Engine & exhaust removal

Engine & exhaust removal

Watch the walkthrough

Watch on YouTube ↗ · JETSURF Service Tutorials #6. Timestamps in the steps below follow the video's on-screen counter (0:00–3:40).

This carries straight on from the engine pull and takes the exhaust out with it — for exhaust replacement, a full rebuild, or hull work. Ventilate the area, kill ignition sources, and label everything. Reinstalling the engine and exhaust is Service Tutorial #7.

Tools & supplies

• Allen key no. 3
• Allen key no. 4
• Bent-nose pliers (exhaust springs)
• Pliers (exhaust retaining ring)
• 10 mm ratcheting wrench
• Clean rags, nitrile gloves
• Fuel-safe container if you're draining the tank

Engine removal

1. 0:00 — Disconnect the CPS fitting on the fuel line, then release the fuel pump connector on the left side of the tank (relative to the direction of travel). See Fuel tank removal & installation for detail.
2. 0:32 — Loosen the Velcro strap securing the tank and carefully lift the tank out.
3. 0:43 — Disconnect the vent line connector by pressing the locking tab toward the tank.
4. 0:52 — Using Allen key no. 3, remove the bolts from the freewheel cover.
5. 0:58 — Using Allen key no. 4, remove the throttle cable and detach it.
6. 1:29 — Using Allen key no. 3, remove the ground wire at the starter and disconnect the connectors.
7. 2:04 — Disconnect the hoses and remove the spark plug.
8. 2:23 — Using bent-nose pliers, remove the two exhaust springs.
9. 2:37 — Using a 10 mm ratcheting wrench, loosen the four nuts on the engine mounting rails.
10. 2:50 — Lift the engine out.

Exhaust removal

11. 3:03 — Remove the silencer, then take out the spring with the exhaust ball.
12. 3:20 — Using pliers, unscrew the retaining ring and remove the rubber gasket.
13. 3:40 — Carefully slide the exhaust out.