Their appears to be a problom with late model 525 sucking
water back through the exhaust and into the engine causing
major probs. 2 Formulas, 1 Black Thunder and 1 Sunsation
have fallen victim to this problom in my area. Mercrusier is
blaming everybody from the manifold makers to Corsa.
However, I have yet to here about any Fountains with this
problom?

I hear the CMI headers keep cracking in the welds.

^^^What he said^^^

CMI's cracking or leaking at the welds, no way! Back in 2001, I had a set on a 500 EFI that looked like they were "crying" when we pressure tested them! We filled them almost full of water and then put 30 psi air pressure (no, not "shop air" at 100 or 125 psi, just 30 psi). At the collector, there were several places that dripped water, and at the tailpipe flange, they looked like they were crying. I put that on a different website and got a personal e-mail back from the guy at CMI who more or less said that couldn't be true. One of my friends is a real whiz with a TIG torch - he took them apart and fixed the leaks.

I heard about Tommy's Black Thunder, but whose Sunsation had a problem? There is only 1 that I can think of with 525's in the area.

On a different note, who did you have install the intercom headsets on your boat. I am thinking of a set for mine. Do you like them

a friend of mine just lost both motors on 2004 fountain 525 we checked the cmi headers found both port headers were cracked.171 hours this is the second set of headers from cmi.
what gives?

Hi Frank

My 2005 42 Ex with 525's had a pinhole leak in one header. No reversion problem. Sent it back to CMI who fixed it free all I paid was postage (Which was plenty).

Ok Who Takes The Blame or Pays When You Loose The Motor?

I had a cracked header, but it was an easy fix. I scored another set from Tyler Crockett who had them on one of his race boats and I'm keeping the second set for the time being. I'm told that there are no real issues with freshwater boats, but salt boats are a different story. I now flush with Salt Away for 10 minutes and then I drain my headers. I just keep an eye on the exhaust for steam and a rough idle can be indicative of a problem, at least in my case it was. I also talked to Merc about diverter use. The diverter companies are stating that they're good for use up to 3000 rpm, but they might be thinking of 496's. Merc stated that diverters on a 525 should never be used above 2000rpm.

I did the intercom install, its fairly easy, Providing you are
comfortable with drilling holes in your boat. You run the cables and head set connections to the suitable places. Route the cables back the cabin where the amp/controller should be located. Obviously you have to make a cut-out for the controller, its not very big. Route a + & - from a nearby accy, patch in a single channel for the FM/AM/CD radio and thats it. When not speaking in duplex to your buds you can listen to music. The music is however mono, its not the greatest sounding. When someone speaks it cancels the music out so the com is clear. I put a switch on my dash where I can quick cancel the music in case the need arises, like a massive ship wake.