top end rebuild

I am in the middle of putting cylinder back on the engine. There are four o-rings that I need to install at the base of the cylinder. When I try to install them they stretch a bit and I end up with about an inch of o-ring that won't fit in the groove. Is there a trick to this? Any experienced builders had this problem?

 

Get a second opinion on this, but I would be inclined to give them the flick.

 

Try pushing them in alternating sides, moving around in a star like pattern.

 

They should fit without any slack when put on the cylinders. Sure you have the right ones? They are needed to keep oil from leaking up to the cooling fins. The o-ring fits in the small grove around the cylinder and the base gasket helps hold them in place. Then you can put the cylinder back on the engine block.You should not need anything to hold then in place.

 

You should Seal that Bottom End Gasket --> On BOTH sides <-- with a Coat of
Permatex Indian Head Gasket Shellac Compound.

The stuff is messy.
It stinks, too.
But, it's the favorite Gasket Sealant of the racing Community.

If you are putting a Gasket between two Parts that you don't want to leak; Indian Head will not let you down.

Don't try to use the Dabber Brush attached to the Cap on the Bottle.
Cut that off.
Pour a little bit out of the Bottle and use an Artist Brush to apply a coat of the Sealant on the Gasket -- Both sides -- and a "Seating Coat" on the surfaces that the Gasket will Seal.

When the stuff cures and forms it seal, ... It will NOT leak.

 

How about Gaska-cinch... I have some of that...

 

A small Bottle of Indian Head is less than 3-Buck.

I never heard of Gaska-cinch.

I go-back 40-years with Indian Head.

 

You can also use high-tack spray gasket sealer, also leakproof once stuck.

But back to your original question, it sounds like you've got the wrong o-rings, or are you trying to re-use the originals?

 

I have the gasket kit for an 81' 650 xj. Everything else seems to match up so I am pretty sure these are the correct o-rings. I guess they could be for a 750... or are they just thinner sleeves?

 

well i coated the o-rings and grooves with gaska-cinch. That seemed to hold them in place enough so I could stuff them in the grooves and get the cylinder on. hopefully ill have no leaks... I will try to post some updates of my project soon...