of the MIGHTY TWO STROKE to the LIMIT before they are FINALLY FORCED to drop it due to US/EU emissions regulations.
We may NOT like it BUT that day is approaching rapidly. That will be a very sad day!!!
I believe that YAMAHA are currently trialling replacement 4 stroke engines for the future SuperJet.
I personally doubt that 4 stroke turbo pole skis will be RELIABLE enough for freestyle use.
Let's face it, you can't fill a 4 stroke engine with water and then get it running 5 minutes later without damage! Nope, end of an era!

I HOPE this THREAD is OVER :twisted:

so you're talking about the 3 bolt gasket? Had probs with that till we put in a key-sert at the most inboard position, got a factory pipe gasket from parker, and torque to standard torque values. never had a problem since. (but this is on a sn/sj)

You could try inserts instead of helicoils.But i don't know if there is enough meat as the inserts are a bit bigger than helicoils.

got any pics?

Waxheads comment about that the shanks on the bolts could be just the opposite. If you have machined the surface flat, making it thinner, is it possible that the shank (unthreaded part of the bolt) is now to long, allowing you to torque up the bolts but not tighten the manifold enough.

A mate had this problem with a planned head causing blown head gaskets on his car.

I was assuming he would check for this
But its a good point , and maybe something to check for