Micky V
Junior Member
1978 SR500
Posts: 43
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Post by Micky V on Jul 9, 2008 7:46:48 GMT -5
Hi All, First post for me. Im in the middle of stripping down my new old 78 SR500 and am having problems separating the cylinder off of the case.  All bolts are off but it looks like the gasket is welded on or the locating rods/dowels are corroded in..... Any thoughts on how I can free it up? Cheers |
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Post by sjef on Jul 9, 2008 10:21:21 GMT -5
Hallo ,
Play tennis?
place a ball up on the piston in its lowest position, put the head on. leave the cilinderbolts free, crank the engine and with some luck the crank lifts the cilinder.
regards sjef
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entropy
Junior Member
Moving towards disorder
Posts: 30
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Post by entropy on Jul 9, 2008 12:01:21 GMT -5
Love that tennis ball idea! Never thought of that one.
You might also try using utility razorblades. Purchase a bulk pack at the hardware store and gently tap them into the base gasket with a light mallet. Careful not to damage the aluminum gasket surface. Use a bunch of blades and work all the way around the base of the cylinder, then try the tennis ball trick.
SR's are notorious for having sticking base gaskets and virtually no pry points. just be patient and persistant.
Good luck.
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Post by aero on Jul 9, 2008 12:17:47 GMT -5
It should be noted that the tennis ball promises less claret then trying to force razor blades under the gasket!
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Micky V
Junior Member
1978 SR500
Posts: 43
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Post by Micky V on Jul 10, 2008 5:00:32 GMT -5
Tennis! Thats great I'll give it a go ;D
Thanks guys, I'll let you know how it goes.
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Post by StewRoss on Jul 10, 2008 5:08:19 GMT -5
A carefully operated rubber mallet will work as well...light tapping on the ends of the fins while working around the cylinder and off she'll come. No hitting up under the fins of course. SR  |
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Micky V
Junior Member
1978 SR500
Posts: 43
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Post by Micky V on Jul 10, 2008 6:30:35 GMT -5
I started with the rubber mallet but this guy is stuck good. No luck with the tennis ball and I only have stanley knife blades so they are a bit thick. I'll try razor blades tomorrow and maybe put all three techs into practice if I can find some extra hands......
Cheer guys
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Post by StewRoss on Jul 10, 2008 6:34:19 GMT -5
Good luck... SR  |
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sven
Full Member
Posts: 166
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Post by sven on Jul 10, 2008 15:52:09 GMT -5
No hitting up under the fins of course. SR True, but you can hit up under the chain tensioner... |
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Post by davewfc603 on Jul 11, 2008 0:26:05 GMT -5
I like the tennis ball trick too, these bike do get some of the strangest parts stuck when you least expect it. good luck dave
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Post by chew652 on Jul 11, 2008 8:19:31 GMT -5
Some Ideas. I actually haven't tried these so use your best judgement.
# 1 Cut a piece of steel bar stock longer than the cylinder is wide and drill holes to match size and spacing of head studs . Bolt it on and hit upward on it instead of the actual cylinder .
# 2(messy) Bolt the head back on using the old head gasket but with out the camshaft.leave the valves and springs on. Fill the cylinder with oil through the spark plug hole and snug up the plug. Try to turn motor and push cylinder off. Clean up oil mess.
#3 same as #2 but put soft nylon rope in cylinder instead of oil.
#4 Spray base base gasket area with gasket remover spray( I buy mine at Advance Auto Parts) ,pray a lot to the god of shade tree mechanics and try the rubber hammer again.
Good Luck,please let us know what worked.
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Micky V
Junior Member
1978 SR500
Posts: 43
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Post by Micky V on Jul 11, 2008 18:51:55 GMT -5
Thanks Chewy, I'll give a couple of those a go, The rod across the cylinder sounds like a good start. i tried the razor blades gently tapped in, that started to work but there are some very tight parts that I'm reluctant to push through.
I got the day off with my Girlfriend so I'll let you all know how I go Sunday night.
Have a great weekend
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Post by caferacercarl on Jul 12, 2008 18:44:34 GMT -5
I have in the past put a bit of 4x2 softwood against the cam chain tunnel area and given it a gentle persuader with a heavy object, cheers.
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Micky V
Junior Member
1978 SR500
Posts: 43
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Post by Micky V on Jul 13, 2008 5:40:59 GMT -5
;D
Done!!!
Thanks guys the cylinder is off. About time. I ended up using your idea Chewy, but instead of using stock I got a thick piece of plywood. Almost an inch and a half. I was a bit reluctant to use some thing as hard at the metal stock. The ply enabled me to cut out some slots for the valve springs (as they are still in. Once the ply was in place it came off no worries at all.
If someone can let me know how to insert a pic I'll put one up of the job.....
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Post by solo2racr on Jul 13, 2008 11:16:30 GMT -5
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All bolts are off but it looks like the gasket is welded on or the locating rods/dowels are corroded in..... Any thoughts on how I can free it up?
