Maintenance & Technical > KX500 Original

Cylinder head what am I doing wrong

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Chrisgg90:
I'm just rebuilding the top end of my 1988 500 after barrel was away to get welded due to being cracked. Every time I put the cylinder head on and torque it down and fill the coolant its seaping out the head gasket. Wasn't doing this before being stripped it down.

I'm using new gaskets and the head is cleaned with all old gasket removed tightened to 25 nm in a crisscross pattern. The head can't be warped as. It's been stitting on the bench the last couple months.

Any ideas ?

kxpegger:
If the cylinder studs were screwed in to tight this can raise or deform the cylinder material area and cause the gasket to not seal. Also depending on the manufacturer the gasket can be directional meaning one side goes up or down. Other than the mating surfaces not being square this is all I have?

sandblaster:
Here is what I would do.
Remove head.
Remove gasket.
Remove studs.
Countersink the stud holes just a smidge.
Lap the head to the cylinder using Timesaver.
Clean the parts to perfection.
Install new studs and torque them to the correct value.
Install the head using a OEM or Cometic gasket.
Torque the head to the correct value.
Fill radiator with the correct amount of Royal Purple's Purple Ice.
Burp it.
Start it and ride about 30 minutes.
Check the torque of the head bolts.
Problem solved, Go riding  8-)

Chrisgg90:

--- Quote from: sandblaster on February 19, 2016, 03:55:59 PM ---Here is what I would do.
Remove head.
Remove gasket.
Remove studs.
Countersink the stud holes just a smidge.
Lap the head to the cylinder using Timesaver.
Clean the parts to perfection.
Install new studs and torque them to the correct value.
Install the head using a OEM or Cometic gasket.
Torque the head to the correct value.
Fill radiator with the correct amount of Royal Purple's Purple Ice.
Burp it.
Start it and ride about 30 minutes.
Check the torque of the head bolts.
Problem solved, Go riding  8-)

--- End quote ---


Cheers sandblaster. What do you mean countersink the stud holes ?

sandblaster:
Get a countersink, put it in your drill, and countersink all the stud holes approximately 1/16" deep.



That way any material that is pulled up from over torquing your studs is removed.

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