Thanks for your help,
yes that round circle directly below the number 1 in your picture is it.
but it did not corrode to leak gently but rather exploded from the inside like &quotalien"
with all the edges flayed open and some white &quotlubricant" coming out.

I thought perhaps it was because I did not know to start the engine before placing the water hose for cooling into the water hose port in back

the reciprocal side (not visible in the photo - same place - other side) has one that is so thin it feels like you could very easily push your finger right through it.

what do I have them weld onto it?

thanks again for your answers!

I have the same problem on my '95 Speedster and from previous posts, it appears to be a common problem.
The leak is due to the weld on the tuned pipe corroding, it should be a simple fix if you remove the pipe and can find a shop that can do alloy welding.

For a temp fix I used JB Weld on both my engines tunned pipe over a year ago with no problems. I have someone repairing them this week and the way it's done they build up a bead all over the plug. Both of my pipes had a small crack in the weld on the other side of the pipe from your diagram in the same place. The reason I waited so long to have it welded was that I wanted to make sure the other 3 plugs were not going to leak also. A very small leak under presure will put alot of water in the bilge.

I had the same problem with a leak on one of my pipes. The Seadoo mechanic tried three times to weld it, but couldn't plug the leak. I finally took it to a master welder, and he wanted $75 to fix it. Mine also got so hot it burned the purple paint off. Went on eBay and found a perfectly good used pipe for $45.

Thanks RudeDog40 - that helps me to know which way to go.
what was the nomenclature so I know exactly what to look for? -
it does not seem to be named or labeled on the diag.

thanks Again!
David

Mine has a Seadoo part number stamped on the side of the pipe. Pretty large numbers so it's not hard to miss. Looked on World of PowerSports. Shows for a '97 XP that the front part of the pipe is a 274000161. the tail-end is a 274000210. Just search eBay for Seadoo Pipe. Most auctions have pictures you can compare to yours. If it looks familiar, email the seller and they should be able to look for the part number on their pipe. There's one listed right now that might fit your PWC, look at the picture and see if it looks familiar:

http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&category=31285&item=2452549036

I would check the classifieds on Sea-Doo.net, if there is not one for sale you can post a wanted ad and someone will reply.

I pulled the exhaust pipe and had a marine weld shop repair the leak. They charged me $20.00. The great part about having two engines, it happened to me twice in three weeks. You should be able to correct this problem without too much problem. Good luck.

Thanks for your help!
I need to understand.
what is the function of this &quotTuning Pipe" ?
Is it inedeed a simple pipe that simply needs a stoutly welded plug???
or is there anything inside the port that blew?

thanks again!

All engine part cannot get super hot per Coast Guard. The muffler has is a two piece. In the middle is where the water cool down the muffler. I think if you pop the plug out, there is a spot where the weld the two piece together. Read the thread and by want I get it keep the engine at the right temp. It act like a car thermostat. It sound like the plug got rusty and the pressure open the hole. Fine someone with a welder. If that don't fix it. You need to find a replacement or pay $600 from the dealer.




Read I think this is what you want.

http://www.sbtontheweb.com/ubb/ultimatebb.php?ubb=get_topic;f=19;t=000929#000002

The tuned pipe and exhaust manifold are designed with a double wall to allow water circulation.
Water is pre-heated by the exhaust system before entering the cylinder cooling jackets.
Water enters cylinder cooling jacket through pasages located below exhaust ports from tuned pipe.
The water flow regulator valve(mounted directly onto the resonator in rear of boat) has a calibrated spring and a tapered needle which regulate the injected water in the tuned pipe.

All of these things work togther to produce the maximum horsepower.

There is a ribon of water going around the tuned pipe were you see the welds. The procedure to repair cracks is the T.I.G. welding process and they need to use a aluminum welding rod. Always ensure water passages are not blocked partially or completly while welding tunned pipe.

After it is repaired you should be able to plug all holes aand presurize the pipe under water to 18 PSI.

thanks for the information!!!!