I just rebuilt the top end of my 97 polaris xlt 600 and i have a leak where my o rings are and can not figure out why they are leaking. I have three new sets of them and have no clue why it is still leaking. Please help if possible.
Thanks
Full Version: 97 xlt 600 rebuild
Did you use RTV sealent on the water cover?
QUOTE(rightguy @ Jun 17 2008, 05:07 PM) 
I just rebuilt the top end of my 97 polaris xlt 600 and i have a leak where my o rings are and can not figure out why they are leaking. I have three new sets of them and have no clue why it is still leaking. Please help if possible.
Thanks
Thanks
Your head gasket is multi-layer steel. How many layers thick was the gasket you took off? Polaris uses two different gaskets on the 600 XLTs, a two layer and a three layer. If you replace a three layer with a two layer (to get more compression) you need to add shims (part number 3084722) to the inside of the water cover to keep the correct relationship between the cover and the o-rings. One shim at each o-ring, use RTV to seal the shim to the cover.
QUOTE(irondog @ Jun 17 2008, 10:39 PM)
Your head gasket is multi-layer steel. How many layers thick was the gasket you took off? Polaris uses two different gaskets on the 600 XLTs, a two layer and a three layer. If you replace a three layer with a two layer (to get more compression) you need to add shims (part number 3084722) to the inside of the water cover to keep the correct relationship between the cover and the o-rings. One shim at each o-ring, use RTV to seal the shim to the cover.
Yup...and the higher compression optional head gasket doesn't do well on pump gas either....been there...squeaked it.
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