Base Gasket Hell !

[AirCooledHeaven]

I'd really appreciate any help with this. I decided to strip the top end on my 1000 to replace a leaking base gasket. Everything was going fine until I tried to remove the gasket itself. It is completely bonded to the barrels, I've tried scraping it, I've tried gasket remover spray, nothing will touch it. I can't see any way to get it off without seriously damaging the gasket face on the barrels. And I thought this was going to be the easiest part of the stripdown!

Thanks in advance.

[hampshirehog]

That's pretty much standard. Try Nitromors paint stipper (be careful as it will take any paint off as well) but if that doesn't work you're just gonna have to scratch away carefully for a few hours with something softer than aluminium - fingernails, plastic scarpers etc.

At least it's stuck to your cylinders - easier than scraping it off your crankcase and trying to avoid bits falling in to the void.

[psyguy]

soaking with gasket remover/stripper liquid should work (provided you have a decent stripper - you may want to try a few different brands, or ask here what brand best to use)
yeah, patience works too :-D

[spchips]

any of the roloc high speed discs or bristle discs work well. Be sure to get the one that won't chew aluminum.

[bwringer]

any of the roloc high speed discs or bristle discs work well. Be sure to get the one that won't chew aluminum.

Agreed. This is the only way I've found that won't make you go mad as you chip, chip, chip away for three days... With any scraping method, you WILL gouge the surface at several points.

Make sure you use a die grinder with enough speed -- a drill won't work and will dig in and tear up the aluminum. You'll also need a smaller disc to get in between the cylinder liners.

Careful about the chemicals you put on there -- make sure to clean them off before flinging them all over the garage.

You also have to clean everything several times afterwards to make sure no abrasive gets left in there.

[SqDancerLynn1]

Take the cylinders to local engine shop & have them chemically cleaned

[AirCooledHeaven]

soaking with gasket remover/stripper liquid should work (provided you have a decent stripper - you may want to try a few different brands, or ask here what brand best to use)
yeah, patience works too :-D

So far tried Loctite 7200, useless...

[AirCooledHeaven]

any of the roloc high speed discs or bristle discs work well. Be sure to get the one that won't chew aluminum.

Sorry what's a roloc? Like a dremel ?

[AirCooledHeaven]

That's pretty much standard. Try Nitromors paint stipper (be careful as it will take any paint off as well) but if that doesn't work you're just gonna have to scratch away carefully for a few hours with something softer than aluminium - fingernails, plastic scarpers etc.

At least it's stuck to your cylinders - easier than scraping it off your crankcase and trying to avoid bits falling in to the void.

I'll pop down b&q & get some, then I can tell my wife it's for decorating...

Do my eyes deceive me or is that a 'seized' 250 in your avatar? Was going to buy a new one when I passed my moped test but my girlfriend at the time said she wouldn't be seen dead on the back of it

[hampshirehog]

Do my eyes deceive me or is that a 'seized' 250 in your avatar? Was going to buy a new one when I passed my moped test but my girlfriend at the time said she wouldn't be seen dead on the back of it

Pretty close - it's a CZ125 type 486. I paid the princely sum of £15 for it 2 years ago, immaculate condition just not running right - only 3k on the clock (belonged to an old boy). After breaking the bank to the tune of £7 for new crankshaft seals and a de-coke - the old boy ran it on 16:1 so you can guess what it was like - it ran like a dream. For all the mickey taking there are a few bits the Japs could copy - some very clever little engineering features and kind of quaint to see the marks on some engine parts which were hand finished.

I bought it as a bit of a joke and an antidote to speed - the cheapest way to make a bike go faster is to ride a slow one beforehand. 60 flat out on the CZ makes my other bikes feel like they are rocket powered! Sadly I had to sell it (wife laying the law down) but it's gone to a CZ enthusiast so probably better housed there than with me.