550SX Half Pipe Cooling Line Routing

[brapperdoodle]

I was able to get this West Coast half pipe fitted to the 550SX but the cooling line routing is a little bit of a mystery to me.

I have routed the cooling line from the pump, into the fitting on the exhaust manifold. But I have a line coming off of the expansion chamber that looks like it runs to the bottom of the mid pipe. So I believe those 2 lines are correct.

That leaves the small fitting on the mid pipe that runs to the stock water bypass, and another fitting on the top of the adaptor plate. Lastly I think I might have installed the cylinder head backwards because there is 1 last cooling fitting facing rearward… something tells me this should be facing the front of the ski. Easy fix, but I need some advice on how to properly route these lines. Thanks!

 

[Big Kahuna]

You install hose from top of expansion chamber down to the stinger.

 

[Big Kahuna]

Head to back of elbow.

 

[blasterdude]

You didn't mention it in your original post, but you have to change the gaskets in the exhaust when you run a half pipe set-up.

https://www.watcon.com/1-2-pipe-gasket-kit

 

[blasterdude]

Factory half pipe 550sx - PWCToday

JS400's JS550's, 650SX's, Wetbikes, jetskis and other seasoned pwc's...

www.pwctoday.com

 

[brapperdoodle]

Factory half pipe 550sx - PWCToday

JS400's JS550's, 650SX's, Wetbikes, jetskis and other seasoned pwc's...

www.pwctoday.com

I cannot open the PDF in that post, could you post it here? Also, Those gaskets look identical to the ones I used for this rebuild. I want to say they came from a Cometic kit? I did notice that there was 1 way to align the gasket for the adaptor plate allowing water to flow through the fitting. But what is the difference in the gaskets if the exhaust manifold and mid pipe are stock?

 

[Big Kahuna]

I cannot open the PDF in that post, could you post it here? Also, Those gaskets look identical to the ones I used for this rebuild. I want to say they came from a Cometic kit? I did notice that there was 1 way to align the gasket for the adaptor plate allowing water to flow through the fitting. But what is the difference in the gaskets if the exhaust manifold and mid pipe are stock?

The gasket allows water to pass to the head pipe coupler then to the stinger.

 

[brapperdoodle]

The gasket allows water to pass to the head pipe coupler then to the stinger.

Great, I believe the gasket I used was the correct one. I will still remove the half pipe 1 last time to confirm, but I do remember noticing that it had to be positioned to allow flow.

 

[brapperdoodle]

I removed the coupler last night and did verify that there is an opening for that passage. Thanks @blasterdude I did not know about that! Good looking out and letting me know, if I had used a different gasket that could have been a bummer! Unfortunately the gasket split apart when removing the coupler, I applied a thin layer of 1211 and re-installed the coupler. It is a brand new gasket so hopefully it will be okay, I will keep an eye on it.

 

[Big Kahuna]

First time I put a pipe on my 91 550 I was not paying attention and a buddy was helping me, I thought he removed the stock gasket, and put on the new one. nope. Melted a hose and the gas tank!!!!!!!!!

 

[CnortSj7]

I am having this same issue right now, I believe it is the gasket on the other side of the stock portion of the pipe from where the half pipe connects that is different (along the same studs). From looking at diagrams online, the stock gasket does not have holes for the water jacket, however the on in the circular gasket in the cometic kit does. Let me know your guts opinions on this. i am going to swap i in the morning and try it.

 

[brapperdoodle]

I am having this same issue right now, I believe it is the gasket on the other side of the stock portion of the pipe from where the half pipe connects that is different (along the same studs). From looking at diagrams online, the stock gasket does not have holes for the water jacket, however the on in the circular gasket in the cometic kit does. Let me know your guts opinions on this. i am going to swap i in the morning and try it.

That is correct. If you can see the pictures in the above post, my gasket does indeed have the cut out for the passage. This would be the style of gasket to run with a half pipe coupler.

 

[CnortSj7]

That is correct. If you can see the pictures in the above post, my gasket does indeed have the cut out for the passage. This would be the style of gasket to run with a half pipe coupler.

Im talking about the next gasket in line, the kit comes with three. The middle gasket in the series of three.

 

[brapperdoodle]

Im talking about the next gasket in line, the kit comes with three. The middle gasket in the series of three.

Oh, yeah I see what you are talking about. It looks like in the parts fiche it shows a gasket with no holes for the water jacket. I would use John's gasket set or something similar to be sure its set up correctly.

But with that being said, it appears on the parts fiche that the coupler gasket is the same as the cometic... now im really confused haha

 

[CnortSj7]

So update for mine, changed out the remaining two gaskets this morning, and no more sizzle! ski runs awesome!

 

[brapperdoodle]

Instead of removing the elbow again to verify I have the correct gasket, could I remove the line going to the stinger and verify it has water coming through?

 

[CnortSj7]

Instead of removing the elbow again to verify I have the correct gasket, could I remove the line going to the stinger and verify it has water coming through?

Yo have to remove the stock elbow, not the chamber and switch out these gaskets. They are between the stock manifold and stock elbow

 

[brapperdoodle]

Yo have to remove the stock elbow, not the chamber and switch out these gaskets. They are between the stock manifold and stock elbow

Yes, I understand. But if the gasket is blocked and not the correct one, water will not flow out of the fitting down to the stinger on the chamber. So, theoretically I could start the ski in the water and remove the hose from the chamber fitting and verify water flow. Or remove 6 bolts and just look at it haha