Bayliner Boat Maintenance: Replacing The Exhaust Tube

Replacing the exhaust tube on a Bayliner boat can be a challenging task, but with the right tools and guidance, it is certainly achievable. The process may vary depending on the specific model of the Bayliner boat and the type of engine it has. It is important to identify the correct replacement parts and follow safety precautions to ensure a successful and safe replacement. Online forums and communities can be a valuable resource for boat owners, offering advice and step-by-step guides on various maintenance and repair tasks, including exhaust tube replacement.

Removing the stern drive

To remove the stern drive, you will need to follow these steps:

Firstly, gather the necessary tools and materials. You will need a set of tools, including screwdrivers, wrenches, and sockets, as well as any specific parts and materials required for your boat model. It is also recommended to have some grease or dish soap and a spray bottle of water to aid in the process.

Next, prepare the boat by ensuring it is securely docked or lifted out of the water. You will need to access the stern drive, so make sure you have enough space to work and that the boat is stable.

Now, begin the removal process:

• Disconnect the battery: Before starting any work on the boat, it is crucial to disconnect the battery to prevent any accidental startups or electrical issues.
• Remove the cowling: The cowling is the cover that protects the engine and stern drive. Remove any fasteners or screws holding it in place and carefully lift it off.
• Disconnect the shift and throttle cables: These cables are responsible for controlling the boat's speed and direction. They are usually attached to the stern drive with clamps or screws. Loosen or remove these fasteners to disconnect the cables.
• Detach the water hoses and electrical connections: There will be various hoses and electrical connections attached to the stern drive. Carefully detach them, making note of their locations for reassembly.
• Loosen and remove the stern drive mounting bolts: The stern drive is typically secured to the transom (back) of the boat with several bolts. Loosen and remove these bolts, ensuring you have a clear workspace to access them.
• Lift and remove the stern drive: With the bolts removed, carefully lift the stern drive out of its housing. It may be heavy, so consider having an assistant to help with this step.

Once the stern drive is removed, you can proceed with replacing the exhaust tube or performing any other necessary maintenance. Remember to keep all parts organized and refer to a repair manual specific to your boat model for detailed instructions.

Finally, when reinstalling the stern drive, follow these steps in reverse, ensuring all connections are secure and properly tightened.

Using a lubricant

When replacing the exhaust tube bellow on a boat, you may find it challenging to fit the new tube into place. One way to make this process easier is by using a lubricant.

Firstly, you should loosen all the hose clamps on the tube you are replacing, as well as the top clamps on the tube at the end of the exhaust elbow. This will give you maximum flexibility. Next, push the old tube all the way down the Y-pipe to expose the bottom of the aluminium tube. You can then remove the aluminium tube and the top rubber tube from the exhaust elbow, as well as the old tube from the Y-pipe.

Now, you can apply the lubricant. Coat the inside of the new tube with a thin layer of grease (according to one source, any grease will do, but some recommend using a can of Mercury/Quicksilver Power Tune or dish soap mixed with water in a spray bottle). Slide the new tube down the Y-pipe, then pull it up onto the aluminium tube. Finally, tighten up all the hose clamps.

One source suggests boiling the new tube in water for 2 minutes, then lubricating it with dish soap, if you are still struggling to fit the tube after trying a lubricant.

Cleaning the exhaust tube

To clean the exhaust tube on your Bayliner boat, you will need to first remove the tube and then clean it with a scrub brush or other recommended methods. Here is a step-by-step guide:

• Remove the Exhaust Tube: Before beginning, ensure your boat engine is turned off and the exhaust system has cooled down. Then, remove the necessary parts to access the exhaust tube. This may include removing bolts, hoses, and clamps that hold the tube in place.
• Clean with a Scrub Brush: Once the exhaust tube is removed, use a scrub brush to clean it thoroughly. Apply a suitable cleaner, such as lacquer thinner, to the brush and scrub off any built-up debris and rust. You can also use other cleaning methods like an acid bath or sandblasting, but these should be done by professionals.
• Reinstall the Exhaust Tube: After cleaning, reinstall the exhaust tube by securely placing it back in its original position and reconnecting all the necessary parts, such as hoses and clamps. Ensure all connections are tight to prevent leaks.
• Other Cleaning Methods: While scrubbing with a brush is ideal, you can also consider alternative methods for more thorough cleaning. One method is an acid bath, which involves removing the exhaust tube and placing it in an acid tank to remove corrosion and built-up debris. Contact your local auto body shop or auto machine shop for assistance with this method. Another method is sandblasting, which uses a sandblaster to remove dirt, debris, and rust. However, sandblasting may be too harsh and could potentially damage the exhaust tube.
• Regular Cleaning and Maintenance: Regularly cleaning your Bayliner boat's exhaust tube is essential to ensure optimal performance and prevent future issues. Depending on the type of water you boat in, the exhaust tube should be cleaned and inspected at least once a year. This will help extend the life of the exhaust tube and prevent unexpected problems while out on the water.

Clogged exhaust outlets

• Burning odours from the engine bay: A burning smell coming from the engine bay can indicate a leaking exhaust manifold. This occurs when exhaust leaks out of the manifold, causing extremely high temperatures that can melt plastic engine parts and electrical wiring insulation. If you notice a burning plastic or wire smell, it is crucial to take immediate action.
• Fuel odours in the passenger cabin: A clogged exhaust system can cause diesel fuel or gasoline odours to enter the cabin. This is a dangerous situation as it indicates the presence of carbon monoxide, which can be harmful to your health. If you smell fuel, do not operate the boat and seek professional assistance.
• Decreased fuel efficiency and power lag: A clogged exhaust system affects the efficiency of your engine, resulting in poor fuel mileage. The combustion chamber becomes inefficient due to the buildup of exhaust gases, impacting the engine's ability to burn fresh air and fuel effectively. This will also cause your engine to stutter and lag when accelerating or maintaining speed.
• Loud engine noise: A clogged or leaking exhaust manifold can result in excessive engine noise. If you notice a significant increase in engine noise, it could be a sign of an issue with the exhaust system.
• Visual signs on the tailpipe: Regularly inspect your tailpipe for any signs of damage, such as a hanging or holed tailpipe. Operating your boat over bumps or rough waters can easily damage this component.
• Excessive exhaust backpressure: While this may not be easily noticeable, excessive exhaust backpressure can cause the engine to stall or refuse to start. It can also lead to rough engine operation and an illuminated check engine light.

To address these issues, it is essential to diagnose and rectify the clogged exhaust outlets. This may involve seeking professional assistance or performing a thorough inspection and cleaning of the exhaust system, including the manifold, catalytic converter, muffler, and tailpipe.

Additionally, when dealing with exhaust issues, it is important to wear appropriate safety gear, such as a nose mask and gloves, to protect yourself from harmful gases and substances.

Replacing the couplers

The exhaust coupler is a cost-effective way to salvage a damaged exhaust pipe. You can use U-bolts, band sleeves, and V-band clamps to connect two exhaust pipes.

Before installing a coupler, you must measure the dimensions of your exhaust pipe to avoid any leaks. You can use a standard measuring tape to measure the inner and outer dimensions. If the exhaust pipe is warped, you can use a string to measure the dimensions and then measure the string with a measuring tape.

Using a U-Bolt Exhaust Clamp

The U-bolt exhaust clamp is an inexpensive solution and the most common coupling device available. It features a pressed saddle and bolt clamp that fits over the exhaust pipe slip fit connection.

When picking a U-bolt clamp, choose one made from stainless steel or one that comes with a galvanized coating to avoid rust. This type of clamp is no good unless you have a sleeve to cover the leak, so you must cut the pipe at the leak, then install the sleeve with two U-bolt clamps.

Using a Band Sleeve Clamp

A band sleeve clamp can firmly grip two pipes by tightening its bolts. This type of coupler works best for joining two straight pipes.

There are various band clamps available, including narrow, tube, and V-band designs. A narrow band clamp is generally reusable but is designed for a specific application. A tube band clamp is thinner and more malleable than a narrow band clamp, making it possible to form a seal without needing additional slots. However, tube bands have a memory, so leaks might occur if the old pipe is replaced with a new one of different dimensions.

Using a V-Band Clamp

A V-band clamp is used in high-boost applications like turbocharger and supercharger installations. It secures exhaust pipes to turbochargers and superchargers, preventing tube blowouts under extreme boosts.

The V-band clamp is the most durable design, but it requires some welding for installation. You must weld its flanges to each side of the pipe union. Then, a special wedge clamp joins the two flanges to create a tight seal.

Using a Flexible Braided Pipe

An exhaust flex pipe is made from malleable materials, making it more durable than a traditional pipe. It is resistant to extreme temperatures, corrosion, and road debris. Its corrugated design also makes it a great noise-cancellation device and a vibration dampener. Exhaust gases flow freely through flex pipes, reducing back pressure and increasing overall engine efficiency.

Frequently asked questions