Nuklear6
I Dream 10' Surf!
I know you said you checked the head but at this point I think you need to use a stock gasket with the stock head and see what happens. Just adding a gasket instead of o rings to the protec head isn't the answer
If you are certain the problem is not in the head, could it be in the base gasket?
Base gasket will not cause water in the cylinder, unless you run your ski half full of water, my guess is if your ski is half full of water you have bigger problems than a base gasket.
They are just casting voids, only engines that I know of that run water through the cases are yellow motor seadoos, Seadoo RFI and DI models and older polaris Fugi engines, there may be a few more I am not aware of, the Yamaha 6m6-61x-62t-64x is not among them.For some reason I was thinking that water jackets ran through the top case half lol? Just trying to help throw some ideas out there.
edit - I just looked at some pictures, what is with the open areas in the castings that at a glance look like water jackets?
Maybe your head pipe is getting hot because not enough water pressure is making it there since its washing down the cylinders?
Put stock head and stock head gasket....perfect