Boxerworks.com

tsa wrote:

grant81rs wrote:Got the new seals, gaskets, clips, o-rings plus every other bloody thing laid out on the workbench ready to go, yep the heads and pots are coming off the 81 this Saturday as I have weeping push rob tub seals myself..

Not sure if your laid out parts include the cyl. head gaskets. For changing the pushrod tube rubber grommets, it isn't neccessary to separate the heads from the barrels; if you back off the torque on all six cyl head bolts, but only remove the nuts from the studs going into the crankcase, you can pull off the heads & barrels as one unit. And then push the gudgeon pin out to allow you to pull the head+barrel assembly off the piston. If doing so you can save your new cyl head gaskets for a later job.

Tsa,

that's exactly how I do this procedure. No reason to pull the pistons, separate the heads if the bike is running well.

thanks,
jimmyg

Kurt in S.A. wrote:tsa -

Are you pulling the cylinder/head completely off the studs or just enough to replace the seals? I'd be concerned about the two small O-rings and getting them pinched going back together.

Be sure and thoroughly clean the mating surfaces, then apply a thin layer of sealant. I would find it difficult to clean these surfaces with everything still hanging on to the long studs.

Kurt in S.A.

hi Kurt,
No, everything is removed from the studs but as noted, the heads, cylinders, and pistons are pulled without separation.

I've used Permatex sealant (Ultra Copper) in the past for this service (about 15 other Airheads) and the trick is to use very, very sparingly so as not to plug the oil passageways that lubricate the rockers arms.

thanks,

jimmyg

thanks,

There is no reason to remove the piston from the rod, it is faster to just leave it in place on the rod. Plus, you get to take a look at the piston.

The ring compressor is built into the cylinder, so it goes back on very quickly.

Gidday Fella,

Both times I have now done this procedure this year it has been on "new to me" bikes that I have just brought from previous owners that have let things go a little on the general maintenance side of things, both bikes needed a good clean up, both were cosmetically sad, so I was curious to remove the heads and barrels completely, separate, inspect and clean up any carbon build up on the piston tops and valves seats etc..

From start to finish it took 2.5 hours to complete both sides this time around, so its not a hard this to do, just prepare and do not stop mid way, get the thing done and sealed back up in one go..

Next time I would just keep the barrels and heads together for the sake of the head gasket cost, either ways its no more work really just a couple of nuts plus you get to check out stuff and have a poke around..

Best of luck

Duane Ausherman wrote:
The ring compressor is built into the cylinder, so it goes back on very quickly.

Only iffen yer gots finger nails.

ME 109 wrote:

Duane Ausherman wrote:
The ring compressor is built into the cylinder, so it goes back on very quickly.

Only iffen yer gots finger nails.

Spudgers work well for those who don't have fingernails.

Major Softie wrote:Spudgers work well for those who don't have fingernails.

Damn! I must have lead a sheltered life. I never ever heard of a Spudger until now. Due to Google I'm now enlightened. For years I've used bamboo skewers and other pointy things. Amazon, here I come.

On second thought I think I'll hold off. Apparently I haven't actually needed a spudger yet and I'm kinda long in the tooth. Yep, for me there may be such a thing as too many spudgers.

Ken

Spudger? That's a new one on me too! Now, to work that one into a conversation somehow without offending someone?
You tube has more...
https://youtu.be/9s6JmLpzMro

We replaced head gaskets on customer's bikes, due to liability. I have reused head gaskets many times without any problem resulting.

Duane,
When reusing head gaskets, must they be positioned somewhat in the exact place they were removed from? Were they debrided? Or cleaned up? Is the gasket left stuck to the part it doesn't separate from?
I must admit I have never reused a head gasket and am curious. Can you, or have you, reused head gaskets more than once?
Are there any bad signs to look for that could convince you it may be a good idea to replace a gasket you were planning on reusing? For instance. Sometimes a gasket shows what looks like corrosion around the edges close to the combustion chamber. Maybe from preignition or lean mixtures maybe but I have seen some ugly head gaskets.