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As far as re-using the head gasket, I thought I might be able to since it hasn't been put into service, but I read this on the internets: This seems to be saying that, once compressed, they shouldn't be reused even if they haven't been put into service.

I'm not sure about other engines, but mine has an engine block with a base gasket, on top of which I will mount the head that is comprised of the cylinder section and the top section (with valves, springs, etc.) with a head gasket in between. The head bolts I am talking about join these two...

I thought I'd ask you guys' opinion on this one. I started to assemble things a few weeks ago and noticed that the dowels that are used to guide the gaskets were completely mangled and in a baggie with my old piston rings that I got back with my heads after taking them to the machine shop last...

Thanks! Although I am not overly confident. I don't really know what I'm doing. If I manage to get it running again I'll most likely try to get it on the road next spring. Just finished school and insurance and gas ain't cheap! But, not going to lie, it's been 4 years and I'd love to take it for...

I got the OEM gasket from KTM. There's only one thickness.

I bought a 24" straight edge last year that I now finally get to use.

OK. Not a great idea to use sand. It was just recommended by another person who said to make sure that the sanding doesn't go anywhere into the engine. Thought I'd run it by here to get a 2nd opinion at least. The filing that I did was minimal based on the recommendation in this thread. I made...

After gathering info from a number of people, including you guys, I think I am going to run a thin layer of Hylomar on the gasket. I might also get a sanding block and 1000 grit and wet-sand the surface as smooth and even as I can get it first.

If I do use sealant, where should I apply it? Around the entire base or just this water jacket? And under where the gasket will sit, or on the inside perimeter of it?

I still have some fine filing to do, but it looks like a much better mating surface than before. Do I still need sealant? I've read conflicting things about sealant with metal gaskets.

OK. I wasn't sure. I did some searches but couldn't really find that information. All I could find were the details of the aftermarket sensor I bought.

Was just about to go pick some of this (SteelStik) up today and checked the temperature rating - it says up to 300 F. I'm wondering how this will be at that spot in the engine and in contact with the coolant. I bought THIS radiator temperature sensor to replace my original one year ago, and it...

That's probably because I have no idea what I am doing. I've done all my work on my bike since I got it, but this is the first time doing engine work. It's a bit intimidating.

Is THIS the stuff? If so, it's labelled as an RTV sealant, which, from what I've read, is a room temperature vulcanizing (hardening) sealant. It's not really advertised as non-hardening or non-setting, but it does say "remains flexible" on the front package, so being called an RTV sealant seems...

Although, now that I am thinking about it, will it not just get washed away by the coolant? The Hylomar website does say that it is resistant to water/glycol:

I think I am going to pick up some Hylomar, either M or Universal Blue, both of which are non-setting, non-hardening jointing compounds. Because of this, their features include unlimited assembly time, which is nice. Also, I'm not sure if this is accurate, but this guy explains one of the...

Here's sort of a side-by-side that gives a better idea of how much corrosion might be under the gasket. I'm not sure if that's a significant amount or not.

It's a 2007 KTM 990 Adventure. I've been a member on Advrider since around that time, and I haven't heard of this specific issue before, and I've followed the forum specific to the 990/950 since then. I posted this there as well, but the specific forum has been a bit of a ghost town since they...

I was born in '77, I guess that makes me old. :p I meant my bike was an older bike (15 years from production), as opposed to something relatively new, and I have about 100,000 km on it, most of which I put on between 2011-2014 during a big (almost two-year long) trip. It has some sentimental...

Sweet. Will check those out. And will look for the finest flat-file I can find. Thanks for info!