I haven't done anything to this stove for 8.5 years, other than cat maintenance and one cat replacement. I guess it was due for some gaskets. I found a piece of the bypass door gasket in the firebox. After ordering a gasket kit, I broke the $8.50 U-bolt that opens/closes the bypass door. Woodstock added it to my order. The gasket kit comes with good instructions, pictures and labeled bags. WS also has how to videos on YouTube. The instructions don't include removing the top. I Highly recommend it. It's two bolts. Much easier access. I wouldn't want to do this job through the flue and block off plate openings. They have a YT video for removing the top. All the gaskets underneath were still looked new. I didn't replace them. WS uses anti seize during assembly. The only bolts or nuts that were tough were the Allen head bolts on the flue and block off plates (that I've had out before and didn't anti seize). I used penetrating oil on them and let them soak, then used a 1/4" impact. Everything was reassembled with anti seize and not overly tight. The cat and bypass door gaskets were the only ones I replaced. The loading and ashpan doors gaskets were nice and tight with the dollar bill test on all four sides. Flue and block off plate gaskets looked fine and never see movement.
Wow, what great timing. I just ordered a gasket kit for my Keystone as well. I was thinking it would be a PITA to do it through the flue opening. Good to know the top comes off so easily. I've been getting a smoke odor after I close the bypass. I just replaced the ash pan gasket, so I suspect its either from the door or the glass, but the bypass one was looking rough, so I just plan on hitting them all while its apart.
There are set screws(bolts) on the bypass door hinges. The YouTube video walks you through properly setting them. I don’t think it was mentioned in the instructions because they didn’t call for disassembly/removal of the bypass door.
The instructions don’t call for a removal. But unless the top is off, you won’t be able to open it far. You’ll be working underneath it. I removed it just to re anti seize the bolts, mainly. Tension would need reset regardless, I would think.
