Member Contributer HighSideNZ Posted November 24, 2014 Member Contributer Share Posted November 24, 2014 Won't know completely until the heads are off. I'm going to do both with new gaskets from TTS and spray them with Hylomar M at assembly. I was nearly going to do this the first time but I thought the standard Honda coating would suffice. We used to use Hylomar back in the day with good success, so I think I'll stick with the tried and true this time around. It'll give me a good chance to have a look in side as well and see how the bores have come up etc. Probably not what I envisaged but hey it was an experiment anyway. Link to comment Share on other sites More sharing options...
Member Contributer HighSideNZ Posted November 25, 2014 Member Contributer Share Posted November 25, 2014 I was hoping that there would be enough room to get the rear head off in the frame seeing the 5th Gen is somewhat smaller than the 6th Gen but no luck by the look of it. I'll have to do a full strip and drop the motor before I can see what damage is done. This is where an inline 4 is so much easier. Phil Link to comment Share on other sites More sharing options...
Member Contributer trjerm Posted November 25, 2014 Member Contributer Share Posted November 25, 2014 It's going to be an awesome bike when you get the bugs worked out!!! great job on the build Link to comment Share on other sites More sharing options...
Member Contributer JZH Posted November 25, 2014 Member Contributer Share Posted November 25, 2014 Brian Law of Dynamo Humm told me that he used the die grinder method as well. He suggested I could certainly do it myself, so nothing particularly tricky about the process. Good luck. Ciao, Link to comment Share on other sites More sharing options...
Member Contributer Mohawk Posted November 25, 2014 Author Member Contributer Share Posted November 25, 2014 Surprised that you can't get the heads off insitu Link to comment Share on other sites More sharing options...
Member Contributer HighSideNZ Posted November 25, 2014 Member Contributer Share Posted November 25, 2014 Not sure about the 5th Gen but the back of the frame, where it joins to the box section for the shock etc., is really narrow. There is no way that you can get the head up high enough over the cam drive gear cassette to free the head. The manual outlines that you need to drop the motor to get the rear head off for the 6th Gen but I was hoping that due to the heads being a bit shorter on the 5th Gen, it may have just snuck out. But that does not seem to be the case. Link to comment Share on other sites More sharing options...
Member Contributer HighSideNZ Posted November 29, 2014 Member Contributer Share Posted November 29, 2014 Well I got the engine out and on the bench yesterday and stripped the rear head off first. Interesting, the gasket was completely stuck to the head but did not stick to the crankcase at all. It is though there is a fault in the gasket coating. I wonder if I got a dud gasket? At assembly time, I cleaned both the head and crankcase surfaces with contact cleaner, like I've always done, so there was no oil on them and they were spotless so that is all I can think of. The gasket seems to be well compressed around the cylinders so I'd have to say the leak is probably due to the coating. One thing, the bores look good and I'd have to say the rings are well bedded by the look of the crosshatching. I gave it a cold compression test before pulling the motor out and the figures were: No 1 = 230psi, No 2 = 240psi, No 3 = 235psi, No 4 = 240psi So it may be that both rear cylinders were leaking a bit. No 1 a bit more that No 3. Not conclusive as it was cold but I'll see what the front head is like today. If it is stuck both sides then I'd have to say a faulty gasket was the cause. I'll post more when I find out. Phil Link to comment Share on other sites More sharing options...
Veefer800Canuck Posted November 29, 2014 Share Posted November 29, 2014 Sorry for your luck. Link to comment Share on other sites More sharing options...
Member Contributer YoshiHNS Posted November 29, 2014 Member Contributer Share Posted November 29, 2014 Could be a bad head gasket. I had one rebuilding the car engine. Leaked like a sieve. Link to comment Share on other sites More sharing options...
Member Contributer HighSideNZ Posted November 30, 2014 Member Contributer Share Posted November 30, 2014 Yep, looks like it was a bad gasket. The font head was quite a bit harder to get loose. Gasket was stuck both sides. Still stuck to the head a lot more than the crankcase but more than the rear. So, just my luck to get a crook gasket. Not much more to do than wait for the parts to turn up and start the assembly. Phil Link to comment Share on other sites More sharing options...
Member Contributer Rush2112 Posted November 30, 2014 Member Contributer Share Posted November 30, 2014 Sorry for the bum luck... but on the bright side, looks like all your modifications and grinding work were spot on and had nothing to do with the issue! Link to comment Share on other sites More sharing options...
Member Contributer Switchblade Posted November 30, 2014 Member Contributer Share Posted November 30, 2014 Looks like you found it . Good job. Link to comment Share on other sites More sharing options...
Member Contributer HighSideNZ Posted December 10, 2014 Member Contributer Share Posted December 10, 2014 Well the gaskets are on their way from the US. TTS couldn't get any until mid January so I'll have to modify the new ones myself again. My other problem is that I broke my ankle yesterday at work and have a moon boot on for the next 6 weeks. Going to make it pretty difficult to get the bike back together at this rate. Link to comment Share on other sites More sharing options...
Member Contributer Switchblade Posted December 10, 2014 Member Contributer Share Posted December 10, 2014 How ? What is your job ? And sorry . Link to comment Share on other sites More sharing options...
Veefer800Canuck Posted December 10, 2014 Share Posted December 10, 2014 Take it easy on the foot, let it heal. Don't be in a rush to get back to normal. The bike will still be there later. Link to comment Share on other sites More sharing options...
Member Contributer Rush2112 Posted December 11, 2014 Member Contributer Share Posted December 11, 2014 ^^^ Ditto to what he said... I know I don't heal like I used to and trying to rush things just makes take longer and hurt more in the long run... I hope you heal quick and relatively painlessly and get back to 100% real soon... Link to comment Share on other sites More sharing options...
Member Contributer Dutchy Posted December 11, 2014 Member Contributer Share Posted December 11, 2014 Kiwi farmer?? :-) Link to comment Share on other sites More sharing options...
Member Contributer KevCarver Posted December 11, 2014 Member Contributer Share Posted December 11, 2014 What's the US source for new gaskets? Link to comment Share on other sites More sharing options...
Member Contributer HighSideNZ Posted December 11, 2014 Member Contributer Share Posted December 11, 2014 Funny thing is I work in IT these days. Rolled my ankle on a path in a car park going down a ramp and heard the old "crack". I use Partzilla for pretty much all my part purchases as the local Honda distributor is hopeless. They hold no stock and everything is "21 days, ex Japan" Yep you're right, the bone don't heal as well as they used to when I was 20/30. Don't know how many people of said to me. "Those motorcycles are dangerous things" I take great pride in saying that the bike had nothing to do with it. Link to comment Share on other sites More sharing options...
Member Contributer KevCarver Posted December 11, 2014 Member Contributer Share Posted December 11, 2014 Oh, so you're going with stock and cutting them yourself? Bikes are dangerous! I've had two friends destroy their shoulders/collar bones in bicycle crashes! Stay off a push-bike... Link to comment Share on other sites More sharing options...
wera803 Posted December 11, 2014 Share Posted December 11, 2014 If you don't want to mess with modifying stock gaskets again, you can always try Cometic Gaskets (www.cometic.com). I used them once when rebuilding an extremely overbored 1997 ZX-6R. They were the only ones I could find that had or could get me the correct size head gasket. Link to comment Share on other sites More sharing options...
Member Contributer KevCarver Posted December 11, 2014 Member Contributer Share Posted December 11, 2014 If you don't want to mess with modifying stock gaskets again, you can always try Cometic Gaskets (www.cometic.com). I used them once when rebuilding an extremely overbored 1997 ZX-6R. They were the only ones I could find that had or could get me the correct size head gasket. I think that was on the list I got from Huey. (Marietta Motorsports) Link to comment Share on other sites More sharing options...
CandyRedRC46 Posted December 12, 2014 Share Posted December 12, 2014 Damn, sorry, I hear you man. I dropped my bike in the garage the other day, then had half the fairing fly off on the high way at speed. After I repaired the bike and got it 100%, I hit a raccoon the next day and f@#$ed everything up all over again. Trust me, I understand the bad luck, though I still think you have me beat.... :( wishing you a speedy recovery brother Link to comment Share on other sites More sharing options...
Member Contributer Switchblade Posted December 12, 2014 Member Contributer Share Posted December 12, 2014 Funny thing is I work in IT these days. Rolled my ankle on a path in a car park going down a ramp and heard the old "crack". I use Partzilla for pretty much all my part purchases as the local Honda distributor is hopeless. They hold no stock and everything is "21 days, ex Japan" Yep you're right, the bone don't heal as well as they used to when I was 20/30. Don't know how many people of said to me. "Those motorcycles are dangerous things" I take great pride in saying that the bike had nothing to do with it. Darn dude . Link to comment Share on other sites More sharing options...
Member Contributer ecn Posted December 12, 2014 Member Contributer Share Posted December 12, 2014 Best of luck on a speedy recovery. This might be a good time to request new safer light weight SSD laptop and work from home voip set up. Link to comment Share on other sites More sharing options...
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