– INSTALLATION INSTRUCTIONS –
Contents
1. Se TRACING J N PERFORMANCE PRODUCTS amp ACCESSORIES Free Flow Exhaust Kit PART RK16085 We strongly recommend the use of a service manual to familiarize yourself with the various components and procedures involved with this installation Please note that some of the original clamps hoses and hardware removed in the disassembly process will be used in the installation process These instructions have been written in point form and refer to illustrations Please follow these step by step instructions and illustrations carefully APPLICATION S 08 04 Kawasaki STX 12F 15F Required Specialty Tools Part Small bottle jack N A Large cutting wheel tool N A Welder N A Recommended Specialty Tools Part 1 3 4 hole saw bit N A 10 L x 1 4 drive extension N A 1 4 drive universal N A 5 16 x 1 4 drive socket N A INSTALLATION INSTRUCTIONS Read through the installation instructions entirely before beginning As part of the installation of this kit you are required to cut and weld aluminum 1 Remove lanyard Disconnect battery cables and remove battery 2 Inside hull under rear grab handle remove air inlet tubes and disconnect hoses for stock bilge pick ups from breather fittings see illustration 1 3 Remove exhaust hose connecting primary muffler left water box to secondary muffler right water box Disconnect remaining hoses from breather fittings Remove exhaust hose connecting secondary muffler to exhaust outl2. 1 gt i errr E J a E T a Waterline from intake side of cylinder iil TIP Prevent chafing by adding rubber padding Illustration 20 MAA pig Waterline to supplied fitting at rear of craft 10
3. cleaner to outside of muffler and rubber seal will ease removal Inside hull remove strap for secondary muffler by carefully cutting or grinding down head of rivet securing it to hull NOTE Apply silicone sealant to rivet area after removing Remove end cap of primary muffler by cutting at weld see illustration 15 Inside muffler remove inner ring at edge see illustration 16 Inside muffler drill out baffle cap using a 1 3 4 hole saw bit see illustrations 17 amp 18 NOTE Sand all edges thoroughly Replace muffler end cap Add bead around modified end of exhaust outlet see illustration 3 NOTE An experienced welder should perform this step Replace primary muffler in reverse order of steps 5 6 NOTE It is necessary to rotate muffler so as to ease installation Take care not to damage seal on hull Applying a generous amount of glass cleaner to outside of muffler and rubber seal will ease installation Place primary muffler into cradle on left side of craft and secure strap Slide coupler on exhaust pipe joint onto muffler inlet flange completely Secure hose clamps NOTE Do not over tighten clamps Replace brass fitting at top of muffler inlet tube with supplied brass fitting Attach waterline from exhaust side of cylinder to newly installed fitting and secure Attach waterline from outlet at top of pump area to fitting at bottom of muffler inlet and secure see illustration 19 NOTE Apply pipe thread
4. N IMAGES ey F Breather fy z y Exhaust hose from islet ber ona primary muffler to secondary muffler iT Hosesto E Hoses to stock bilge outlets j stock bilge P f Exhaust hose a pick ups from secondary TIP After disconnecting tuck ends into muffler to opening at driveline hull support exhaust outlet Illustration 1 Illustration 2 Place worm gear at 11 o clock TIP Weld a bead around end after cutting to prevent coupler Top dead center of exhaust from sliding forward outlet flange 12 o clock Illustration 3 Illustration 4 Word doc RK16085 H1 2 2 11 3 TIP Insert outlet into hull At clamp angle outlet upward as shown to allow worm gear to clear opening Illustration 5 Coupler installed completely onto curved end of exhaust tube Illustration 5 Word doc RK16085 H1 2 2 11 Hose clamps loosely installed onto muffler outlet flange Modified exhaust outlet installation completed Illustration 6 a g a pe t TIP Make sure exhaust tube does 4 not rub against hull F Illustration 6 WRA F on We i MA i ral E i TIP Rotate breather fitting Hose to rear bilge pick up routed between exhaust tube and muffler PRIMARY MUFFLER MODIFICATION PROCEDURE At top of oil separator tank disconnect and completely remove hose connecting top of tank to front of air box At center of tank disconnect hose from fitting on rear of cylinder h
5. der front of secondary muffler right water box Remove rubber padding between muffler and hull 3 pieces total Lift muffler up onto battery tray ledge see illustration 11 At battery tray just in front of muffler place bottle jack approximately 1 from end of muffler see illustrations 12 amp 13 Expand jack until it is suspended between top deck and battery tray NOTE Position of bottle jack base is critical Take care not to crush electrical wires battery strap clips and steering cable Slowly expand bottle jack to create room for muffler to move forward and up onto upper ledge of battery tray Once muffler is able to rest on upper ledge of battery tray retract bottle jack so that top deck rests on top of muffler see illustration 14 Move bottle jack forward approximately 2 3 4 and expand until it is suspended between top deck and battery tray see illustration 14 NOTE Position of bottle jack base is critical Take care not to crush electrical wires battery strap clips and steering cable Slowly expand bottle jack until muffler moves Continue expanding bottle jack slowly while pulling on muffler until you are able to remove completely Once muffler is clear retract bottle jack completely and remove from hull Remove muffler from hull through rear engine compartment opening and discard NOTE It is necessary to rotate muffler so as to ease removal Take care not to damage seal on hull Applying a generous amount of glass
6. ead At bottom of tank disconnect hose from fitting on tank see illustration 7 NOTE Leave hose connected to engine Remove oil separator tank from hull At throttle body loosen hose clamp securing air inlet tube to throttle body see illustration 8 At top of hull cross section loosen the two M8 bolts securing air box to hull Remove air box through forward engine compartment opening by rotating 90 degrees NOTE Cover throttle body inlet to prevent foreign objects from entering Remove the three Phillios head screws securing mounting plate for electrical components to hull Carefully lay assembly in bottom of hull under footwell see illustration 9 Inside hull label and then remove waterlines secured to fittings at inlet of primary muffler left water box TIP It will be easier to remove waterline from lower fitting during step 6 Loosen clamps securing coupler at muffler inlet exhaust pipe joint Slide coupler forward onto exhaust pipe joint completely TIP Using a small screwdriver lift edge of coupler on exhaust pipe joint and apply glass cleaner Move screwdriver side to side to distribute fluid Remove muffler from hull through rear engine compartment opening see illustration 10 NOTE It is necessary to rotate muffler to ease removal through opening Take care not to damage seal on hull Applying a generous amount of glass cleaner to outside of muffler and to rubber seal will ease removal Inside hull remove foam padding un
7. ee illustration 6 Secure hose clamps TIP Use recommended specialty tools to reach clamp at exhaust outlet coupler NOTE Do not over tighten clamps 23 Install hoses to stock bilge pick ups onto breather fittings NOTE Route hose for rear pick up left side through Free Flow Exhaust Tube see illustration 6 24 Replace remaining stock bilge hoses and air inlet tubes 25 Installation is now complete Thoroughly inspect engine compartment and bilge for tools rags parts etc Run craft on stand using flush kit After engine cools check all hoses and clamps to make sure they are secure NOTE Do not over tighten clamps Remember the water belongs to everyone Please ride responsibly Technical Support For answers to questions regarding installation or trouble shooting RIVA Performance Products contact RIVA Technical Support directly at 954 247 0705 or by e mail at tech _support rivamotorsports com Limited Warranty RIVA Free Flow Exhaust Kits carry a 90 day limited warranty to the original purchaser They are warranted to be free of defects in materials and workmanship under normal use and service Customer modified components will be void of warranty This warranty is limited to defects in the primary components only Finish and or wear marks in or on primary components are not covered under this warranty RIVA Racing s liability is expressly limited to the repair or replacement of the components contained within or associated wi
8. er into couplers prior to installing Word doc RK16085 H1 2 2 11 1 9 Install straight end of exhaust tube into coupler on exhaust outlet Align curved end of exhaust tube with primary muffler outlet and slide coupler onto outlet completely see illustration 6 Secure hose clamps TIP Use recommended specialty tools to reach clamp at exhaust outlet coupler NOTE Do not over tighten clamp NOTE Do not over tighten clamps 10 Install hoses to stock bilge pick ups onto breather fittings NOTE Route hose for rear pick up left side through Free Flow Exhaust Tube see illustration 6 11 Replace remaining stock bilge hoses and air inlet tubes 12 Installation is now complete Thoroughly inspect engine compartment and bilge for tools rags parts etc Run craft on stand using flush kit After engine cools check all hoses and clamps to make sure they are secure NOTE Do not over tighten clamps Remember the water belongs to everyone Please ride responsibly Technical Support For answers to questions regarding installation or trouble shooting RIVA Performance Products contact RIVA Technical Support directly at 954 247 0705 or by e mail at tech _support rivamotorsports com Limited Warranty RIVA Free Flow Exhaust Kits carry a 90 day limited warranty to the original purchaser They are warranted to be free of defects in materials and workmanship under normal use and service Customer modified components will be void of warrant
9. et see illustration 2 NOTE Retain hose clamps 4 Remove section of foam between top deck and pump area inside hull and discard 5 At rear of hull remove and discard plastic exhaust outlet nozzle Remove exhaust outlet from hull Cut exhaust outlet 5 3 4 from flange see illustration 3 NOTE Sand or file rough edge after modifying 6 Install one supplied silicone coupler onto modified exhaust outlet and secure using OE hose clamp see illustration 4 Install exhaust outlet into hull and secure using stock hardware see illustration 5 NOTE Be sure rubber gasket is in place between flange and hull Do not apply sealant to gasket Apply blue Loc tite to bolts Do not over tighten bolts 7 Install supplied billet exhaust outlet tip using supplied hardware see illustration 6 NOTE Do not use any sealant Use blue Loc tite on bolts Do not over tighten bolts NOTE To achieve optimum performance with this Free Flow Exhaust Kit we recommend the modification outlined on pages 5 amp 6 be performed at this point Installation of the Free Flow Exhaust Kit will be completed using the steps and illustrations on pages 5 10 8 Thoroughly clean primary muffler outlet using a non residual cleaner Install second supplied silicone coupler completely onto curved end of exhaust tube see illustration 5 Loosely install two OE clamps onto primary muffler outlet and one onto coupler on exhaust outlet TIP Spray a generous amount of glass clean
10. ng plate under footwell TIP Lots of glass cleaner and patience T ir F r Mes f 1 LUTE he i F i r 1 paani Illustration 9 Illustration 10 Word doc RK16085 H1 2 2 11 Lift muffler up onto ledge of battery tray Bottle jack pressure points Illustration 11 Illustration 12 WARNING POONG GET UIN i eee oy DEATH Al aay AVE RTISSEMEN ecru bi macan Boy larma rat cn 1 inch between ereen l Pidi Move jack T jack and muffler 2 3 4 e Lift muffler up onto upper ledge of battery tray Illustration 13 Illustration 14 Word doc RK16085 H1 2 2 11 Remove ring Cut at weld all around inside the way around hex edge of muffler end cap 3 Illustration 15 Illustration 16 Drill out baffle Do not drill any cap with 1 3 4 other holes in hole saw bit ee I baffles Illustration 17 Illustration 18 Word doc RK16085 H1 2 2 11 9 Supplied brass Waterline from fitting installed exhaust side of Note angle cylinder Waterline to stock fitting on Illustration 19 liaa ths ried 7 F F uinu hamana eT OY DEATH TO AVOID COLLONI SCAM COMBTANTLY tar panpin sias sie aaiim Ma sii ki ube OPERATE DEFE ro aay tee are danna Renee TAWE CARRY AS TUIH im md o ere fitting at rear of craft Illustration 21 Word doc RK16085 H1 2 2 11 ae ee gt nnmn mt Th tla a Supplied bypass o a MANEN nt
11. sealant to fitting Do not over tighten fitting NOTE Do not over tighten clamps Install supplied 1 2 brass splicer into waterline from intake side of cylinder and secure Attach supplied 1 2 waterline to splicer and secure using supplied hose clamp see illustration 20 NOTE Do not over tighten clamps Install supplied bypass fitting in a location that will allow water to be expelled so as not to come in contact with rider s TIP Choose a flat area at rear of craft see illustration 21 NOTE Apply silicone sealant to flange and threads of bypass fitting Word doc RK16085 H1 2 2 11 5 20 Attach open end of supplied 1 2 waterline to newly installed bypass fitting and secure using supplied hose clamp NOTE Do not over tighten clamp TIP Secure spliced waterline to hull Attach a small piece of the rubber padding previously removed to hull support to prevent chafing see illustration 20 21 Thoroughly clean primary muffler outlet using a non residual cleaner Install second supplied silicone coupler completely onto curved end of exhaust tube see illustration 5 Loosely install two OE clamps onto primary muffler outlet and one onto coupler on exhaust outlet TIP Spray a generous amount of glass cleaner into couplers prior to installing 22 Install straight end of exhaust tube into coupler on exhaust outlet Align curved end of exhaust tube with primary muffler outlet and slide coupler onto outlet completely s
12. th this kit RIVA Racing agrees to repair or at RIVA s option replace any defective unit without charge if product is returned to RIVA Racing freight prepaid within the warranty period Any equipment returned which in RIVA s opinion has been subjected to misuse abuse overheating or accident shall not be covered by this warranty RIVA Racing shall have no liability for special incidental or consequential damages or injury to persons or property from any cause arising from the sale installation or use of this product No other warranty express or implied including but not limited to the implied warranties of merchantability and fitness for a particular purpose applies Various states do not allow for the limitation of incidental or consequential damages and therefore the above exclusion or limitation may not apply to you Warranty does not include the expenses related to freight or transportation of parts or compensation for any inconvenience or loss of use while being repaired A copy of the original invoice must accompany all warranty claims Warranted replacement parts will be returned freight collect Word doc RK16085 H1 2 2 11 6 PRIMARY MUFFLER MODIFICATION PROCEDURE ILLUSTRATIONS Hose from air box to oil separator tank Remove completely Air inlet tube from air box to throttle body inlet Hose from cylinder head to center of oil separator tank Illustration 7 Illustration 8 Electrical component mounti
13. y This warranty is limited to defects in the primary components only Finish and or wear marks in or on primary components are not covered under this warranty RIVA Racing s liability is expressly limited to the repair or replacement of the components contained within or associated with this kit RIVA Racing agrees to repair or at RIVA s option replace any defective unit without charge if product is returned to RIVA Racing freight prepaid within the warranty period Any equipment returned which in RIVA s opinion has been subjected to misuse abuse overheating or accident shall not be covered by this warranty RIVA Racing shall have no liability for special incidental or consequential damages or injury to persons or property from any cause arising from the sale installation or use of this product No other warranty express or implied including but not limited to the implied warranties of merchantability and fitness for a particular purpose applies Various states do not allow for the limitation of incidental or consequential damages and therefore the above exclusion or limitation may not apply to you Warranty does not include the expenses related to freight or transportation of parts or compensation for any inconvenience or loss of use while being repaired A copy of the original invoice must accompany all warranty claims Warranted replacement parts will be returned freight collect Word doc RK16085 H1 2 2 11 2 INSTALLATIO
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