Tips for removing muffler- 2001 Super Air Nautique GT-40

[brock.higdon]

Its awfully cramped back there. Any advice?

[TX-Foilhead]

You're going to have to move it about 4in for the fiberglass to clear the rubber pipe. I doubt you have enough room to pull it backwards. I would remove the outlet tube and pull it up. A flat screw driver and something to lube things (wd40, fogging oil, whatever you have) will help get it loose.

[brock.higdon]

You're going to have to move it about 4in for the fiberglass to clear the rubber pipe. I doubt you have enough room to pull it backwards. I would remove the outlet tube and pull it up. A flat screw driver and something to lube things (wd40, fogging oil, whatever you have) will help get it loose.

Can you elaborate a little more on "remove the outlet tube and pull it up"?

[brock.higdon]

You're going to have to move it about 4in for the fiberglass to clear the rubber pipe. I doubt you have enough room to pull it backwards. I would remove the outlet tube and pull it up. A flat screw driver and something to lube things (wd40, fogging oil, whatever you have) will help get it loose.

As in- Unbolt it off the manifolds and pull those hoses towards the front of the boat off the muffler?

[TX-Foilhead]

No, I was thinking loosen the muffler output underneath the invertaflow. Then you could pull up on it and roll it towards the motor to allow you a little better access to get the screw driver in to pry things apart. Removing the hose from the risers is much harder than removing it from the muffler.

You want to slide the screw driver between the fiberglass and the hose, add a squirt of lube and work it side to side to loosen the hose. Don't try to pry it up, the fiberglass will give before the hose. The heat seems to cook things together so the outlet hose is usually the easiest to remove.

If you plan on replacing the hose then cut the inlet hoses in the middle with a sawsall, that's the easy way.

[jhersey29]

Why not just remove the riser and work backwards?
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[TX-Foilhead]

Go for it and let's us know how it works.

[Paxdad]

The easiest way is to use a sawzall/ reciprocating saw with the super long blade. Just cut that stuff right out!!! Just kidding had to say it!

[Rick]

The easiest way is to remove the riser and work the hoses off the front of the muffler. Then remove the clamps and twist it loose from the exhaust hose. This is the easiest way, costs you about $16 for new riser gaskets, and allows you to assess the condition of your risers and manifolds.

[99SAN]

Yep, what rick said. Been there done that, it wasn't fun until I figured out I had to remove the riser

[brock.higdon]

Man. This really sucks. I went ahead and cut the muffler right at the end of the rubber hose from the riser. Loosened the pipe clamps down on the bottom at the hull. The problem is, I can't move the muffler up (hitting little fiberglass tray looking thing for drain behind engine cover), I can't move forward because it hits the engine, and can't move down because its still connected to the outlet.

[brock.higdon]

Just wanted to update this. Went out last year with it "straight piped" a few times. Worked great. We have been out about 6 weekends so far this season with no problems until yesterday. The boat was idling and all of a sudden it sputtered and died. I knew it wasn't out of fuel and I could smell a lot of fumes. Opened the back hatch and realized the PCV had came loose from the boot that connects to the outlet in the hull. Started the bilge while I cleaned out the locker, then a few minutes with a flathead and it was fixed better than it was before. I double hose clamped it but I think that one of the hose clamps was too far towards the back of the boat and was actually pushing the pvc out of the boot. It gave the girls a good break to swim, and we played the rest of the day no problem. About 21 hours on the set up so far.