Stinger
Removal
Stinger
Removal
So, you want to remove your OEM stinger. Could you be doing a carb rejet or maybe installing a Stinger3? Whatever it may be you will need some tools. Here is a basic list of tools you will need:
Flathead Screwdriver
Phillips Screwdriver
Socket wrench
Extension
10 mm socket
12 mm socket
Whenever you do work on a ski it is good practice to bag and tag the pieces and bolts/nuts/washers that you take off. I use zip lock bags and a Sharpie marker. It is always a good idea to disconnect your battery before you do any of the work to your ski. Here we go:
First of all, remove the plastic heat shield over your Stinger and toss it in the attic and forget about it.
1.) Removing the battery tray: Disconnect battery wires from the terminals and spark plug wires from the spark plugs. Remove the four (4) 12mm bolts that hold the electrical box to the battery tray. These are the four brass nuts that are visible in the battery tray once you remove the battery. Push the electrical box towards the front of the ski until the four studs clear the battery tray. Next, remove the two black 12mm nuts on the top rear of the battery tray and then the two 10mm nuts with the white tops on the top towards the front of the tray. While doing this make sure you don't drop the passenger side clip down below the engine. Push the positive cable, negative cable and the vent tube through the hole in the side of the battery tray. Now you can pull out the battery tray and support bracket.
2.) Getting the electrical box out of the way: Disconnect the three plugs on the driver's side of the electrical box to allow maneuverability. These plugs are the exhaust temperature sensor, the water temperature sensor and AC magneto. Once the plugs are disconnected you can set the electrical box behind the bulkhead out of the way.
3.) Getting into the Stinger: Where the stinger meets up with the exhaust chamber you will see a big rubber boot with two clamps on it. Loosen those two clamps and slide the boot towards the front of the ski. This will expose another coupler that is gray. Loosen the clamp that is towards the rear of the boat. You do not need to loosen the front clamp.
4.) Disconnect the water hose that is located towards the middle top portion of the stinger.
5.) Remove the 14mm bolt where the Stinger mounts to the bracket on the rear end of the engine case. This is located towards the end of the Stinger towards the back of the boat.
6.) Remove the 12mm bracket bolts on the passenger side of the No. 2 cylinder. They are a little hard to see but easily accessible with an extension.
7.) Remove the 14mm bolt/mount which holds the intermediate housing grease hose. In the pic below it is the bolt on the right. The grease hose is the little black cap to the far right.
8.) Remove the remaining three (3) bolts that hold the Stinger to the top of the head/cylinders.
9.) Loosen the last clamp which is located at the end of the Stinger where it couples with the waterbox.
10.) Gently pull toward the top front of the Stinger in a backwards motion and try and disengage the Stinger from the front coupler at the expansion chamber. Once you have that apart you can pull up and then forward to disengage it from the back at the waterbox. When that is done, gently pull the Stinger straight upwards and out of the hull. You have now removed the Stinger.
