Servicing ZR409 heat exchanger

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  • Lakejackson
    • May 2012
    • 160

    • Lake

    • 2011 Sport 200

    Servicing ZR409 heat exchanger

    Has anyone serviced their heat exchanger recently? I pulled the end caps off mine and need new gaskets. Nautique Parts says the gaskets are only available with the metal end caps. Costs about $150. Anyone else experienced this?


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  • Lakejackson
    • May 2012
    • 160

    • Lake

    • 2011 Sport 200

    #2
    Following up on this. It took a few weeks, but Nautique Parts was able to get me all but one part I needed. Best I can tell PCM started using 5” heat exchangers on the ZR409 sometime around end of 2010, beginning of 2011. Then they switched back to the 4” for 2012. The 5” requires 5”gaskets for the end caps. One end of the heat exchanger has a standard o-ring for the bolt that holds the end cap on. The other side takes a thicker o-ring that is flat on both sides. Nautique parts sent me the 5” gaskets and the standard o-ring. They couldn't find the thicker flatter o-ring. No part numbers exist for either of the o-rings. The five inch heat exchangers have the thermostat mounted directly to the heat exchanger.


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