PAINFUL Corsa Problem. Advice needed...
 

I have Corsa Captains Call on my HP500EFI. This weekend I had a problem with the starboard side diverter. It actually went INSIDE the pipe toward the header, and would not go back to its pivoting position with the solenoid. I had to pull the pin off of the solenoid actuator, and pry the diverter back into place with vice grips. When the diverter popped back into place, I lost a large piece of my thumbnail in the process which hurt(s) like B&^%H!!!

Has this happened to anyone before? What have you done about it? Long term damage? I did not use my 'mufflers' again this weekend for fear of it happening again. I will do some serious investigation starting tomorrow, but I need to know some things to go on. ANY and ALL input is MUCHO appreciated!!

Keep in mind that Corsa has a three year warranty on parts ... should you need any. I have not heard of your problem before.

I had a similar problem. On 2 of my 4 units, an internal splash diverter, just to the stern of the pivoting flap, came unwelded and jammed the pivot. Sent them all back to the factory for re-welding. Corsa sent them back UNREPAIRED. Returned them, and Corsa did the same thing a second time: returned them UNREPAIRED.
The third time they finally did it right.

By the way, tey would NOT cover the repairs under warranty, even though I had the boat for less than 3 years.

Well, I pulled off the tips, and checked the diverters. The SB side one definately had a butterfly shape to it, looking from a side view. I did not pull it all apart. The SB side solenoid is definately shot now. I will replace that. I utilized two hammers and a small pry bar, and bent the diverter back into an almost straight position, to the point I did not want to bang on it anymore, and break the diverter and be in real trouble. I will replace the solenoid, and we will see what happens.
Thanks everyone!

The diverter vibrates causing the bushings to wear and the diverter jams.The fix 1.Keep the diverter open.2.Replace the bushing.

Thanks DD, very simple and great explaination and help.