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June 14th, 2010, 02:33 AM   #1
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New headgasket, leaking all over, is it screwed?

Whats up Guys?
I have a 2000 fe400e. I was getting coolant in the oil, and weeping from the block slightly when it was run, causing a emulsion to form and seep out. The previous owner rebuilt the head recently before I bought it, it had 4 hours on the head. Everything was fine til I let it run for a bit, thats when I noticed the leak. I spoke to the local dealer, they said you ave to retorque the head after a few hours of running it, after a rebuild. I figure thats sucks, better order a head gasket. Well, Ive installed the new headgasket, gave it 48 hrs + for all the sealant to cure before I filled it up with any fluids. As soon as I put coolant in, it ran right out the deck. Im pretty sure the torque wrench I was using, was ok. Is there something im missing here? Something specific to these engines? I followed the factory manual. Is the headgasket screwed now, because coolant was gotten past it? Thanks a lot for any input, im getting pretty frustrated at this point. Need to sell the bike, because work has been slow, but want to make sure I can sell it in good faith, and in tip top shape. Sucks, dont want to sell it, but Ive got plenty of toys, and would rather pay my mortgage.

Thinks in advance.

Oh yeah, the deck, and the head seemed pretty straight, and true.
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June 14th, 2010, 07:19 AM   #2
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Re: New headgasket, leaking all over, is it screwed?

When the dealer said retorque the head, that's what he meant. Not replace the head gasket. When you take it apart again check the head and deck for straigntness with a straight edge and feeler guages. You will probably be alright. Do not use sealer on the head gasket, they go on dry.
I think some of the older models had a small o-ring seal as well, but that may have been on the rocker cover. Get a parts diagram and have a look.
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June 14th, 2010, 07:27 AM   #3
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Re: New headgasket, leaking all over, is it screwed?

If the coolant is running out of the deck then something is warped, badly. You need a clean up cut on the cylinder and head.
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June 14th, 2010, 03:12 PM   #4
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Re: New headgasket, leaking all over, is it screwed?

Thanks for the replies guys. When I talked to the dealer they recommended a new gasket since it had leaked already. The gasket was put on dry. the sealent was used on the covers. I guess it could be warped, but if it was warped that badly, Id think I wouldve been able to eyeball it, no? Big question is, do I need another gasket because this one has leaked by, or can I reuse it? If the gasket is still good, should I try to just torque it down more? Maybe wrench was off? It wasnt leaking like this before. The old gasket only leaked when it was running, and just a little bit. This pours right out, as soon as I pour it in. Before it was more coolant in the oil, than leaking out. I havent put the oil in yet.
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June 14th, 2010, 04:12 PM   #5
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Re: New headgasket, leaking all over, is it screwed?

Take a good look at the gasket. Chances are you can reuse it. Take a good look at everything when you get it apart. It's hard to believe anything is warped that bad. Check and make sure the cylinder sleeve is flush with the deck as well.
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June 14th, 2010, 04:23 PM   #6
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Re: New headgasket, leaking all over, is it screwed?

Thanks for the input berger. I will double check those things. Im actually in Tempe. If I need to shave the head, got any local recommendations? Im half tempted to just take this thing into premier KTM, but theyre pretty far away, and currently dont have a trailer. What should I be looking for on the gasket, to know if its good? Wear, residue, thin/thick spots? I may end up yankin the head off this evening. Maybe the wrench was off, I borrowed my buddies, seems unlikely, but I have no idea when the last time he calibrated it was.
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June 14th, 2010, 05:33 PM   #7
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Re: New headgasket, leaking all over, is it screwed?

Originally Posted by UberDub
Thanks for the input berger. I will double check those things. Im actually in Tempe. If I need to shave the head, got any local recommendations? Im half tempted to just take this thing into premier KTM, but theyre pretty far away, and currently dont have a trailer. What should I be looking for on the gasket, to know if its good? Wear, residue, thin/thick spots? I may end up yankin the head off this evening. Maybe the wrench was off, I borrowed my buddies, seems unlikely, but I have no idea when the last time he calibrated it was.
Premier is no more as of last month. Pull it apart, I'm sure you will find an obvious problem.
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June 15th, 2010, 05:02 AM   #8
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Re: New headgasket, leaking all over, is it screwed?

My money would be on the cylinder/case height. Make sure they're level.
HG should be OK but just check for any obvious damage.
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June 15th, 2010, 07:03 AM   #9
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Re: New headgasket, leaking all over, is it screwed?

I got it apart. My buddy torqued it down. I dont think he set the wrench right or somethin. They were barely snug when I took them off. Manual says 40nm IIRC. Gasket looks good. Im gonna put the head on a piece of marble tile I have. Pretty sure thats pretty flat. Question now I have is, should I get new gaskets for the water pump, timing chain tensioner, and transmission cover? Or would sealant suffice? These dont like being taken off, and put back on so many times. Mine are worn, even the new one now.
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June 15th, 2010, 07:08 AM   #10
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Re: New headgasket, leaking all over, is it screwed?

I just put it on the marble....it doesnt look 100% true. There is a very slight gap if you look level, and close. Barely visible. about 1/2 mm maybe smaller. I dont think it was on the side that seemed to be leaking. Am I being too pedantic? I mean its pretty close. Barely noticeable, I had to really look. How much is too much?
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