xlt1200 leaking head/head gasket

[Georgia088]

I did a top end rebuild on a XLT1200. Got it all back together. Thought everything was good. Ran it for about 15 minutes, and it seemed to start bogging down. Pulled the seat off and the hull was full of water. I took it out and drained the water. I connected a hose to it to see if I could tell what was leaking, and it is defiantly coming out of the head. I put a new head gasket on when I did the rebuild, but it obviously didn't seal at all. What are the odds the head is damaged some how? Should I just get a new head gasket and try it again? It is leaking in several places not just on one cylinder which makes me believe the head gasket is bad or I did something wrong. Any advice?

Thanks!

[Jonesyfxr]

Grease both sides of the head gasket, torque the head to spec via the torque sequence on the head and step torque accordingly.

[Georgia088]

Grease both sides of the head gasket, torque the head to spec via the torque sequence on the head and step torque accordingly.

What should I grease it with? Thanks!

[Jonesyfxr]

I use wheel bearing grease, but anything along those lines works. Also, make sure the gasket is installed properly.

[steve45]

Head gasket or head cover gasket?

[Georgia088]

I would call it the head gasket. It’s the bottom gasket of the head. The one that seals the cylinders/jugs from the head. I didn’t notice any leaking from the top gasket that seals the two pieces of the head together. But, it was leaking so bad I may not have noticed. It was leaking so bad something is very wrong I think. I’m not sure if I put the gasket on backwards? How do you tell, the holes all lined up. Or, if the head is warped. It didn’t appear to be when I put it back on, but I didn’t have it checked either. Thanks!

[Jonesyfxr]

Do you have any pictures to upload??

[Georgia088]

Do you have any pictures to upload??

I don't have any of my actual ski, but in the picture I am uploading, it is leaking at the point gasket 11 is supposed to seal. I have circled where the water was spraying out.

I just don't see how it could be put on backwards because of the hole alignment. Could it? Thanks!

[Jonesyfxr]

Look in the service manual, there's a top and bottom to the gasket and it has to be torqued to spec in the order of the numbers at the bolt holes.

[Georgia088]

Look in the service manual, there's a top and bottom to the gasket and it has to be torqued to spec in the order of the numbers at the bolt holes.

Thanks! I pulled the head back off and found my mistake. I did have the gasket upside down.... I put it back on and no leaks. Just lack of paying attention I guess. Thanks for all the help!

[Jonesyfxr]

No problem dude!!!
glad you found it!!