Base gaskets...is it time?
Tourer
Joined: Mar 2014
Posts: 351
Likes: 0
From: Colorado
The Evo section answers and repairs this problems all of the time and the answer is............This is a perfect time to install 9.5-1 pistons and a EV27, those little bubbles always excites "more power" caveman instincts of this section. I am not one of the power addicts of this section and you can trust me when the time comes 
Dirt don't hurt
Joined: Jan 2011
Posts: 21,065
Likes: 4,561
From: Haslet Texas
If I had it to do over I wouldn't do it.
Just my 2 cents.
Thread Starter
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Tourer
Joined: Jul 2013
Posts: 273
Likes: 35
From: Central MD
Thanks for the reassurance folks. Apparently it looks worse than it is. I put some paper towels under it overnight and not a drop off the case.
Uncle Larry- Not running synthetic, and it was at operating temp when I took the pics. It was the first time I fired it up this season though.
Glidein- Will double check the vent system, thanks.
Hack'd- It already has a SEIII cam in it (which I think is equivalent to the EV27). If it can wait 'til next winter, we'll see how crazy I want to get with it. Reliability is most important to me. I've got 76K on it, and was hoping to reach 100K without too much nuttiness.
I cleaned it up and put a bead of flowable silicone (Permatex 65AR) over the area. Hopefully that'll get me through the season and through a 2800 mile vacation this summer.
Uncle Larry- Not running synthetic, and it was at operating temp when I took the pics. It was the first time I fired it up this season though.
Glidein- Will double check the vent system, thanks.
Hack'd- It already has a SEIII cam in it (which I think is equivalent to the EV27). If it can wait 'til next winter, we'll see how crazy I want to get with it. Reliability is most important to me. I've got 76K on it, and was hoping to reach 100K without too much nuttiness.
I cleaned it up and put a bead of flowable silicone (Permatex 65AR) over the area. Hopefully that'll get me through the season and through a 2800 mile vacation this summer.
Road Master
Joined: Jan 2012
Posts: 856
Likes: 9
From: North Carolina
The base gasket job isn't difficult, just time consuming. Half of the time for me was spent scraping gasket. I was very careful not to goober up the aluminum. I once read about a guy that claimed that he let a base gasket go for a while and when the base gasket got real sloppy it caused the head gasket to go. I used Genuine James base gaskets and HD everything else when I did mine.
Outstanding HDF Member
Joined: Nov 2013
Posts: 2,358
Likes: 34
I second this. The worst part is removing the old gasket, I spent a ridiculous amount of time trying everything on it. If I did it again I'd pay someone to clean the head and cylinder surfaces and I'd also buy the rocker box tool instead or using a cut Allen wrench.
Tourer
Joined: Mar 2014
Posts: 351
Likes: 0
From: Colorado
Thanks
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Outstanding HDF Member
Joined: Oct 2007
Posts: 2,114
Likes: 67
From: USA
Freshened up the top end on my ’96 springer last fall @ 36K miles. My base gaskets were leaking worse than yours. Stock pistons were cleaned and reinstalled, new rings, new EV27 cam and new roller tappets. Bike runs great and very pleased with performance.
Seasoned HDF Member
Joined: Aug 2008
Posts: 5,080
Likes: 2,153
From: Ohio
There is no reason why a 75 hp Evo equipped with a CV cannot get 45-48 mpg, turning screws and guessing at jets is just a guess in tuning so struggling an efficient engine cannot produce.
It always comes down to what the owner wants, If the owner is satisfied with a flat sounding Evo exhaust sound then that is what matters it is his bike and the motto of the Evo section and money plays a part in engines, will snowball until completed so if cleaning up 8.5-1 pistons for a budget reuse is what many applaud plus working on a bike in your garage is about, if wanting a little giddy up by efficiency then compression will work and not a hidden secret.
Yes those base gaskets become harder than a wedding d$!k and can destroy a set of cylinders trying to get then off, alot of neat tricks in these forums on a home method of truing bases up for reuse