Going ahead with engine rebuild

[hannibal]

I got the oem gaskets ordered. The only things Im concerned with doing this are removing the cam tensioner and getting the timing set correctly. Also, getting the cylinder over the new piston rings by myself. Anyone have any suggestions on this? Thank you

Did you find an OEM gasket set? I was lucky to find one on Ebay but couldn't find the advertised part number anywhere to verify. Bought it and it was mostly complete.

This was my first time opening an engine. As for reinstalling the cylinders, I recommend patience, your favorite adult beverage, and more time and patience.

Since the head is off, I lapped valves and replaced valve stems. Since the cylinders are off, I replaced the rings and honed the cylinders.

Don't sweat the cam tensioner removal. That's straight forward in the service manual. Reassembly and setting timing is well explained in the manual as well.

[TheNewGuy]

Thank you all for the in depth knowledge. Will keep everyone posted. Thanks again

[Rust_to_Redemption]

The bike is 41 years old. The o rings you mention are the same age. Wouldn't it just make sense to replace that old rubber while the engine is apart?

Just do a full rebuild while you have the engine apart anyway, so you don't have to take it apart again later.

[TheNewGuy]

Got the head off. The jugs are Stuck though. Any ideas other than the rubber mallet ive been trying

[alke46]

Got the head off. The jugs are Stuck though. Any ideas other than the rubber mallet ive been trying

On mine, I was able to get one corner to pry up just a bit then I put a wooden shim into the opening. Went to the opposite side and did the same thing. Once both sides had a tapered shim under it, I just lightly tapped the thicker end of the shim to drive it under the jugs. Once the seal is broken you can then lift it off the crankcase.
Good luck.

[TheNewGuy]

On mine, I was able to get one corner to pry up just a bit then I put a wooden shim into the opening. Went to the opposite side and did the same thing. Once both sides had a tapered shim under it, I just lightly tapped the thicker end of the shim to drive it under the jugs. Once the seal is broken you can then lift it off the crankcase.
Good luck.

Tried the wooden shims with no luck they just cracked in half. All the corners are really tight. No room for a shim. Perhapse a small scraper? I know youre not supposed to use metal to pry with but out of ideas.

[alke46]

I would try heating the gasket area with a propane torch to see if I could break the bond between the crankcase and jugs.

[TheNewGuy]

I would try heating the gasket area with a propane torch to see if I could break the bond between the crankcase and jugs.

Going to try the torch tomorrow. I'll keep you posted.

Thanks

[chuck hahn]

Lay a few layers of old towel on the floor. Use a ratchet strap slung over a rafter and some rope wrapped around the jugs to lift it about an inch off the floor. Slide the padding under and use a 2X2 to knock the pistons down. Raise it some more and repeat till the jugs pop off.

[Nessism]

Usually you can use a piece of wood and wack it with a sledge to knock the cylinder loose. Get a piece of wood large enough to bridge at least two of the vertical bridge ribs that hold the horizontal fins together. That way you spread the load out when applying force.

[TheNewGuy]

Thank you that worked. Time to start cleaning. Unfortunatly 90% of the base gasket stuck to the block and not the jugs. Anyone have any secrets for cleaning/decarboning? I was thinking some Simple green?

[hannibal]

I used simple green pro (it's purple) and a brass wire brush on my Dremel. It took forever and there was some carbon build up on the piston tops I couldn't get off even with the Gumout product. FYI, you should clean as much as possible before removing the cylinders to minimize how much crap could fall into the crankcase.

[Nessism]

Carb dip will soften the carbon.

[TheNewGuy]

Update:

Got the oem rings yesterday. Oem gaskets will be here tomorrow. The machine shop should have the jugs and head back to me this week. Will post when I have everything I need. Thanks everyone

[TheNewGuy]

Ok. I need help. Got the jugs on but now yhe engine wont turn over by hand feels jammed. Did the chain roll onto itself? How do I fix this?