Repair / Repairs / Remove a hard old gasket without gouging the faces

Repair

Remove a hard old gasket without gouging the faces

Rider jobNo special toolsTime: 1 to 24 h (soak time) (estimate)

Gaskets on old or hard-used bikes can bake onto the metal. Scraping them dry scars the faces and causes leaks later. A spray remover softens the gasket first.

Safety

  • Use in a ventilated place, away from flames. Wear gloves and eye protection. Follow the label.
  • Do not use a steel blade on aluminium faces. Use a plastic scraper.

Steps

  1. Remove the cover or part and the bolts. Do not pry on the faces.
  2. Spray gasket remover over the whole old gasket. Spray type works better than the brush-on type.
  3. Wait an hour or two. For a very hard gasket, spray again and leave overnight.
  4. Scrape off the softened gasket gently with a plastic scraper.
  5. Clean the faces with solvent and a rag until bare, and dry them. Look for nicks and warping.
  6. Fit a new gasket and seal as the manual says: Replace an engine cover gasket, Gasket sealant.

Check your work

  • The face is bare, smooth and free of old gasket and sealant.

If it did not fix the problem

  • A deep gouge or a warped face: ask a workshop whether the face can be dressed, or fill small gouges with liquid gasket where the maker allows it.
Sources

Values marked K-Light 125 are for that reference bike. Use your own bike's manual for its values. Text CC BY-SA 4.0, Transitions Lab.