SuzukiSavage.com - Removing Cylinder Base Gasket.

Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Removing Cylinder Base Gasket. 11/11/22 at 19:33:57 Hey guys. Getting the cylinder bored on Monday and the base gasket is really stuck on there and not coming off easy or in one piece. Any tips on getting it off? Just time and patience I guess but it's really baked on there.
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zevenenergie

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Re: Removing Cylinder Base Gasket.
Reply #1 - 11/12/22 at 02:57:39

High Dave,

I sometimes see engine builders put their blocks in a kiln to burn off all the oil and gaskets.

I once did it with a rosebut acetylene burner with the highest possible excess of oxygen. The block stays reasonably cool and the oxygen burns everything that wants to burn. It's a bit risky maybe on a savage cylinder.

If you don't have all that then maybe acetone can help. That solves just about everything.

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Do what you know is right. (you can always use fear as a counselor later)

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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2625 Amongst the Twisty Roads	Re: Removing Cylinder Base Gasket. Reply #2 - 11/12/22 at 03:38:43 A razor blade and time is all that is needed.
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Removing Cylinder Base Gasket. Reply #3 - 11/12/22 at 03:58:25 Yeah I have been working at it. But what's left is hard as a rock. I might just see if the shoe can do it when it's in to be bored
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Removing Cylinder Base Gasket. Reply #4 - 11/12/22 at 08:23:16 I was going to suggest leaving it alone and ask them to get it. I'm pretty sure they have what they need.
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: Removing Cylinder Base Gasket. Reply #5 - 11/13/22 at 11:31:34 Harbor Freight sells some hard plastic chisels in a set of various sizes. They worked like a charm for me, and you can't harm the sealing surface like with a razor blade.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Removing Cylinder Base Gasket. Reply #6 - 11/13/22 at 15:28:29 I've seen these used on YouTube. They look to be doin a great job. I've seen them in use and watched in amazement that they aren't wearing away in minutes. Then I saw the price.. They better Not go away like an eraser. https://www.ebay.com/itm/3M-07524-Roloc-Gasket-Remover/403394889765?var=0&mkc...
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28755 L.A. California Gender:	Re: Removing Cylinder Base Gasket. Reply #7 - 11/13/22 at 16:50:22 Well, it's a box of 10 and you can get them cheaper elsewhere.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Removing Cylinder Base Gasket. Reply #8 - 11/13/22 at 18:50:23 Yeah, saw it was ten.. Still not super cheap but I've seen Condon ,the generator guy, run them and other YouTube folks. I should have one, but not ten.
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Moarpower Senior Member Offline SuzukiSavage.com Rocks! Posts: 331	Re: Removing Cylinder Base Gasket. Reply #9 - 11/13/22 at 19:35:59 They look cool but I'm having a hard time removing this materiel with a steel chisel! It's like it's turned to stone. Clearly the original gasket. It literally like a rock. I even used a soft wire wheel on a drill and it barely scratched the surface. I have manage to remove some but what's left is just amazing.
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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2625 Amongst the Twisty Roads	Re: Removing Cylinder Base Gasket. Reply #10 - 11/14/22 at 05:48:00 Be careful not to remove any aluminum otherwise you will have a permanent leak upon reassembly. I use a utility blade held at a ~30 degree angle - wiggling it back and forth as I advance it forward. The blade MUST be new and sharp. You may go through many blades for the small amount you need to remove.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Removing Cylinder Base Gasket. Reply #11 - 11/14/22 at 09:21:59 Sounds like plenty of reason to let them get it
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DragBikeMike

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Re: Removing Cylinder Base Gasket.
Reply #12 - 11/14/22 at 11:40:30

I agree with Justin. Let the machine shop clean up your base gasket.

My experience with the newer asbestos-free gaskets has been a mixed bag. Sometimes they just sort of flake off in chunks. Pretty easy to remove. Other times the things seem to be welded on and are hard as concrete. Taking a wire wheel of any kind to your aluminum gasket surface is not gonna do the cylinder any good at all.

There are commercial gasket removal products that you spray on to soften the gasket. I don't like em. They eat up paint and powder coating (and I suspect your fingers too).

I use my lower torque plate with some 220 grit wet & dry abrasive. Lot's of water keeps the gasket material from loading up the abrasive paper. It does a nice job but you must be careful to only remove the gasket material and not the aluminum. The torque plate is machined perfectly flat. You can't use any old scrap material, it has to be perfectly flat. Like don't try this with a chunk of wood.

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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4166 Honolulu	Re: Removing Cylinder Base Gasket. Reply #13 - 11/14/22 at 11:41:49 It's easy to use and removes the old gasket in short order. Just gotta be careful not to remove aluminum.
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4166 Honolulu	Re: Removing Cylinder Base Gasket. Reply #14 - 11/14/22 at 11:43:54 The finished product is good. But as I said, you gotta be careful.
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