old stubborn gaskets

[scottsgs]

Hi all,

Well I am right up to my arse in this gasket and o-ring job on my 81 GS850G. I am having a time with removing the remnants of the old base gasket. I have tried penetrating oil and a bladed scraper. However I have gouged the aluminum in a couple of spots with the scraper. Will I have any problems with leaks later on? Is there an easier way? Could I use a Dremel with a wire brush to clean up rough edges? Do the mating surfaces need to be spotless? Sorry about all the questions. I just don't want to miss the needed details.

Thanks,

Scott

[catbed]

get permatex gasket remover, its like liquid magic. spray it on, wait like 10-15 minutes, come back and scrap it off. its awesome. i used it on my base gasket. they dont need to be PERFECT but PERfECT is okay.

ps. make sure you remove the orings around the cylinder sleeves and mask any paint on the engine.

[chuckycheese]

Take care!!

You will want to be very, very careful that you don't 'score' the surface. Don't do anything that will compromise the integrity. Scraping gasket material is good...scraping away metal is a 'no no'.

[robertbarr]

get permatex gasket remover, its like liquid magic.

Another vote for the Permatex gasket remover, on any aluminum gasket surface with stuck-on remnants.

Be sure to mask off anything you don't want harmed, like paint & engine covers / alternator covers, because it'll eat the plastic coating. (Hmm.... actually, I haven't tested this. OK, because it's possible it'll eat the plastic coating.)

[mark]

In my experience, even with permatex it takes time. A good gasket scraper used carefully and patiently worked the best for me. Even scotch-brite pads can be too aggresive if you aren't careful.

Use the permatex, wait for it to bubble up, take what you can get, and then use a little more.

It doesn't need to be "spotless" from my experience, but pretty close....the dark spots should be more like stains than anything else.

If you have gouged the surface enough to have protruding metal burrs, remove those. I had a "burr" on my cylinder head when I pulled it. The guy at the machine shop had a nice high quality flat file. Just a couple of minor passes and it was perfect. Your gasket should fill in minor scratches that have occured.

Hope it goes well.

[rickt]

Gasket Removal Tool

Take a small piece (6-8") of copper tubing (1/4 - 1/2" diameter). Flatten one end completely with a hammer. Using a file or grinder, sharpen the flat end until its like a knife edge. Will loosen old gaskets without gouging aluminum.

rickt

[Nessism]

Valve cover gasket on my recently purchased 850 is hard as a ROCK. Never seen anything like it; hope it's not a bad omen. Bought some gasket remover spray and going to try dabbing it on after spraying some in a cup. Do you guys think it will help on a full thickness gasket? I realize it will take several applications so no worry there.

[robertob]

Stanley knife blade used gingerly and a little acetone. Scotchbrite and lacquer thinner to finish up.

Works good, don't sniff too much.