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No, just torque them all to 10 lbs, then to 21 lbs. Its a good idea to retorque them all to 21 lbs. after running the engine for 15-20 mins.

The waterbox acts as a muffler. Just check exhaust pipe and head are not getting real hot (water sizzles when put on pipe) when you are trying to rev it up. If not then the waterbox is not your problem.

I just went through this with my 550/650 conversion ski. It was doing the same thing. Then noticed the exhaust pipe was getting extremely hot. Got home took waterbox out and the baffle in side had broken loose, blocking the exit in box. I pulled the box apart, removed the loose baffle and glued...

On the pipe you are kind of limited to what will fit. I am using a modified stock exhaust right now. check out this: http://www.pwctoday.com/showthread.php?t=148631&highlight=650+exhaust

Very nice!!! and creative. I used bungee/shockcord on my limiting rope it would run out of strech before the pole went to far, but shrink back and fold up under the handle pole when it went down. Very nice hood straps too!!! Does the jet works flow control valve help that much? I'm thinking of...