Front pipe gaskets - is nothing easy ?

[McCabe-Thiele (Ted)]

I thought I would fit the four  round copper composit gaskets into the cylinder head but they do not seem to just drop in like I expected.
Now the gaskets I have came with the bike so they might not be the right ones.

Are they usually such a tight fit -  do I need to drift them into place with a suitable socket or what?

[Bryanj]

They should push in, are you sure the old ones are out

[McCabe-Thiele (Ted)]

Yes old one I removed with a lever. The ones I have must be cheapos or the wrong ones. I guess I'll need some from DS.

[Nurse Julie]

Yes old one I removed with a lever. The ones I have must be cheapos or the wrong ones. I guess I'll need some from DS.

Many moons ago I had the same issue. I had purchased 4 new gaskets from DS and they were about 2-3mm too big on the OD. I asked DS and they confirmed they were the correct ones. I bought an aftermarket set from elsewhere and they fitted perfectly.

[smoothoperator]

Mine came with the NE gasket set and are very tight, got one in but I have left 3 others half in half out for another day. There is paint in there from when I sprayed the head which may be an issue. I have some unused spares in ancient packaging which are of a different design, they look like they might have asbestos or similar in.

[McCabe-Thiele (Ted)]

I have had a bit of a hunt round amongst my spare parts and found what look like some sort of Asbestos replacement type gaskets bound with copper wire spiral binding.

I can't get my calipers into the exhuast port to measure the diameter its about 38mm at its narrowest being tappered from about 40-41m.

In the photo are two that are too big to fit they measure 39.7 mm for the enclosed copper gasket & 39.3mm for the open sandwich one with the blue filling.

Looking on the internet there are also alloy ones available - like this one below.

I suspect the two copper gaskets are for the 500.

https://www.ebay.co.uk/itm/283814932934?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m1438.l2649

The exhuast port has no paint on it so that's not causing the problem - I've given the port area a clean & removed what little paint that was - still too tight except of course the white soft gaskets.


.IMG_20220118_131444 by Macabe Thiele, on Flickr

[Laverdaroo]

Ted, I used the ones on the left to do the 400 and they were really really tight to get in but after a whizz round with a bt of wet n dry and a gentle persuede with a rubber mallet and a drift/socket they 'plopped in' quite nicely. I bobbed a bit of 'ginger grease' round mine just to aid them as they were such a tight fit.they came from DSS also.

Keep persevering buddy they'll go with a bit of a fettle

[McCabe-Thiele (Ted)]

I've already started using some 180 grit to get one in as a trial - it just needs a bit more fettling.

[Laverdaroo]

You'd think y
they'd just bob in but like i say, I had a bit of faffing to do to get them in. Keep at it mate.

[McCabe-Thiele (Ted)]

I have a small soft handled Posidrive that I've put in the drill chuck to make a hand held lathe type arrangement so I can end up with a round gasket as it will hold the gasket nicely.

[Laverdaroo]

genius, thatsmy sort of approach too in the absence of a lathe or piller drill.

[McCabe-Thiele (Ted)]

Upped my game using a faster drill and a small flat file, I was able to taper the effect so it would go in easily but still a tight fit.
One down three for tomorrow if it warmer.

[Laverdaroo]

well done mate

[Alexrayz]

I have had a bit of a hunt round amongst my spare parts and found what look like some sort of Asbestos replacement type gaskets bound with copper wire spiral binding.

I can't get my calipers into the exhuast port to measure the diameter its about 38mm at its narrowest being tappered from about 40-41m.

In the photo are two that are too big to fit they measure 39.7 mm for the enclosed copper gasket & 39.3mm for the open sandwich one with the blue filling.

Looking on the internet there are also alloy ones available - like this one below.

I suspect the two copper gaskets are for the 500.

https://www.ebay.co.uk/itm/283814932934?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m1438.l2649

The exhuast port has no paint on it so that's not causing the problem - I've given the port area a clean & removed what little paint that was - still too tight except of course the white soft gaskets.


.IMG_20220118_131444 by Macabe Thiele, on Flickr

That's asbestos?! Frack man I touched those things and and my face afterwards. Guess I'll die. Didn't know these were for the pipes, I assumed it only was copper washers. Thanks!

[McCabe-Thiele (Ted)]

Not blue asbestos just some other heat proof filler. From what I know about asbestos you will not die for another 30 yrs anyways.

P.S. I havent got 30 yrs left unless I live until I'm 103. lol