1200 STX-R Triple Pipe Kit
Contents
1. eB WR NFR NF 20 W WD WWD DD DF COND amp lt Part Number 5 0935 5 0936 COMASM0937 5 0938 5 0939 COMASM0941 5 0942 5 0943 COMASM0944 5 0945 COMHOS0053 COMHOSA180 COMFTG0023 COMBRK0225 221 224 COMBRK0222 COMBRK0223 COMBRK0220 COMCLP0007 COMCLP0010 50001 790 50023 COMFAS0026 COMFAS0036 COMFAS0205 COMMNT0052 COMMNT0030 COMFAS0045 50090 50100 50070 COMFTG0095 COMADHO0002 COMFTG0122 COMFTGO121 COMFTGO0110 COMFTGO105 COMCLP0015 COMFTG0034 FOR COMPETITION USE ONLY US EPA regulations Factory Pipe Bill of Materials Kawasaki STX R Triple Pipe Part Description STX R PTO Chamber assembly STX R CTR Chamber assembly STX R MAG Chamber assembly STX R Collector assembly STX R Center stinger tube assembly STX R MAG CTR Flange assembly STX R PTO Flange assembly STX R Flange water bypass assembly STX R Inline water assembly STX R Hardware kit includes items 10 55 3 8 x 15 Waterline 1 4 x 24 Waterline 1 8 BSP x 3 8 Hose ftg strt STX R Ultra Throttle cable bracket STX R Ultra MAG Pipe crankcase bracket STX R Ultra MAG Pipe to housing bracket STX R Ultra MAG Rear mount bracket STX R Ultra CTR Pipe front head bracket STX R Ultra CTR Head bracket 42. Install all three brackets onto the cylinder heads Torque the cylinder head bolts to 22 ft Ibs Locate the MAG pipe crankcase bracket item 16 and two 10mm x 1 25 x 20mm flanged head bolt item Install the bracket to the crankcase there two open threaded holes just below the intakes with the slot facing the rear of the boat Locate the three 3 8 x 1 8 27 B S P straight fittings item 14 Using pipe thread sealant on the threads install one into each cylinder head where you previously removed the 90 deg fittings Install the MAG and center exhaust flanges item 6 and the PTO exhaust flange item 7 to the cylinders reusing the stock metal gaskets Note the MAG and center flanges have the straight brass fitting and the PTO has the 90 deg brass fitting Fig 3 Attach the each flange using two 8mm x 1 25 x 35mm bolts item 25 and two spring hooks 8mm item 23 on the top of the flange and one 8mm x 1 25 x 40mm bolts item 26 for the bottom of the flange Install the exhaust flange water bypass assembly item 8 Fig 2 to each of the exhaust flange fittings using 4 hose clamps item 21 The 24 section of the assembly goes toward the rear of the boat will attach later to the overboard bypass fitting See video instructions Remove the two forward outside bolts on the grab handle located next to the rear air vents Drill these holes out using a 3 8 drill bit Remove the two air vents Note With the ai
3. 2 long silicone coupler item 55 onto the waterbox inlet and tighten the clamp Slide the remaining retained hose clamp on the 3 hose but leave loose at this time Locate the collector assembly item 4 and loosen the two clamps on the 2 silicone couplers Push the couplers down on the tubes until the hoses are flush with the ends Install the collector into boat through the rear storage compartment opening Remember the PTO pipe should not be mounted yet Getting the collector in can be very tricky Please refer to the instructional video Mount the PTO pipe to the top deck Use two 3 8 x 16 x 1 3 4 hex head screws 3 8 ext tooth washers and 3 8 flat washers item 48 34 47 for securing the rear mounts Use a 3 8 16 x 3 4 hex head bolt 3 8 ext tooth washer and 3 8 flat washer item 33 34 47 for securing the front mount Attach the springs on the PTO exhaust flange to the pipe 82 83 84 85 86 87 Attach the 3 8 black waterline coming from the side squirter to the 90 deg brass fitting at the end of the PTO pipe Secure it with a 6 hose clamp item 22 Slide a 2 high torque hose clamp item 50 over each of the three tubes on the collector and leave loose at this time Place the collector outlet into the 3 coupler on the waterbox Attach all three couplers from the collector to the pipes and stinger tube Note You may need to move the collector waterbox and stinger tube around for proper alignm
4. 47 Now tighten the motor mount bolt 59 Reinstall the coupler cover 60 Attach the two springs on the MAG exhaust flange to the pipe 61 Reinstall the 90 deg brass fitting to the MAG pipe and attach the 3 8 clear waterline Note If you are going to be installing aftermarket carburetors do so at this time as per the manufacturers instructions 62 On the stock carburetors install the 1 4 x 24 pulse line item 13 to the brass fitting on the rear intake using a 4 hose clamp item 21 63 Remove the two bolts from the rear counter shaft housing area Using the same bolts install the new throttle cable bracket item 15 64 On the Stock intake manifold remove the balance tube hose and fittings and install the two 3 8 N P T x 1 2 plugs item 35 Using Pig putty item 36 fill in the holes which go between each intake manifold 65 Install the intake manifold back onto the engine Carburetor Adjustments These carburetor recommendations are for 730 feet above sea level No claims are made by Factory Pipe for the performance reliability or function of this exhaust system on a modified engine Carburetor adjustments will vary depending on engine modifications fuel altitude and other variables Please consult a qualified technician if you are not familiar with tuning your carburetor s These changes MUST be done prior to running the engine with this exhaust system High performance engines require precise jetting and damage can
5. SS hose clamp 1 47 6 SS hose clamp 3 87 2 Hole spring hook SS 8mm Spring w clear hose cover 8mm x 1 25 x 35mm Socket head SS 8mm x 1 25 x 40mm Socket head bolt 8mm Flat washer SS Fiber washer w 152 OD J11729 190 Lord mount J11729 177 Lord mount 10mm x 1 25 x 20 Flanged head cap 3 8 16 SS Nut 3 8 16 x 3 4 Hex head bolt SS 3 8 Ext Tooth washer SS 3 8 NPT Pipe plug 7 Stick repair putty 3 8 Vinyl cap 1 2 Vinyl Cap Side squirter 3 8 Hose Side squirter 1 4 Hose 12 SS Hose clamp 1 2 3 8 NPT x 3 4 Strt hose ftg 43 45 46 47 48 49 50 51 52 53 54 55 56 57 1 COMCRB0001 170 Keihin main jet 3 COMCRB0003 Keihin pop off spring 1 COMFAS0048 10mm x 1 5 x 30mm Hex head cap scrw 16 COMFAS0086 3 8 Flat washer w 1 O D SS 2 COMFAS0281 3 8 16 x 1 3 4 SS Hex head 2 COMMNTO0150 1 1 2 x 1 3 4 Long spacer mount 4 COMCLP0021 250 High torque SS hose clamp 2 5 COMFAS0212 5 1 2 Plastic zip tie 3 COMFAS0210 4 Plastic zip tie 1 0211 15 71 1 0011 STX R Crossover tube 1 COMHOS0091 3 Silicone coupler 2 1 2 1 COMCABO0001 STX R ULTRA Throttle cable modified 1 COMINTO001 1200 STX R Video instructions Required Parts Not Included in Kit Modified Kawasaki CDI module Factory Pipe Part FIN1200ST02 DO NOT use the stock CDI module as engine damage will occur Tau Ceti Flame Arresters use w
6. brass fitting Using a 37 64 drill bit drill out the water in hole and then tap using 3 8 18 N P T tap After tapping make sure all chips are removed Install the 3 8 N P T x 3 4 barbed straight fitting item 42 using pipe sealant on the threads 23 Reinstall the water intake manifold back on the engine making sure all three gaskets are in place Attach the 3 4 water in line to the straight barbed fitting using the stock hose clamp previously used on the 90 deg fitting 24 Remove the pump nozzle and stator assembly you will have to drop the ride plate for this Drill out the water in brass fitting using a 23 64 drill bit the brass fitting does not need to be removed while drilling Make sure you drill all the way thru the brass fitting and pump stator Reinstall the pump nozzle and stator making sure all hoses are secured 25 Remove Stock throttle oil injection cable and install the new modified throttle oil injection cable item 56 26 Install one of the 177 lord mounts item 30 and one of the fiber washers item 28 onto each of the two CTR pipe head brackets item 20 24 28 29 30 31 32 33 34 35 36 Install one of the 177 lord mounts item 30 and one of the fiber washers item 28 onto the CTR pipe front head bracket item 19 and secure the mount to the bracket using a 3 8 flat washer item 47 3 8 ext tooth washer item 34 and 3 8 16 S S nut item 32
7. occur if the carburetor s are not properly tuned Note The carburetors will be reversed when installed with the Factory Pipes vs the stock pipe Rear carburetor Has the throttle linkage Main Jet 170 Pilot Jet Stock Replace with supplied valve seat spring Center carburetor Main Jet Stock Pilot Jet Stock Replace with supplied valve seat spring Front carburetor Main Jet Stock Pilot Jet Stock Replace with supplied valve seat spring 66 Remove the throttle position sensor TPS You will not need this as the TPS circuit in the new CDI module is disabled 67 Lightly seat all three low speed screws turn clockwise and the turn out counter clockwise 3 8 to 1 2 turn 68 Place the carburetors in the boat and attach the oil lines pulse line return line and main fuel in line using 4 hose clamps item 21 Note Make sure the main fuel in line and the return line fuel out are connected to the correct fitting It is marked on the carburetors 69 Install the carburetors on the engine making sure the gaskets are in place Install your aftermarket flame arrestors at this time We recommend the Tau Ceti flame arrestor kit for the STX R 70 71 72 73 74 75 76 77 Attach the throttle cable to the throttle cable bracket Adjust and tighten This completes the reinstallation of the carburetors Slip the CTR pipe into the center exhaust flange Install and secure the three pipe mount b
8. same bolts 52 Install the oil injection cable to the oil pump and then attach the cable to the bracket Adjust the cable per Kawasaki STX R service manual instructions 53 Install a 177 lord mount item 30 to the middle MAG pipe bracket using a 3 8 16 x 3 4 hex head bolt 3 8 ext tooth washer and 3 8 flat washer item 33 34 47 The rubber mount will sit on top of the bracket and bolted from underneath The stud of the rubber mount faces upward and will fit into the slot on the crankcase mount bracket 54 Slide the MAG pipe onto the MAG exhaust flange 55 Install a 3 8 16 x 3 4 bolt 3 8 flat washer and 3 8 ext tooth washer item 33 47 34 into the front MAG bracket oil injection bracket and secure 56 Install a 3 8 16 S S nut 3 8 ext tooth washer and 3 8 flat washer item 32 34 47 onto the mount stud which goes into the slot of the crankcase bracket 57 Remove the left rear motor mount bolt 58 Locate the MAG pipe rear bracket item 18 Attach the stud end of a 190 lord mount item 29 to the rear bracket using a 3 8 16 S S nut 3 8 ext tooth washer and 3 8 flat washer item 32 34 47 Install the bracket on top of the motor mount plate and loosely secure with the 10mm x 1 5 x 30mm bolt item 46 Adjust the mount so it aligns with the rear mount bracket on the MAG pipe and secure the bracket to the lord mount using a 3 8 16 x 3 4 bolt 3 8 ext tooth washer and 3 8 flat washer item 33 34
9. ect all fuel lines at the fuel pump fuel in return pulse Disconnect the oil injection line at the carb and leave all the lines in the boat as you will reuse them later Remove the intake manifold and pulse line Leave the reeds in place and cover with a towel or rag to prevent debris falling into the reed cages Remove the stock exhaust system and exhaust manifold Do not remove the waterbox Remove all the exhaust manifold studs that are connected to the cylinders Retain the exhaust manifold gaskets as you will use with the triple pipe install Remove all three cylinder head water bypass lines and the three 90 deg brass fittings from the heads Remove cylinder head brackets that are between heads Remove the water intake manifold water into cylinders that is located on the back of the cylinders Retain manifold as you will modify later Remove drive line coupler cover Remove the fuel line holders that are glued to the hull on the intake side of the boat Remove stock CDI box Remove the zip ties that hold the TPS and the heat sensor Leave the wire harness loose at this time Remove the waterbox and crossover tube with the sound suppressor 16 Remove the water bypass lines from the fittings in the hull that are located behind the crossover tube Two of these lines were connected to the cylinder heads and one was connected to the stock exhaust system 17 Remove the fuel filter from holder and leave in boat Remove the fuel
10. ent Once the collector is properly aligned secure all the hose clamps including the center stinger tube coupler under the cylinders all couplers on the collector and the 3 coupler on the water box Secure any loose wires using zip ties item 51 Insert the air temp sensor bypass connector supplied with your Modified Kawasaki CDI module green Operating without this connector will cause the timing to retard and cause poor engine performance Double check that all hardware couplers clamps and waterlines are secure Reconnect the battery cables We suggest you run the boat in the water with the seat off to look for any leaks and make sure there is good flow coming from all four side squirters 10 11 9 A A 227 58588 22 HARDWARE 12
11. filter holder from boat You are now ready to begin installation of the Factory Pipe Triple Pipe System It is highly recommended that you watch the included video instructions before you begin the installation process Taking the time to watch the video will save you hours of frustration The procedures in the video follow the same order as the written instructions 18 On the right side of the boat route the fuel filter to the front and locate a spot around the front of the fuel tank rubber tank strap etc to secure it using a 15 zip tie item 53 Make sure the filter is secured in a vertical fashion Route the rest of the fuel line back down the left side of the boat and let it hang out side the engine compartment at this time 19 Install the two 3 8 rubber caps item 37 and the one 1 2 rubber cap item 38 on the bypass outlets on the top of the pump box Secure all three using 4 zip ties item 52 20 Install the modified Kawasaki CDI Module in ignition box 21 Locate the water in line assy item 9 and place the 3 4 waterline under the motor strap and up towards where the water intake manifold is located Measure 4 in from where the current 1 2 water line comes in thru the hull and cut Connect the 1 2 side of the water in line assembly to the 4 piece you just cut and secure with a 1 2 hose clamp item 41 22 Locate the water intake manifold which you previously removed from the engine Remove the 90 deg water in
12. ining spacer mount Attach the lord mount side of these assemblies to the two rear mount brackets on the PTO pipe using a 3 8 16 x 3 4 hex head bolt 3 8 ext tooth washer and 3 8 flat washer item 33 34 47 Note The assembly with the longer lord mount goes on the right side and the short lord mount assembly goes on the left side Attach a 190 lord mount item 29 to the remaining front PTO bracket using a 3 8 16 S S nut 3 8 ext tooth washer and 3 8 flat washer item 32 34 47 Do not mount the PTO pipe to the top deck at this time Push the pipe as far back as possible and let sit Reattach the solenoid and fuse box bracket to the top deck Install the CTR pipe item 2 Do not attach any to the exhaust flange or mounts Just lay it in position Located the MAG pipe item 3 and remove the 90 deg brass fitting on the head pipe which has the 3 8 clear line attached to it this must be remove for installation purposes Install the MAG pipe into the boat but do not attach it to the exhaust flange at this time 50 Install a 177 lord mount item 30 into the MAG pipe bracket using 3 8 16 5 5 nut 3 8 ext tooth washer and 3 8 flat washer item 32 34 47 The rubber mount will face the rear with the stud end going forward and fastening to the pipe bracket 51 Remove the two bolts from the MAG housing just above where the counter balance is located Install the MAG pipe bracket oil cable bracket item 17 using the
13. ith stock CV carbs Special Tools Required for Installation 1 2 3 8 37 64 and 23 64 drill bits 3 8 x 18 N P T pipe thread tap thread sealant Check contents against Bill of Materials Immediately report any shortages where you purchased your Factory Pipe Read all instructions carefully before starting installation You must run fuel with minimum octane rating of 92 premium pump fuel Running a lower octane fuel can cause detonation and serious engine damage Always warm up the engine prior to full throttle high speed operation 10 11 12 13 14 15 Factory Pipe Instructions Kawasaki STX R Triple Pipe Disconnect the battery Disconnect the exhaust heat sensor at the connector that is located in front of the pipe near the gas tank Be sure to leave sensor in the pipe and disconnect at the connector Remove the stock flame arrestor both sides front and back Do not remove the adapters Remove the throttle choke oil injection cable bracket connected to the stock exhaust system Then disconnect the cables from the bracket and at the carbs choke amp oil injection pump Retain the allen bolt from the oil injection cable as you will reuse this with the new cable Remove the choke cable from boat or zip tie it out of the way It will not be used in this installation Remove the carbs and disconnect the throttle position sensor TPS at the connector The TPS is located at the rear of the carbs Now disconn
14. r vents removed it is important to remember that if the watercraft gets tipped upside down without these vents installed it will fill with water quickly and cause damage Locate two areas on each side of the rear of the top deck to install water overboard bypass fittings side squirters These areas should not be obstructed so that the waterlines going to them have a clean route Once you have marked where your fittings will go drill the holes with a 1 2 drill bit Install one 1 4 side squirter item 40 and one 3 8 side squirter item 39 in the port left side of the top deck The other two 3 8 side squirters go on the starboard right side of the top deck When securing the side squirters angle the flow direction to the rear Locate the two previously retained pieces of stock 3 8 black waterline One piece should be approximately 41 long Attach this piece to the left 3 8 side squirter using a 6 hose clamp item 22 Cut the remaining piece of waterline to produce 19 length and a 27 length Attach these pieces to the two 3 8 side squirters on the right side of the boat using 6 hose clamps item 22 Leave these waterlines hang outside the engine compartment at this time 37 38 39 40 41 42 43 44 45 46 47 48 49 Install stock waterbox and secure with rubber strap Note The smaller opening goes to the rear Remove the black plastic sound suppressor from the exhaust crosso
15. rackets to the three head brackets using the 3 8 16 x 3 4 hex head bolts 3 8 ext tooth washers and 3 8 flat washers item 33 34 47 Install the two springs on the center exhaust flange to the pipe Attach all three waterlines from each cylinder head to the 90 deg brass fitting on each pipe using 6 hose clamps item 22 Fig 6 Install all three spark plug boots to the spark plugs On the port left side of the boat attach the 1 4 waterline from the exhaust flange to the 1 4 side squirter using a 4 hose clamp item 21 Route the black 3 8 waterline coming from the 3 8 side squirter to the 90 deg brass fitting on the rear of the MAG pipe You mad need to cut this to length depending on your routing On the starboard right side of the boat attach the longer 3 8 black waterline from the side squirter to the brass mender coming from the CTR pipe using a 6 hose clamp item 22 You may need to cut this to length depending on your routing Note Do not use grease or oil on silicone couplers Use only glass cleaner or water with dish soap if required 78 79 80 81 Locate your center stinger assembly item 5 Install a 2 high torque hose clamp item 50 on the coupler going to the CTR pipe outlet Slide the assembly in the boat under the cylinders and slide the coupler onto the pipe outlet Leave the hose clamp loose at this time Using one of the two retained stock 3 exhaust clamps install the 3 x 2 1
16. ver hose in the rear of the boat Replace the suppressor with the 3 3 dia x 3 1 2 long tube splice item 54 Make sure it is routed as low as possible then secure using the stock clamps Note The tube splice is intended for recreational and superstock set ups If you are racing in Limited class the sound suppressor must be in place Install the three 3 8 x 15 waterlines item 10 11 12 onto the straight 3 8 fittings on the top of each cylinder head Secure all with a 6 hose clamps item 22 Locate the two small indentations between the engine compartment opening and the rear storage compartment opening Align the PTO chamber mount template with the existing dents making sure the arrow points toward the front of the boat Drill the hole using a 3 8 drill bit Fig 4 Remove the two front bolts which attach the black plastic grab handle Fig 5 Drill these holes out using a 3 8 drill bit Install one spring item 24 on each exhaust flange spring hook total of six two per flange and leave them hang at this time Remove the three phillips head screws that hold the solenoid and fuse box bracket to the top deck Lay it in the bottom of the hull for now Install the PTO pipe item 1 into the rear of the engine compartment Do not attach it to the exhaust flange at this time Install a 190 lord mount item 29 into one of the 1 1 2 x 1 3 4 long spacer mounts item 49 and a 177 lord mount item 30 into the rema
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