Help with fixing Head Pipe

[mjcolemo]

I have a 96 SeaDoo Challenger, that has a hole in the head pipe. The motor is a 787. I have read several posting about how to go about fixing the hole which isn't an issue. But I have a few other questions. First if I take the head pipe off the motor to have it welded, will I need to get new gaskets? I'm guess that I should, and if so where can I order a set of gaskets from? Also I noted a post or two that indicate that there could be an issue with the bolts that hold the pipe to the exhaust manifold breaking! Is this a common problem? If so I might just take it to the local dealer to work on as I don't have the proper tools to extract a broken bolt.

Normally this boat runs strong, and I enjoy taking it out. But I found the problem with the head pipe because the engine had no get up and go. It would hit about 5500 rpm and just go flat even though I still had throttle to spare. Sometimes it would roll up to 6000 rpm, but mainly it stopped at 5500. Could this issue be related to the hole in the head pipe?

Thank you and have a nice day!

 

[JPX]

Probably are going to need new gaskets. But if you must be cheap about it, plan on using a lot of copper silicone gasket maker (tube from auto parts store).

The bolts break because when they get loose, the pipe beats on them. If the pipe doesn't crack, the bolts get destroyed.

The key is keeping the bolts tight (loctite on the threads). Make surethe rubber isolators are in good shape (two on the side that holds the big pipe to the side of the engine) . They help dampen the vibration on the exhaust.

If the hole is spewing water, then the water jacket is compromised. It doesn't directly affect engine output (unless the crack allows water into the exhaust channel). If the hole is spitting out oil/exhaust, then this would contribute to poor performance.

 

[mjcolemo]

JPX Thank you for the information. No problem with getting the gaskets as I want it fixed properly. Just was curious if since the one is a brass washer, if it would need to be replaced. I would need to check, but the bolts are tight, and the isolators are in good shape.

Is having the hole welded OK, since it's in the water jacket? Or sould I try and get a good used part (I don't really want to pay 700.00 for a new pipe).

Thank you for the feedback on the engine output. I was hoping that it was all tied together, but apparently not. The hold in the pipe is definately in the water jacket as the water shooting out doesn't appear to have any oily residue in it. I'll check the link.

Thank you again for your feedback.

 

[JPX]

These guys keep insisting that JB weld works fine for the hole repair. Welding is still a possibility (TiG I imagine is the type of welder needed).

The big 2.5" copper ring (exhaust gasket under the clamp ring) really isn't supposed to be reused. But you do what you gotta do.


Photos of my water leaky pipe:

 

[mjcolemo]

That look a lot like what I'm seeing. I'll definately replace the washers. I like the boat and plan to have it a while longer, so it might as well be fixed right. Thank you again for all of your input.

 

[jbarrpalmer]

welding will work . i had my pipe welded on a 97 xp but watch out for salt water it will eat right through the spot that was welded if it is not flushed properly.