440/550 Works® Pipe - Installation Instructions EX4150 & EX4200

NOTE: This pipe is designed for all Kawasaki 440 and pre-1986 550 models. This pipe is not designed for 1986 or newer stock 550 models. Kit Includes: 1 - Works® Pipe front body with 2 brass fittings installed (EX4150HD) 1 - 21" section of 3/8” I.D. Hose 2 - 3/8” hose clamps 1 - Rear cone with brass fitting installed (EX4350) 1 - 2-3/8" wide rubber coupler (EX4140) 1 - 2-3/8" wide clamp assembly (EX4160) 1 - Exhaust pipe to manifold gasket (WCGSK002) 2 - 8mm locknuts with lockwashers and flat washers 1 - 15° rubber exhaust hose 1-5/8” I.D. (EX4180) 1 - “T-Barb” 3/8”x3/8”x1/4” leg for stock bypass fitting If you have any questions regarding the contents or condition of your Works® Pipe please contact us directly at (800) 292-9394.

Important: Read Before Installing This Works® exhaust is designed to be used in conjunction with a water box silencing device. A well designed water box will provide the proper amount of back pressure to allow the exhaust to perform at its maximum. Under no circumstances should this exhaust be used without an effective water box. If you intend to use an aftermarket water box, verify with the manufacturer, that it will not exceed the 86 decibel sound level limit established by the US Coast Guard and IJSBA competition rule book. The Coast Guard can impound and levy fines against boats exceeding this limit on a no questions asked basis. The Westcoast aluminum water box (part # EX5500) can meet this sound level limit when used with this exhaust system NOTE: This system is designed to fit all stock and most aftermarket 440 exhaust manifolds. When installing on a 550, a 440 style exhaust manifold must be used. This manifold is available from Westcoast (part # EX4480). We recommend using the extended length tailcone, WPP #EX4350L for the 550 pump. IMPORTANT: Due to the horsepower increase created by the addition of an exhaust system, it will be necessary to readjust and possibly rejet your carburation system. If you are not experienced at carburetor adjustment, we recommend you have this procedure done by a qualified watercraft technician. Removing the Stock System The main pipe body and "U" bend head pipe can be removed as an assembly. Put a rag on the open exhaust port to keep any bolts from accidentally dropping in. The stock rubber hose to the water box will no longer be used, cutting the end at the water box may be necessary to remove it. At this point we recommend that you remove your gas tank so that the water box can be removed and inspected. If you are using a stock water box, thoroughly check it for cracks or broken rivet heads. If there is any doubt about the condition of the water box, it should be replaced. If a new exhaust manifold is being used, the stocker should be removed at this time. If a stock 440 exhaust manifold is being used, the exhaust gasket surface should be thoroughly cleaned.

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Installation If an after market exhaust manifold is being used, the 2 studs from the stock manifold will usually be used in the new one. These studs have a long threaded end and a short threaded end. The long threaded end must go into the manifold. We recommend that blue Locktite be used when installing these studs. Install the exhaust gasket on the manifold and then install the main pipe body. (If you desire to use a sealer on the exhaust gasket, we recommend coppercoat.) With the body in position, install the 2 flat washers, lock washers, and lock nuts to 18 ft/lbs. Check to see that no water inlet hoses are touching the pipe body. If so, the hose routing must be changed. Then adjust the rubber coupler so that only half of its length is on the main body. Install the coupler clamp and then the rear cone. Rotate the rear cone so that the brass fitting is at the top. Evenly tighten the two clamp nuts. Install the "elbowed" exhaust hose between the water box and the exhaust cone, and firmly clamp both ends. Plumbing If you have a dual waterline kit already installed, please refer to your dealer for proper plumbing layout. On a stock cooling system the hose from the front of the cylinder head will go to the straight fitting where the head pipe meets the manifold. The supplied 3/8 hose will run from the 90 degree fitting on the back of the head pipe to the straight fitting on the cone assembly. All the hose ends must be securely clamped. If your ski was equipped with a factory water bypass, you must use the reducing T-Barb and install it onto the line from the headpipe to the tailcone. Inspection With the hood off, connect a garden hose to your ski via a flush kit and start your ski. Turn on the water and visually check to see that there are no water or exhaust leaks. If everything looks okay, install the hood and check to see that the engine still operates smoothly. In the event of a tiny exhaust gas leak under the hood, the engine will quickly begin to lose power and throttle response. After your first 15 minute ride, all the bolts and clamps should be re-checked. Tuning The straight or "constant" diameter section of the rear cone assembly is ribbed on the outside so that it can be cut to various lengths. Shortening the tuned length of this section will raise the entire powerband of the engine but is designed for motors that have a RPM range of 7500+. That is, there will be an increase in peak RPM. (NOTE: Stock motors should use this tail cone at its current "long" length.) Discretion must be used because in some cases the low end power will probably suffer slightly. If you find that two different lengths will suit two different riding styles for you, spare cones are available at a reasonable price. #1 EX4150 WORKS PIPE ORIG 11/93jh

Hose Routing for Works® Pipe on Stock Cooling System

Westcoast Performance Products USA, Inc. 3100 E. Coronado, Anaheim, CA, 92806 Page 2