300/440/550 90" 650 leaking water-box question!

[oldschoolski]

Still trying to dial in my newest ski to me. A 90'TS 650. I think I've finally fix the electrical issue I've ask here about(cut back the spark plus wires), but while I was running the ski on the houses water hose, I saw were all the water has been leaking from. At the point were the waterbox and the large black exhaust duct connect meet. Well at the bottom if itanyway. I cant see a hole, but poors out fast enough to filled the engine bay quickly. Question is do I have to remove just about everthing rear of the (batt, elect-box)engine to remove the water-box? With the oil tank attached to the top of the water-box, seems like the whole unit will have to come out as one large unit? Any tips......

Thanks

 

[oldschoolski]

Leaking water-box

"Holy-*#!@%$ Batman" how does this come off? I removed the CDI unit, battery and the oil tank. The head pipe contacts at the first billow with two hose clamps, I loosen those. The second billow connects the pipe to the water box with two hose clamps, I loosen those. The pipe sits on a "slide" brachet with four 10mm bolts, I removed those. Now, I grab-it, pulled-it, twisted-it (the pipe that is) and could not get the dam thing to get off the water-box.:261: Seems like there is a pipe within the billows or something keeping it from just pulling apart. Anybody have a TS650 or know how the water-box gets removed??

 

[WFO Speedracer]

Ok you remove the head pipe from the engine to the coupler,you must remove the four 6mm bolts holding the exhaust head pipe to the coupler ,not the bands they hold nothing actually.Then the electrical box and oil tank are removed.You loosen the clamps at the boot,the lower part of the exhaust pipe just slides into the waterbox but it goes into the waterbox about a foot or so.After you remove the exhaust pipe you can remove the waterbox.

 

[oldschoolski]

Thanks..I did just that. I was not to sure and went ahead and tried it. I just came in to add this post to tell what I discovered. I found on the bottom of the waterbox a 10mm plug (one of two) that had rusted through. Also noticed a small dime size hole inside the waterbox, on the wall that divides the box in half: internally. Should that inside hole be a problem? I can see a large hole right about in the middle of it, factory hole I would guess..Thanks for the help...

 

[oldschoolski]

waterbox

Now that I have the box removed, thanks Wedoseadoo, what if any modifications can I do on the waterbox or the exhuast pipe? I know on my two 550's, I can pull out the mesh inside the waterbox, but is there anything I can do on this TS? even worth doing anything?