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22-10-2015 XB9S 2003 replacing base gaskets
24-10-2015 - What did we do today 22-10-2015 XB9S 2003 replacing base gaskets
bike cleaned, and ready to strip
pita 2003 intake stack, glad Buell only had this on the 2003 models
throttle cables out the grip
old model fuel line, push the line forward, press the red tab , and pull it off ( carefull if you just primed the ignition there can be fuel pressure left )
loosening the clutch cable
rear axle loose, to remove the tension on the belt
What did we do today., idler puly bracket off
and exhaust removal , this exhaust douse not use the stock bracket
left foot peg bracket off, other wise this will poke in the primairy cover
supporting the weight off the engine with a flat jack
and unscrew the front mounting bolt
header nuts loose , always a gamble if there corroded and seazed
lucky... need to buy a lottery ticket , al nuts come loose , take off the header
unplug the injectors and tps sensor
and loosen and remove the intake manifold
as the heads need to come off , remove the coil bracket
and the top mount for the tierod
intake manifold off , nasty gaskets
and rear sparkplug wire id gone
so rocker box cover off
and start unscrew in the 9 bolts holding the rocker box , start with the some ones and do the 4 big ones last
a rag placed on the rear right corner will help to catch the oil comming out when you take off the cover
front same procudure , cover off
rag right front to catch the oil
some one asked some time ago, what is the effect off mineral oil, whell it breaks down more under heat, this bike is been running some time with mineral oil , hence the brown coat inside the rocker box , and it has a typical smell to
bump sticks out , there color coated, but when the markings are gone, the long one is exhaust
little breaker bar to loosen the headbolts , there tight,
the stock head gaskets will stick when there some time in, a little tapping with a tumb detector will break it
off with the heads... looking good , valve look good, not to much carbon ( 35000 km )
for now i secure the cylinder with some nuts ( these are special made for this ) but you can use the short head bolts and a socket
and the same story for the rear head, but with a longer extention , rotate the engine down to the happy spot so you have a good grip in the bolts
rocker covers off
and pull off the cylinders
some rubber hose put over the studs to protect the piston, rings look ok, not to much wear , and no play on the pision pin
the part it all started it , sweating base gaskets
rear piston looks good to
now the fun begins.... moment off mediation and concentration not to chisel the cylinder bases
one down , on to go
cylinders cleaned , degreased and coated with a light coating off assembly lube
pistons cleaned, check the slot gaps for position, importend put the base gaskets on, and piston mounting clamp ove the pistonring
and pushin the cylinder over the piston, screws on for now, and front cylinder first
front one the same
now first the pushrod covers back on
heads cleaned and prepped, mount the upper pushrod cover o-rings in the heads, with a litle oil on the o-rings
cylinder head on... first push the o-rings over the pushrid covers than find the position dowels in the cylinders , doing this other wise can nick the o-rings to easy and can cause theme to fail after 3-400 km ( oil leaking ) you really don't want to do this twice
cylinder head bolts, few drops off oil in the threads, and on the flange
and tighten down in steps
bump sticks back in , rocker cover gasket on
postion the rocker box , and start all the bolts first , than start tightening with the 4 big bolts evenly and give the lifters time to bleed, 4 big bolt to 22 Nm and the 5 little screws 14 Nm
cover back on... this one is ready
do the same for the rear one , keep a eye out on the temp sensor cable , you will be not the first to pinch this cable between the covers wink-emoticon
something can help a little , spary a little oil on the valve springs and rocker arm , just to easy the wear on start up , it take a while before the oil is up there
coil bracket back on line this one out in the middle and top mount back on
headers back on , take care off the O2 sensor wire so you will not pich this in the rear port
intake manifold back on
don;t for get to put the breather valves in before you rotate the engine back up
engine back up, and hool up the top side
ready to rumble
and with 1 push off the starter, she is smoking, and runs nice ... i let here heat up for some time to check the gaskets as they can sweat a little
so far so good... she is dry, airbox back on
and test ride to morrow , i leave the scoop off for the test ride, to check for leaks and sweating after the test ride