Coolant leaking around the head

I need some help, what did I do wrong?

Coming to the end of top end rebuild and when I put coolant in the bike it starts seeping out between the head and the cylinders. No heat, no pressure, didn't even get it fired up.

There is a head gasket on there. There are washers under all the nuts. The head was properly torqued and I followed the torquing sequence.

Any ideas?

Thanks, John.
1985 Voyager.

I have seen some of that type of nut bottom out with the stud going too far into the nut.
We used to get that with the race bikes after machining the head and barrels for extra compression. I wouldn't expect to get that on a standard engine. Check that all the studs are down as far as possible into the crankcase. Maybe try a second washer under each nut also a possibility is catching on a locating dowel and holding the head up but unlikely.
These are suggestions based on the Z1000 & 900 engines although I have owned mine for 37 years I have never had the head off so I am not real familiar with the "usual" problems that occur.

Say John:

Did you have the head decked when it was off?

Were you able to take a straight edge to the surface?

Did you use a factory head gasket or aftermarket?

While it was off, did you see any corrosion on the gasket mating surface area around the combustion chambers?

I would recommend you take the head to a trusted machine shop and have them check it with their straight edge first, before you consider decking it.

If this was my bike, I would probably have it decked to make this surface last as long as possible.

Regards.

Todd.

sometimes the gasket under the top hose connection housing might leak a bit and it will leak along the head line, is the leak at the middle of the motor or at a side ?

I am assuming the water is NOT leaking from the water pump leak hole? Its at the front face in the middle of the block at the bottom (under the water pump) ?

Ensure the 2 collets/guides at either end of the block are correctly seated in the crank cases & the block itself.
Also always GREASE the washers & bottom edge of the head nuts to allow them to rotate when tightening. I recommend you ALWAYS use a Genuine K Head Gasket (from past experiences). You maybe lucky with a pattern one but they often blow soon after.

Other than that, as others have stated, it maybe a warped head or the nuts bottoming out.
You are safe to use maximum 2 extra washers (at 1mm each) ontop of the original ones under each head nut.

Pete F

I had this problem with a pattern gasket. The gasket had no sealant around the water jacket areas. The coolant was pouring out from in front of 1, 2, & 3 cylinders almost as fast as I could pour it in.

I'm not sure if the head wasn't quite seated properly but a genuine head gasket put it right.

Another problem I have heard of is that if you have had the head studs out you can get hydraulic lock if there is any oil at the bottom of the stud hole in the casing causing the stud to not bed all the way to the bottom and leaving it too long to torque correctly.