Can't get my cylinder jugs off

I have tried prying a bit, but I am loathe to break a fin in this process.

Any tips for getting this sucker off?

I thought about putting a piece of wood block over the head studs and using two clamps, one on the front and back of the cylinder jugs. But I don't know if that might damage the studs or lower case.:dry:

I had to use a tire iron where I milled the tip to fit the cylinder pry gap exactly so it would give max lift. My cylinder base gasket was sealed on at the factory with something like 3-bond sealer. It sealed so tight, the gasket clung to both surfaces and I had to tear it apart as I pried it off. It was a real bugger to get off.

Jodyb17 wrote:

I have tried prying a bit, but I am loathe to break a fin in this process.

Any tips for getting this sucker off?

I thought about putting a piece of wood block over the head studs and using two clamps, one on the front and back of the cylinder jugs. But I don't know if that might damage the studs or lower case.:dry:

on the big bikes i think there is a slot near number 4 on the lower perimeter where jugs meet the case.....edit...yup just checked there is one..try that yet?...hopefully yours has one also....g/l......

Yeah, my bike has a slot on each side by 1 and 4 for a screw driver.

I managed to pry it loose using the clamps, the biggest screwdriver I could fit into the slot with a wrench on the handle. Whatever they used on the gasket worked well.

After I got the cylinders free from the gasket, getting them off was a supremely colossal bitch. I'm understating it there. Am I a wuss or these typically this tough to remove?:blink:

How is this done in the shop? Bike mechanics earn their money for damn sure.

I don't know how I am going to ever get them back on. I guess I'll tackle that later.

Once it's free at the base, it should not be hard to slide the cylinder off the pistons unless it's rusted or some other bizarre problem.

bountyhunter wrote:

Once it's free at the base, it should not be hard to slide the cylinder off the pistons unless it's rusted or some other bizarre problem.

Agree with bountyhunter...once the jugs are free of the cases, they should slide up and off the pistons relatively easily.

Well there was a bit of surface rust on the wall of #3, but it was above the piston. It was most difficult to get them off of pistons 1 and 4.

Other than rust, does this indicate a problem? Engine turned over pretty easy with the kick starter.

I'll post pictures of my pistons and cylinder soon.

This is a pic of the 3 and 4 cylinders. Its tough to take a picture of em, but this is how they look.

This is piston #1. It was the only piston with a stuck ring. Its the middle ring.