Engine & exhaust installation

Engine & exhaust installation

Watch the walkthrough

Watch on YouTube ↗ · JETSURF Service Tutorials #7. Timestamps in the steps below follow the video's on-screen counter (0:00–9:10).

This is the reassembly side of Engine & exhaust removal. The two parts that need care are the coupler axial play and the throttle cable range — get those wrong and the board won't run right. Finish with a throttle position sensor check.

Tools & supplies

• Silicone spray
• Lubricant / grease for the gasket
• 10 mm angled ratchet wrench
• 5 mm Allen key (coupler M5 screws)
• 4 mm Allen key (coupler lock screw, throttle cap)
• 3 mm Allen key (sprocket cover)
• Bent-nose pliers (exhaust springs)
• Magnet or diagnostic tool (TPS calibration check)

Exhaust & engine

1. 0:00 — Lubricate the sealing O-rings with silicone spray.
2. 0:37 — Slide the exhaust into the hull. Make sure the exhaust spring bracket is correctly aligned with the engine.
3. 1:00 — Carefully lower the engine into the hull.
4. 1:42 — Apply lubricant to the gasket between the engine and exhaust.
5. 2:18 — Support the engine and align it with the turbine shaft so the coupler can be installed freely.
6. 2:56 — Secure the engine to the hull with the four nuts, tightening them with a 10 mm angled ratchet wrench.

Coupler & axial play

7. 3:40 — Install the coupler and set the axial play: push the freewheel as far back as possible by hand and hold it there.
8. 3:47 — With the freewheel held back, tighten the coupler using the two M5 hex screws and a 5 mm Allen key, working them alternately.
9. 4:30 — Tighten the coupler locking screw with a 4 mm Allen key.

Exhaust springs, electrical & throttle

10. 4:43 — Using bent-nose pliers, attach the two exhaust springs and connect the water supply hose.
11. 5:40 — Reconnect the electrical connectors, and fasten the ground wire to the starter with Allen key no. 3.
12. 7:47 — Route the throttle cable under the freewheel, running it between the engine plate and the engine. Seat the barrel end of the cable in the throttle lever's crescent-shaped slot.
13. 8:00 — Fit the cable lock cap and tighten it with a 4 mm Allen key.
14. 8:05 — Test throttle movement by hand for full range. If it's off, loosen the cap and re-adjust.

Covers & final check

15. 9:00 — Install the sprocket cover with a 3 mm Allen key.
16. 9:10 — Use a magnet or diagnostic tool to verify the throttle position sensor calibration is correct.