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What was the torque? recheck the torque, 25 ft then 50ft.then 1/4 turn.And did you send the cylinder head out to a machine shop, for straightening and machining,You have a aluminum cylinder head they warp.
sometimes the water pressure from the house is insufficient, when it happened to me it would run weird. The water would come out in spurts because little water would come out of the water hose. You could try and lower the pressure on the machine to compensate for the lack of pressure going in, that's all I can think of.
this sounds like the seals may have been damaged inside the pump or that the water inlet/outlet could be damaged. If you take off the front cover (use a star bit screw driver) then run the pressure washer you will be able to see were it is leaking from and then you can get the right part to replace it.
I have the same Problem, the leak is from the seam of the Manifold housing. There is a small crack in the seam. A manufacturing defect.. A New Manifold Complete Replacement K2.26*
Part # 97501760 is $61.03, about the half the price what I paid for this pressure washer at Walmart... :(
If under 1 year old, and you can find a receipt,Karcher will replace the whole Pressure washer under warranty.
Sounds like a typicul sable cracked cylinder head. usually the head nearest the firewall. If youdo a head gasket job, be sure to have the heads presure tested and milled. Try starting the car with the radiator cap off and full. Water will spurt out right away if the head is cracked
A couple of other options spring to mind. It may be an air-lock, try disconnecting the high pressure hose and letting the water flow under its own pressure for 5 mins or so. It may also be a crack in the cyliner head...£16 from Espares..takes about an hour to strip and refit. you will need allen keys (to remove the cylinder head) and torx type screwdrivers for the casing.