Help! Water lines - More ports than hose OEM

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Where Do i run my water lines? 93 SJ and was told there are some mods, motor is built 61x with AF head. In picture 1 there are two ports coming from from pump area. One has Yellow cap (on right) and was once running to suction bilge, 2nd is the inlet from pump. I was told the yellow cap line was added as 2nd cooling line, but only one cooling and 1 bilge at the rear. The Head has two small ports, 1 on each piston and two large ports on rear piston. 1 on intake manifold and 1 behind it on the exhaust OEM elbow. There is a small hose on the exhaust and based on size, i assume it goes to small port on front piston. What do i do with the rear piston small port. Last picture is out the Hull. Please tell me how to run these lines and what should i do with the capped line. I have two bilge pumps and not suction bilge.


Please tell me how to run these lines and what should i do with the capped line. I have two bilge pumps and not suction bilge.

 

[Kaylee.S]

I'll see if i can help here...

First, your spark plugs are in backwards. lol

Seriously tho, are you planning on running dual cooling? ie., Do you have a second cooling line going from the other side of the yellow capped tube to your pump?

The port on the intake is for your pulse line. It hooks up to the fuel pump side of your carb and provides an air "pulse" to work the diaphragm and provide fuel pressure.

The rest of the routing is kind of dependant on whether you're running single or dual cooling lines from the pump. Good luck!!

 

[capitalx]

I'll see if i can help here...

First, your spark plugs are in backwards. lol

Seriously tho, are you planning on running dual cooling? ie., Do you have a second cooling line going from the other side of the yellow capped tube to your pump?

The port on the intake is for your pulse line. It hooks up to the fuel pump side of your carb and provides an air "pulse" to work the diaphragm and provide fuel pressure.

The rest of the routing is kind of dependant on whether you're running single or dual cooling lines from the pump. Good luck!!

Thank u. Yes for dual cooling. Currently the suction hose is connected but I'm going to tap the pump for 2nd . (I've been looking for a pic of tap)

 

[TaintlessEd]

Thank u. Yes for dual cooling. Currently the suction hose is connected but I'm going to tap the pump for 2nd . (I've been looking for a pic of tap)

No need to look for a picture. If you know how to tap something it's really easy.
It's the same for every pump anywhere.
If your current pump has a single cooling exit you're going to look on the exact opposite side of the pump and drill/tap 180 degrees opposite the existing.
If you want to put in a third cooling line you'll put it right in between the two you already have.
For Yamaha it's really hard to mess up. They set you up for success from the factory lol. When you pull your pump and look on the opposite side as the existing cooling outlet, you'll see a large nipple. Drill and tap right into that.

As far as the routing, there's multiple ways it'll work.

Let us know if you still need help.


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[capitalx]

No need to look for a picture. If you know how to tap something it's really easy.
It's the same for every pump anywhere.
If your current pump has a single cooling exit you're going to look on the exact opposite side of the pump and drill/tap 180 degrees opposite the existing.
If you want to put in a third cooling line you'll put it right in between the two you already have.
For Yamaha it's really hard to mess up. They set you up for success from the factory lol. When you pull your pump and look on the opposite side as the existing cooling outlet, you'll see a large nipple. Drill and tap right into that.

As far as the routing, there's multiple ways it'll work.

Let us know if you still need help.


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And what about the two small nipples on top of each cylinder. My other concern is the placement of main cooling lines. Mine are both on 1 cylinder so is it possible water doesn't circulate to the other

 

[TaintlessEd]

And what about the two small nipples on top of each cylinder. My other concern is the placement of main cooling lines. Mine are both on 1 cylinder so is it possible water doesn't circulate to the other

The stock head has one small nipple and that goes to the exhaust like so

I would plug the other small nipple on the top.
Further more I wouldn't dual cool the ski if it were mine. You have a stock exhaust manifold so I don't really know how to get the second line into it.
Also unless you're running balls out all the time, ride in super warm water, or running race fuel I don't really see the need for it.
You can in fact over cool these skis and they will run like doggie dooddooo.
If it were my ski I would just buy about 20 feet of my favorite hose (clear braided is my choice, A-you can see the water flowing, B-if your head gasket or Orings start to go you can see the early signs C-you know when to change out your cooling line because it turns a little yellow.) and redo the whole cooling system,
Hook the stock bilge back up as a fail safe in case the other two go out, and then I would go rip!



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The stock head has one small nipple and that goes to the exhaust like so

I would plug the other small nipple on the top.
Further more I wouldn't dual cool the ski if it were mine. You have a stock exhaust manifold so I don't really know how to get the second line into it.
Also unless you're running balls out all the time, ride in super warm water, or running race fuel I don't really see the need for it.
You can in fact over cool these skis and they will run like doggie dooddooo.
If it were my ski I would just buy about 20 feet of my favorite hose (clear braided is my choice, A-you can see the water flowing, B-if your head gasket or Orings start to go you can see the early signs C-you know when to change out your cooling line because it turns a little yellow.) and redo the whole cooling system,
Hook the stock bilge back up as a fail safe in case the other two go out, and then I would go rip!



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I appreciate your advice and will follow it. I'll save the 2nd cooling line for when i find a good deal on Factory B pipe. What about the two large water ports on the rear cylinder. How do i know i'm not circulating water around a single cylinder? If oem head has 1 port then where does it leave the engine.

 

[TaintlessEd]

I appreciate your advice and will follow it. I'll save the 2nd cooling line for when i find a good deal on Factory B pipe. What about the two large water ports on the rear cylinder. How do i know i'm not circulating water around a single cylinder? If oem head has 1 port then where does it leave the engine.

Edit: read it wrong. Gave a weird answer and fixed it.


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And after all this: How now to i run my lines? Suction line back to bilge and single line for cooling. Recap: 1 &2 large taps on rear cylinder head - 3 nipple on exhaust manifold - 4 nipple on exhaust elbow - 5 tiny nipple on top of both heads. (this one i don't understand - Why so small? Is it releasing water from head to exhaust or accepting water from exhaust? 6 tiny niple on exhaust. I also have two pissers out the hull by exhaust.

 

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TaintlesEd - what brand of braided hose and size and please suggest fuel line and size. I'm a true novis!

 

[TaintlessEd]

And after all this: How now to i run my lines? Suction line back to bilge and single line for cooling. Recap: 1 &2 large taps on rear cylinder head - 3 nipple on exhaust manifold - 4 nipple on exhaust elbow - 5 tiny nipple on top of both heads. (this one i don't understand - Why so small? Is it releasing water from head to exhaust or accepting water from exhaust? 6 tiny niple on exhaust. I also have two pissers out the hull by exhaust.

I would look for a stock diagram and work off of that.

TaintlesEd - what brand of braided hose and size and please suggest fuel line and size. I'm a true novis!

3/8 from Home Depot is what I use. Stainless steel hose clamps too.

And don't worry about being new! Just make sure you ask questions if you're unsure especially when it comes to cooling and fuel. Two easy ways to mess things up.


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[capitalx]

I would look for a stock diagram and work off of that.




3/8 from Home Depot is what I use. Stainless steel hose clamps too.

And don't worry about being new! Just make sure you ask questions if you're unsure especially when it comes to cooling and fuel. Two easy ways to mess things up.


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I can't find stock water flow anywhere. I've exhausted the search. Everyone days check parts diagram but I don't get a full view. I then need to tie in the 2nd nozel from head

 

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