Orings too big

[Rickrod3]

Was having a pretty good day putting my motor back together when I got to putting the orings on the bottom of the jugs.
Bought gasket set from partsnmore part # 18-0160

Has anyone else ever had this problem?
TIA
Rick

[boyat68]

Rickrod3:

Having never had to repair the engine, I offer the following with a grain or two of salt.

If the o-Rings are not too far off, perhaps cooling them in the refridgerator for an hour or so may shrink them enough to allow them to fit.

[Rickrod3]

Might work have a refrigerator right next to my bench.
I think I'll have a brew while I'm trying it out.

[DGXSER]

ALso never pulled the jugs...off the bike anyway. I did however just put a new oil filter on Thunderstruck and found the new O-ring at first seemed to large, but it did find its way into the channel and has sealed it up like a frogs behind in a deep lake.

[Rickrod3]

Maybe I'm doing something wrong. The rings seem to fit around the sleeve its when I try to get them into the groove that it looks too big.
Should I just lay them over the sleeves and when the head gets tightend up they will. Go into. Place?

Thanks in advance

[TopCatGr58]

Hey Rick,

It's been many years since I tore mine down that far, but IIRC, I just put the Orings up to the base of the cylinders. When the jugs are put in place, the Orings will get squeezed against the crankcase, and that's partly how they seal....so I don't think they are supposed to go DOWN into the groove between the cylinders and jugs assembly. However, with recent talks about base gasket leaks, I would also use Yamabond on both sides of the gasket to ensure a good leakproof seal! YMMV!
T.C.

[Rickrod3]

Thanks TC

Rick

[79XS11F]

When I did my 2 engine builds the O-rings were also a little big. They can be tucked into that gully. They will fit. Just work your way around each jug and stuff them into place.
Rob

[Rickrod3]

with the yamabond I would imagine it would have to be torqued down right a way.
I'm not ready to permently put on my heads I guess I could wait or just torque the head an remove them again to work on them.

[TopCatGr58]

Rick,

You shouldn't have to rush to torque. The Yamabond remains pliable, and once you put the jugs down onto the case and make contact with the mating surfaces, that will make a seal, and then the torquing will just squish any excess out of the way. You should only need a small thin film on both sides of the gasket, not thick bead of it.

Also, I don't know if I'd actually stuff/force the O-rings up/down into the jugs groove, because you want the O-ring there at the mating point of the jugs and case. The oil will be making it's way along the outer edge of the cylinders and up to the junction of the outside edge of the cylinders and the case. The O-ring should be at that point to prevent the oil from getting past that area and inbetween the junction into the gasket. IF the O-rings are squished up past that jugs/case junction, then they would not be in the path of the oil anymore, and become useless....I think!
T.C.

[mro]

use Yamabond on both sides of the gasket to ensure a good leakproof seal! YMMV!
T.C.

Bet you don't know how much trouble it will be to get apart in the future.

If the mating surfaces are in good condition (and they should be) new gasket should not leak unless there be other issues.

mro

[trbig]

Also, I don't know if I'd actually stuff/force the O-rings up/down into the jugs groove, because you want the O-ring there at the mating point of the jugs and case.

They get stuffed into the gap. You're trying to keep the oil from getting up between the cylinder sleeves and the block. The block has it's own gasket. If they were simply wanting them to be on the outside squished, there would be just a regular gasket there. Yes, they will seem a bit large, but I oil mine up a bit, then take a common large screwdriver and poke it in at 4 points around the jugs, then the four middle points of those, and so on until it's tucked into there. If you start at just one side and work your way around, you'll have a big "Hoop" of o-ring when you get back to where you start. I believe they're a bit large because they want to make sure they get a tight seal in there.


Tod

[Rickrod3]

Thanks Todd I tried your method and was able to get them just as you said.

Thanks to all for your input and ideas.
Another problem solved.

Rick

[trbig]

As stated in a couple recent posts, some have been having leaks in the base gasket between the cylinders and the block. You may try the Yamabond or Tribond along with the gasket to make sure it doesn't leak.

The next motor I do, I'm not going to put a base gasket on at all. The Yamabond/Tribond makes a great seal.. it's what keeps your two cases sealed together. If you've ever had to scrape on that base gasket to get it removed.. you'll understand. The Yamabond/Tribond stuff cleans off easily.

Tod

[Ken Talbot]

Hey, TC - check out this post to refresh how you handled the o-rings! Since that thread, I've put a lot more miles on Tsunami, and still have no leak.

Somewhere in the back of my mind, way down deep, I have vague memories of a stern warning to NOT use the o-rings any more - something to do with something different with the way the base gasket is made, and even vaguer (if that's a word??) warnings about possible cracking the block if the o-rings were used. Anybody else remember anything about this?