okay, so I am in the middle of my first top-end attempt, so be gentle. Can someone give me some tips on the best way to remove the old base gasket from the cylinder? I'm pretty sure it was fit dry so it is really on there. I know it is crucial not to scratch the cylinder surface, so I'm wondering if there is something in particular people use to soak the paper gasket or other technique/tool that people have found effective and safe. ANY constructive advise would be appreciated.

Thanks.
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-Jim
'93 MC21

A gasket scraper is the tool you need.

By their nature, and because of the job they do, base gaskets don't really respond much to being soaked... they're pretty resistant to most liquids!

I've always found that a new Stanley knife blade, held at the shallowest possible angle, is the best thing for gasket removal. The key is to take all the time in the world to scrape the stubborn gasket off carefully.

Just make sure the sharp edge is always in contact with as much of the gasket face as possible. You don't want any sharp corners digging in to the soft alloy.

I generally find there's not enough room to put the blade in a handle, and find I have much more control over it by hand anyway.
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Andy.
NSR-WORLD.COM

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Basically if they're stuck on badly it's a pain, it can take a good few hours to get it all off. I don't know why some stick that badly, maybe some idiots are using some kind of instant gasket as well.

The cases can be even worse if the motor is in the bike.

I coat the gasket with a smear of grease, it stops them sticking at all and I've never had one leak yet.
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i have had to do this a few times myself and after several new gaskets, it seems they all like to stick. Andy's method is the most common and to add to it, a bare stanley blade works well with a few layers of tape wrapped around your thumb.
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I'm with Fontyyy, a thin smear of grease and they don't stick.
I've spent many hours removing dried out / welded on gasket material, when breaking down engines for the first time (since I had them).
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Rich
MC21 Track Bike / RS250 NF5 'Spencer', NX5 'Cadalora' & NXA 'Aoyama' / RS500 / Two Brothers Racing RC30

I removed my base gaskets today and found that a spray of Brake Cleaner made the 2nd cylinder a fair bit easier. The first one took me about 30 mins, (lubing with CRC water dispersant and the 2nd one was about 10 mins).

I scraped them with a new razor blade.

I smear my gaskets with Castrol Lithium grease. Works a treat. After a couple of fun weekends on the RS250NX5 I pulled off the cylinders and the gaskets came off like new. No signs of sticking.

I've tried various other greases and they still tend to stick a little over time.

Yeah, assuming I ever get to that point, I'm going to mount the new gaskets with a smear of grease.

KTM39, what is your secret? I started in on them with Stanley blade and brake cleaner and after 30 minutes I was maybe a quarter of the way done with one cylinder! Either mine are stuck on there worse or my technique is wrong (or both), but this is taking forever. Maybe I'm being too cautious? Are you getting any large pieces at a time to come off - I'm getting only balled up, mushy shavings.

It seems like some mad chemist should have come up with something that dissolves paper gaskets without harming metal. Thanks everyone for the tips.
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-Jim
'93 MC21

Jim wrote:
It seems like some mad chemist should have come up with something that dissolves paper gaskets without harming metal. Thanks everyone for the tips.

Well he did and there are many other products.

I've used one and a plastic scraper. It worked OK but it did take more than 10 minutes but I don't care as long as the gasket is removed without damage to the surfaces.

http://www.beltco.com.my/catalog/PERMATEX/PERMATEX-GASKET-REMOVER-4MA/
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Poul
"If Life Gets Boring, Risk It!"
MC21SE, KISS box
MC21SP, HRC box, racing loom

I did try brake cleaner and it didn't do all that much, but I'll try the Permatex to see if that works better, thanks.
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-Jim
'93 MC21

1st cylinder I got no pieces bigger than about 5mm, (using CRC).
2nd cylinder I pulled off a few pieces about 25mm, (using brake cleaner).

It's possible that the gasket on my 2nd cylinder just wasn't stuck on as stubbornly as the first one, but either way, job's done and my barrels are back on.
I'll post up some pics later - right now, I want to get back into the shed and fit my new Tyga pipes!

I do have a gasket scrapper, but still find em to thick. I now use my late Gran's butter knife. It's thin enough to get under the gasket without being too sharp to gouge the barrel/cases.

I think StephenRC45 uses something similar..... but not one from my Gran.

I used gasket solvent spray which is like paint stripper and a sharp knife blade
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