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Hey guys. Its been a frustratingly long summer with my 05. Had a collapsed sleeve to start the summer. Split the case, removed all the pieces and rebuilt the engine. New piston, new pot, new gaskets. Took it for a test ride. Started out good. Within 15 km it puffed a big white cloud of smoke and over heated. That was head gasket #1. Took it apart and found one of the head bolt threads let go on 1 bolt on the new pot. Installed heli-coil and new head gasket #2. Test ride #2. Went better. got about 30km out of it before it got hot. Limped it home. Took it apart and Got the head shaved as it had a little warp to it. Pieced it all back together. Had a friend think maybe the water pump wasn't doing its job, so we put one in, also installed head gasket #3. Made it about 2km into the test ride. Overheating again, white smoke out the back. again. Loaded it up and took it back home. Found a thread about a possible sleeve dropping issue on the new pot. Did a measurement and found the sleeve had dropped and was now flush with the pot. Got ahold of the company and they sent out a warranty Pot. took it apart again (We are getting good at the dismantle and reassemble of this thing). Once re assembled with the new pot we fired it up and within 2 minutes of it running there was coolant coming out the exhaust. Any ideas? We are stumped at this moment. We are going to take the head off and go through it thoroughly to see if there are any cracks in it. Something doesn't make sense. We aren't even drinking beer anymore when we work on it.


-every time we fill with coolant we bleed the system.
-every time it overheats we sit for about an hour before limping it home


The 2 ppl helping me with this are both mechanics by trade, 1 is a journeyman automotive and the other is a 20 year atv/boat mechanic.
 

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I had a similar issue. I just replaced the 660 cylinder with a 700 cilinder and piston and got a bad casting. There were holes from the water jacket into the timing chain area. Check for bad casting when you pull the cylinder. It took me 2 times of flooding the crank case before I figured it out.
 
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