Cylinder Head preparation

[Piston720]

This is my first time and I do plan on having a friend help with the reinstall of cylinder block, because as you said, it sure is a tight clearance.
Removing in the bike really was not a problem. It was helpful to have the weight of the bike when loosening the various bolts.
The main studs took me 3 days but they finally broke loose. Be careful of the camshaft bearing bolts as I broke 2, and I was being careful. But after 30 years I guess we would all be well seated.

[Piston720]

Look at Ebay Item 270304033541.
I found one last year and it cost me $300. It was in excellent shape.
Goodluck.

[Steve]

How did you go about getting the pistons with their new rings back up into the cylinders? It looks like a minimum two person job, am I right?

Having two people definitely helps, but one knowledgeable person could probabaly do it. I followed a suggestion from one of my manuals (Haynes?) and made a couple of wooden pieces that look like tuning forks without handles. Just barely narrow enough to fit between the cylinder studs, but still hold the piston skirts, and they also have a notch that is just wide enough to straddle the connecting rod, they are about an inch thick, or whatever fits between the skirts and the block when the pistons are at their heighest. Slide the holders under pistons 2&3, use some large hose clamps as ring compressors, slide the cylinders over 2&3, sliding the clamps as you go. When the rings are in the cylinders, remove the clamps. Rotate the crank until you can slide the holders under 1&4, put the clamps on and repeat the process. When all the rings are safely in the cylinders, do whatever it takes to get the cylinder block down to the lower cases.

Looking at the photos it appears that Steve has some work to do on the base gasket remnants as well. ....

Good eye, Flaggo. Yeah, there was still a lot of work to do, but I just had to line up the parts for a picture as I had never had a bike engine that far apart before.

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[Flaggo60]

.........Yeah, there was still a lot of work to do, but I just had to line up the parts for a picture as I had never had a bike engine that far apart before.

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I missed the second picture-it appears the gasket remnants cleaned off fine-was it a huge job removing a 25 year-old base gasket?

[Steve]

It wasn't all that bad. TheCafeKid and I used a combination of tools, including a 1/2" wood chisel and other scrapers. You have to be VERY careful that you don't gouge the aluminum cases when using a steel scraper. I don't remember how long it took, but I do remember that we took our time.

The results were worth it, too. that bike is back together and running well. The engine starts easily, carbs appear to be correctly jetted for the stock airbox (with K&N filter) and a pipe. Since #2 son does not yet have his license, he rode behind me on the way to our GoldWing chapter meeting in October. Keep in mind that the two of us total over 500 pounds, then realize that the bike had more than enough power. It probably won't be until spring when we find out how the gas mileage is. After he learns to ride it well enough and there is less chance of him dropping it, we will put on the Windjammer fairing and saddlebags so he can join us on our trips. Then, when he can afford it, he wants to paint it.

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