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Old 03-30-2011, 11:43 AM
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Originally Posted by JTeam
The new 525's do not have the bypass and I called CMI and they said get rid of it. That's good enough for me.
Sounds good then. I'll probably do it.
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Old 03-30-2011, 08:54 PM
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Originally Posted by thirdchildhood
Where can we get the parts?

Is this mod needed or is it just for installation of the new headers and tailpipes? The service bulletin does not say that all older set-ups should have this mod done. My headers have always stayed cool. When I stop the boat and check the engine room one thing I do is see if I can hold my hand on each header tube.

And here is a link to where that bulletin was posted since I'm sure not everyone saw it.
http://www.offshoreonly.com/forums/3360439-post36.html
You can buy the plugs anywhere. The header rail takes a 3/4" plug and the tail is a 1/2".
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Old 03-30-2011, 09:46 PM
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Originally Posted by redbud35
You can buy the plugs anywhere. The header rail takes a 3/4" plug and the tail is a 1/2".
OK but I'll still have to order two .406" upper restrictors since both uppers must now be the same. The starboard side are smaller now.

Last edited by thirdchildhood; 03-30-2011 at 09:49 PM.
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Old 03-31-2011, 07:33 AM
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Originally Posted by thirdchildhood
OK but I'll still have to order two .406" upper restrictors since both uppers must now be the same. The starboard side are smaller now.
Or you can go get a 13/32 drill bit and simply drill out the stb. side unless you enjoy giving Merc your money.
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Old 03-31-2011, 07:37 AM
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Originally Posted by redbud35
You can buy the plugs anywhere. The header rail takes a 3/4" plug and the tail is a 1/2".
Are you just capping off the part of the header rail fitting that the bypass hose connects too? Or replacing that entire fitting with a plug?

If so, would'nt that eliminate the blue thumb screw at the end? I like having them to drain the headers. I have them on the front of the rail too but I prefer to use the rear. When I pull the front plug on the port side I have to deflect the stream of water so it doesn't pour on to the alternator.

Last edited by Dave M; 03-31-2011 at 07:40 AM.
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Old 03-31-2011, 07:40 AM
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Originally Posted by thirdchildhood
OK but I'll still have to order two .406" upper restrictors since both uppers must now be the same. The starboard side are smaller now.
You only need one. The port side is already .406
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Old 03-31-2011, 07:48 AM
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Originally Posted by Dave M
You only need one. The port side is already .406
The diagram I posted indicates that there are restrictors on each side of the jumper hose but no big deal since I can just drill them/it out .

I'm still not sure I will do the mod. My headers run cool and I don't want to increase the chance of reversion if I don't have to. I'll run it by my mechanic.
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Old 03-31-2011, 08:12 AM
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Originally Posted by thirdchildhood
The diagram I posted indicates that there are restrictors on each side of the jumper hose but no big deal since I can just drill them/it out .
I'm not sure I'm following what you are saying. According to the bulletin.....

To do this the merc way you need
(1) 22-842453406
(2) 22-32803
(2) 22-8M0022059

Replace the restrictor on the top side of the starboard tail with the .406 (22-842453406). Port side is already .406

Replace restrictors on the bottom side of the tails with a plug (both sides). (22-32803)

Replace the fitting on the header rail (Both sides) (22-8M0022059)
Attached Files
File Type: pdf
Mercury header update.pdf (286.9 KB, 798 views)
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Old 03-31-2011, 08:58 AM
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Got it. Pretty simple mod. Thanks
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Old 04-01-2011, 07:58 AM
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Originally Posted by Dave M
Are you just capping off the part of the header rail fitting that the bypass hose connects too? Or replacing that entire fitting with a plug?

If so, would'nt that eliminate the blue thumb screw at the end? I like having them to drain the headers. I have them on the front of the rail too but I prefer to use the rear. When I pull the front plug on the port side I have to deflect the stream of water so it doesn't pour on to the alternator.
I'm glad I came back to this thread. I used the supplied plugs to plug the end of the rail. (CMI supplied) them with the new headers. Then plugged the bottom side of the tail with a brass plug from ACE Hardware. The guys at CMI never said anything about a differant fitting for the jumper on the top of the tail.
I bought all the fittings on my 370 from ACE to convert. I guess I need the ported plugs changed?
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