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Discussion Starter · #1 ·
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I had a nasty antifreeze leak which i originally thought was a head gasket but turned out to be an o ring on the thermostat assembly.

heres a link so you can see the parts in question:

http://www.bikebandit.com/houseofmotorcycles/honda-motorcycle-gl1100-gold-wing-1980/o/m2328

-click cooling system
-thermostat schematic

the parts im dealing with are
2
14 (o ring im having trouble with)
5

Ok, here's the problem. The old o ring was stretched and broken so i ordered oem honda o rings to replace them with. I made the repair and started the bike up and that o ring failed again in the same exact place as the old one, but this time it didnt break....just stretched out. As i install the o ring it walks up on the lip of the pipe as i shove it in. If i put the o ring in part number 2 and then shove the pipe in, the o ring deforms and does not seal.

I am stuck and dont know what to do next. I tried fatter o rings of the same size but i cant get them into part number 2 if the o ring is on the pipe nor can i shove it into part 2 and then put the pipe in. It still deforms or just will not fit.

The pipe looks fine and im not seeing the malfunction there. It seems like the pipe should have a squared lip instead of a rounded one so the o ring doesnt walk up it as i shove it in.

Has anyone else had this problem? Can i just use gasket maker silicone to seal it without the o ring or something? I am thinking a hardened o ring exactly like the honda oem one would work.

Thanks in advance
 

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Are the fittings clean and smooth?

Are you using plenty of lubricant?
 

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Discussion Starter · #4 ·
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just tried lithium grease but the oem o ring is tooo stretched out to work now as it just does the same thing when i try to install it.
 

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Discussion Starter · #5 ·
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i have some red high temp silicone. you are saying an o ring can be made with it? how long will it hold?
 

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Discussion Starter · #7 ·
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i originally put the silicone on the oring and it didnt seem to help much.
 

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Well, the first time I redid those O rings I had alot of difficulty with the OEM seals.
Since then I use O rings I got in a metric O ring kit from an auto parts store.
As long as they fit snug and everything is clean, together with the silicone life will be good.
 

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I feel your pain. I had the same problem and ended up having to reorder the o rings. The best thing I can tell you to do it make sure you have the two metal pieces in perfect alignment. Once you do that, it slides in much easier. And, I used dish soap as a lubricant.
 

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I used Orings from a metric O ring set I got from harbor freight, smear em with a little coolant and they pop right in with no problem and no leaks.
 

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Discussion Starter · #11 ·
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i went to advance auto and bought some o rings. oem is 29.9x2.3 i think

i got 22x28x3

looked like it would fit but they didnt work. i have ordered 3 more oem o rings from the local honda shop which should be in friday.

im having a hell of a time getting these things to work lol, lube, dish soap or gasket maker..... ill keep trying

thanks all
 

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Harbor Freight has a metric o-ring kit full of different sizes for under 6 bucks. Well worth the investment.
 

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My method has been to make sure the surface is flat and clean. Then I install the O ring in the housing with siicone sealer to hold it. I let it cure for a while and then install. So far that has worked fine for me.If I had corrosion I'd use more sealer.
This seesm so obvious, but have you put the housing on a piece of fine sandpaper on plateglass (I actually use a marble cutting board) to make sure the housing is not warped?
 
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