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Discussion Starter #1
Greetings!

My Legend TT 900 was standing for 15, now trying to recover it.
Cylinder head leaking coolant at the back and left side, radiator is also leaking and oil was diluted with gas. Third carb butterfly valve not turning. Gummed gas all ower the carbs. Gas tank contained half liter solid rust.
After reading some topics and articles decided to replace the head gasket. This is however really expensive... considering the other repairs still need to be done. Then, luckily, i found this "When to retorque head bolts?" topic here containing vital informations.
First, they should be retorqued? I missed it, my ride has only 5k miles. I will give it a try tomorrow.
Second, the head bolts can be reused! Any more confirmation on this would be great. Dont want to break the bolts or the threads.

And finally some pictures.
 

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Discussion Starter #4
Ok, wrench on the way to me, i will get it in the afternoon.
Meanwhile, i was looking for alternative sources for head gasket. It is around 80 pounds from the UK. Desperately, contacted the hungarian dealer, he was also surprised how expensive it is for this model. Price is well over 100 pounds.
So called one of the manufactures making head gaskets based on samples. Initial price is around 20 pounds.
Anyone has experience with non OEM Triumph head gaskets? Are they any good? Any known alternative source with quality confirmation?
Thank You!
 

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Wrench arrived, set it to 30Nm but no turning of any screws only clicks. My hope of simple retightening is gone.
Cylinder head tear down comes tomorrow.
For the radiator, i can skip it from the circuit and fill up the engine with coolant/inhibitor to prevent further corrosion until the radiator comes back from repair.
Inside of the tank looks promising after washing with solvent, flushed with water, left with citric acid solution for a few hours then washed with washing soda solution a few times. Now filled with dedicated rust remover. Half day of work and still not completely clean.
 

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If coolant is leaking from underneath the head probably your gasket is started to despair.
After 15 years of standing head gaskets likes to rust. Mine was standing for 11 years and thanks God I decided to take off the cylinder head. Now I regret that I didn’t took pictures of damaged head gasket. Motos ODO was only 3500miles.
About bolts: can you imagine how much work it would require if any of them brake during torquing, they are working in coolant in that engine so you can just imagine how they look like after 15years of standing... I threw out my old bolts...
my one advice is: don’t take shortcuts with your bike. Anyhow I wish you good luck with that project.
 

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Discussion Starter #8
Thank You very much!
We will see how the bolts and threads look like tomorrow :)
I am afraid that not only the gasket but the head is also corroded :/
 

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Discussion Starter #9
Wow, i just received confirmation on a car repair forum on a local gasket manufacturer. More members say they make quality products. Moreover, once they were supplier for Triumph. Maybe they have gaskets on stock or no need the sample.
 

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Wrench arrived, set it to 30Nm but no turning of any screws only clicks. My hope of simple retightening is gone.
If you want to try retorquing them, you need to loosen them about 1/4 turn first, then retorque. The torque required to break them loose is always higher than the torque used to tighten them. Do them one at a time, (loosen one, then re-torque it,) in the order specified in the service manual. Don't use the torque wrench to break them loose.

That said, I think the likelihood of success is negligible. It's not leaking because they loosened up, so tightening isn't likely to help.

I don't know if it will work with a wet liner engine, but we used to make head gaskets out of soft copper sheet, back in the day...
 

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Discussion Starter #11
I don't know if it will work with a wet liner engine, but we used to make head gaskets out of soft copper sheet, back in the day...
Thank You!
Haha yes, for my 1956 two stroke Pannónia it would be ok :)
I have found the right shop making gaskets after the sample. Getting a coffee and starting the head disassembly. Wish me luck :laugh2:
The problem is that the radiator repair shop answered that they are not repairing motorcycle radiators :(
 

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Discussion Starter #12
The gasket manufacturer had one gasket on stock for my bike. I will get it tomorrow.
 

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I can not access some cam cap screws with the torque wrench when it comes to reassembly. Two which are closest to the cylinder head to frame mounting points and the one over the intake cam mid cylinder closest to the frame.
 

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Going step by step according to the factory manual... and bang! Those two head to crankcase screws at the front between the exhausts is missing from the steps. And i was wondering why i could not lift the head. Then noticed that the back is already lifting some half mm so something is keeping the head back at the front. Be careful!
I was very efficient with supporting the engine i think :) With the first height setting the head to frame screws had no restriction. the thick oak plate is supported by two car jacks.
I could not pull out 3 head bolts only remove them with the head.
Also finished cleaning the tank. You can see it drying with a hair dryer :) Added some oil after that.
Please comment on the pics, especially on the condition of the head and crankcase meeting surfaces. Is this a common sight or very bad?
Now some problems to solve. How to clean those surfaces?
How to clean the cooling jacket and the bolt holes?
Its fun to do this repair, really enjoying it :)
Some eye candy:
 

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Discussion Starter #16
Two more things. How to clean the black off the valves and head?
Head bolts were truly dirty. Just realized that they were standing in the coolant. However, after cleaning two of them i was surprised that they had only minor surface rust. Moreover, the threads were nice clean. I will check the others as well carefully.
 

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Wow beautiful head gasket 😉
I did one additional thing: I took out cylinder sleeves (thanks to that cleaning of the all the engine tricky areas was easier) I checked if any of the piston rings ware seized (and they were seized, later you need to set them up as service manual is recommending) later resealed sleeves with Hylomar (you just need to mark which sleeves goes where) it is relatively easy job if you know what you’re doing. Cylinder sleeves are not attached in any way to the rest of the engine (only glued with Hylomar) You can buy hylomar in any bmw service. They got cylinder sleeves in their cars 😄
BMW part #81229400339

It’s good to do this when upper part of your engine is taken apart. Later when you notice that you have any oil leak through the piston rings or coolant leak because the cylinder sleeves are not sealed any more it gonna be bigger problem. It’s just my suggestion...
Great job so far.
 

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Discussion Starter #18
Wow beautiful head gasket 😉
I did one additional thing: I took out cylinder sleeves.
Great job so far.
Thank you very much, i was not aware of this. Sure i will check it!
Also noticed a small gap between the first and second cylinder sleeve. This is not a big problem then?
 

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Discussion Starter #19
Hylomar is very hard to get here, or i am a bit unlucky because the few shops i could find are out of stock.
I have bought some toothbrushes, gun barrel brushes to clean the water mantle and bolt holes.
 

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Hylomar is very hard to get here, or i am a bit unlucky because the few shops i could find are out of stock.
Have you tried at BMW dealership?
I gave you part number.
About the space between sleeves- don’t worry about it.
About cleaning the surfaces where head gasket was I used water sand paper grade around 2000 and dish sponge pads (not metal one, look attached picture) Maybe professional mechanics are using different techniques, but I’m not the professional mechanic 😄
You need to be gentle with those surfaces.
 

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