Engine rebuild question

During the process of removing the cylinder head on my bike, my cylinder block came loose from the base gasket. I currently have about a 1.5mm gap. What should be my next step? Remove the cylinder block entirely and replace the gasket? Or should I push the block back down and reinstall the head when ready?

The engine has 8k miles and I don't have new rings or a hone. Just thought I'd throw that out there for consideration...

i just redid mine, if you are able to see with a flashlight and its not damaged. but i would replace it,

Depends. Can you see the gasket surface? If the gasket is separating (breaking apart), should be replaced. If it came off clean and looks good, you might be able just to torque it all back down.

What I would do: if the cylinder head is free from the gasket (and the gasket looks OK) I would carefully lift the cylinder up a little bit being careful not to raise it high enough that the rings come out. Then I would apply a thin bead of sealer like yamabond or Ultra Black on top of the base gasket then set the cylinder down and use the head to apply a little pressure to seat everything. Let it cure.

YMMV.

I'm not sure if your suggestion is possible. Despite draining the oil, the gasket became completely saturated with oil when the block pulled away.

If it's not torn, I'd just bolt it back down.
Steve

83KZ750LTD wrote: I'm not sure if your suggestion is possible. Despite draining the oil, the gasket became completely saturated with oil when the block pulled away.

Was there a leak there before? I just wonder how it became saturated with oil.

If not, it might seal by re torqueing.

No way I'd even consider reusing that gasket. The old gasket is guaranteed to be hard as a rock and brittle. VERY likely to leak in the near future. Regarding replacement gaskets, OEM Kawasaki gaskets are far superior to aftermarket. Particularly Athena brand gaskets which are pure junk (the green gaskets). Not worth the risk.

Replace the base gasket. I would find a new set of rings and have the cylinders honed so the rings seat quickly. Use genuine Kawasaki gaskets, o-rings and valve seals. It's always cheeper to do this work correctly.