Due to oil leak at the mating line on the front cylinder of my 96 FXDL I decided to replace the head and base gaskets (no leaking prior from base).

Everything going ok, just waiting on gaskets to arrive and all I need to do before reassembly is remove old gasket from cylinder base.

I couldn't see where the leak was occurring, the old gasket didn't show any damage. I set the head back on the cylinder without a gasket and there is no rocking so it appears the surfaces are flat. All of the head bolts seemed to be torqued fine.

At any rate, one thing that was strange was that one of the head bolts (front outer) appears to be oxidized/rusted. See pics? I will certain run a thread chaser through that bolt with oil before reassembly. Wonder if anyone has seen this before and possible causes?

Rust/corrosion inside bolt




Oxidized bolt

 

It just happens over time. 26 yrs of time.
Do like you said and clean it up. Ya might move that one to where it,s not seen

WP

 

Also, yes to lubing the head bolt threads, just don't use to much. Also a light coating of lube the underside of the flange to each of those head bolts where they make contact with the heads for a more accurate torque value.

 

Agree with the others…..but, could replace the head bolts if you wanted. They’re cheap enough.

Other than that….I would consider doing the rear as well depending on mileage. Basically nearly there with much labor already behind you.

 

I too would replace the bolts, and chase all the threads. That's if you can get them. It seems like everything is on backorder.

 

Nothing out of the ordinary in photos, so all that's been covered. I agree, you should do front and rear especially since you've already ordered gaskets and you're 2/3 the way there already.

Note - unless you ordered teflon or copper head gaskets, most head gaskets including OEM no longer use the o-ring on the cylinder drains, just so you know.

 

Ok...enough of you have mentioned it I guess I will pull the other jug and replace both cylinder head and base gaskets. I ordered these gaskets here. Cometic was mentioned in another thread but like everything else they are out of stock. I'll try to find some new head bolts if they are available as well. So with these I would not use the o-rings, correct?

Thanks everyone!

 

Also, bike has 16k miles on it.

 

Correct. They will not be in that set. I mentioned it because your originals are the earlier OEM style that did use o-rings.

If you pull the cylinders and pistons together, you will need to replace the wrist pin locks that you remove. Be sure you get them for OEM pistons. Different manufacturers use different locks, some will interchange, others will not, so don't chance it. And again, do not re-use the lock rings you remove.

If you leave pistons on the rods and remove cylinders only, you will need new rings (Hastings 2M-6164) and to lightly hone with a 240 or 260 grit ball type hone. No torque plates required for that.

Wrist pin locks: part# 22589-83B Most retailers keep them

 

Ok…I’m trying to get rear rocker box off. I got the 4 Allen bolts out but I can’t get the top cover out because off no clearance between the frame and the rocker box.
Are there any tricks here?