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  1. #1

    D Plate Gaskets Leaking on Flush Hose

    Over the winter, I replaced the cat-con with a D-plate on my 2001 XLT1200. I re-used the gaskets, but sprayed them with copper spray-a-gasket. Today, I cranked it up for the first time using the flush hose. While it was running, I noticed a couple of very tiny water drops seaping out through the gasket area.

    When I turned on the water hose, I had the faucet turned all the way up. Was this too much water pressure and could have caused the leaking? Or, do I need to replace these gaskets?

    I really don't want to have to take the stinger out again!


  2. #2
    buzzzzzzzzzzzzzzzzzz> Fail!!!!

    well you just might rabbit, you just might...lol...

    no the house water pressure is not to much...
    difficult to answer without seeing condition of gaskets and stinger/cat housing... rule of thumb: replace gaskets with NEW to ensure that this does not happen...
    what to do: look for a perfect mating surface, no corrosion, when installing a D plate with new gaskets in the correct orientation and torque all the bolts to spec...

  3. #3
    WATER WOODY's Avatar
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    Just to add, the threads on the pipe are VERY soft and strip easily. Do not over tighten.

  4. #4
    wakejumper48's Avatar
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    working on my buddies 1200 adding a D plate, rebuilding carbs hasent ran for 5 years fun...
    i was tighten the last bolt and "pop" the bolt broke. pulled it apart and about 1 maybe 2 threads sticking out of bolt hole. took and grinned a slot in the middle of the bolt and unscrewed it with a flat head screw driver lucky
    what should they be tighten to? hand tighten or?

  5. #5
    Quote Originally Posted by wakejumper48 View Post
    working on my buddies 1200 adding a D plate, rebuilding carbs hasent ran for 5 years fun...
    i was tighten the last bolt and "pop" the bolt broke. pulled it apart and about 1 maybe 2 threads sticking out of bolt hole. took and grinned a slot in the middle of the bolt and unscrewed it with a flat head screw driver lucky
    what should they be tighten to? hand tighten or?
    Tightening torque: 1st - 11ftlbs, 2nd - 24 ftlbs... apply red loctite 271

    Cover/catalytic converter
    housing/catalytic converter

  6. #6
    Just relax and enjoy the ride. XLT Chad's Avatar
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    +1 Dont forget the locktight. If those bolts backout, you will pump a ton of water into your hull, ruin your weekend and have your buddy laughing his ass off at you! DONT ask me how I know this!!!!

  7. #7
    Gus13letter's Avatar
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    I always torque everything per the specs in the manual. Also most of the gaskets can be cleaned, lightly coated with copper spray and reused. Be sure to clean all the other mating surfaces too. I use a small air tool with a scotch pad. Some dont like that idea, but thats what I did with all of mine and are ok.

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