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Head gasket GS1000G questions

  • Thread starter Thread starter Matchless
  • Start date Start date
those crush gaskets have me a little stumped. How does your carburetor attach to the heads (if at all?)
 
heavy copper washer = under the acorn nuts
thinner copper washers (my best guess) are for the head oil-ways (on top of the head gasket)
the smallest washers i am trully puzzled about :-s



Matchless said:
Hi All, Thanks for all the replies, my gasket has no metal inserts the 3 layers are actually loose and just held together with 4 small studs.
Here is a picture of the copper gaskets that came with the set.
Left are the exhaust gaskets, then the 4 copper crush gaskets, then the four heavy copper washers, then 4 very small copper washers.
I am sort of trying to get everyting together before I open her up.
Click to expand...
 
psyguy,
You have actually hit the nail right on the head and I have since learnt the hard way. Once the topend is open I may need rings and valve guides and will need to find a supplier who will send usps. Do you know if z1enterprises stock those?
 
Schweisshund said:
those crush gaskets have me a little stumped. How does your carburetor attach to the heads (if at all?)
Click to expand...

Rubber intake boots with o-ring between the head and the intake boot. My gasket set is for the GS1000G 1980-81 specifically. Its actually a pity that gasket suppliers do not have a small parts list in these sets.
 
Matchless said:
psyguy,
You have actually hit the nail right on the head and I have since learnt the hard way. Once the topend is open I may need rings and valve guides and will need to find a supplier who will send usps. Do you know if z1enterprises stock those?
Click to expand...

in my experience jeff from z1 is very friendly, they can get many more aftermarket parts than what their website suggests and can get any suzuki oem part (takes another 10 days as they are not the oem stockists themselves)
 
psyguy said:
in my experience jeff from z1 is very friendly, they can get many more aftermarket parts than what their website suggests and can get any suzuki oem part (takes another 10 days as they are not the oem stockists themselves)
Click to expand...

Thanks, I have never dealt with them, but on your advice will approach them first. I actually only looked at their site and did not see everything. Its good to know.

I have a feeling that your guess on the 4 crush washers must be the closest. It seems that not many people so far have used the Athena gasket sets. Mine even has the intake o-rings included in addition to the header pipe gaskets and even including an oilfilter cover o-ring that usually comes with a filter. There was even one only, as small as the idle screw o-ring, wonder where that one goes?
 
Matchless said:
Thanks, I have never dealt with them, but on your advice will approach them first. I actually only looked at their site and did not see everything. Its good to know.
Click to expand...

what i do is i go to bikebandit.com look up the oem part numbers and the description on the micro-fiche and compile a list that i send to z1 in an email... :oops:
 
psyguy said:
what size are those 4 small washers?
could be #17 on this page
http://www.alpha-sports.com/suzuki_parts.htm
Click to expand...

Yes I think #17 is a possibility, it measures OD=10mm and ID=5mm and the number is 09168-0510. There are 4 and Flatout shows 4 required. I cannot see where they go but maybe for the intake manifold vacuum port screws.

The heavy copper washers are definitely on the outside of the head under the domed nut as I can see the old ones.

If you look at the diagram on Apha Sports the OEM gasket shows something on the 4 corner stud holes. The OEM may have a seal pressed in there. Mine has nothing and the holes are similar to the others maybe the 4 copper crush washers go there. I will only be able to see once I have the head off if the face on the head and cylinder is smooth there or has an indentation for this. That is if the washers are actually for the head at all.
 
psyguy said:
cam chain tensioner o-ring (#19) ?
http://www.alpha-sports.com/suzuki_parts.htm
Click to expand...

I overhauled my cam chain tensioner and replaced a larger 0-ring, a small seal and a smaller oring, but cannot recall such a tiny one. I see the part number shows 09280-06003 superceded by 09280-06005 and the measurements of mine are 3mm ID and 1mm thickness, seems much smaller. I now recall that the small one was the same size as Robert Barrs fuel tube o-rings 6mm ID x 1.8mm thickness.

My full gasket set then seems quite comprehensive if I include the rectangular one that is most likely only missing from my package.
Thanks again for the info and help.
 
Last edited:
I have the top end off and the head gasket looks the same as the one I have! Unfortunately the rectangularuat o-ring around the cam chain is mangled and unusable, seems like it was pinched so I will definitely need one.
Seems like the motor was overhauled by PO, still some honing marks in the bore, no ridge, heavy carbon on the pistons though. Will start cleaning and then measure.
Does any one know where I can get the next piston oversize dimensions? I would like to check what is fitted, standard or oversize.
 
Matchless said:
I have the top end off and the head gasket looks the same as the one I have! Unfortunately the rectangularuat o-ring around the cam chain is mangled and unusable, seems like it was pinched so I will definitely need one.
Seems like the motor was overhauled by PO, still some honing marks in the bore, no ridge, heavy carbon on the pistons though. Will start cleaning and then measure.
Does any one know where I can get the next piston oversize dimensions? I would like to check what is fitted, standard or oversize.
Click to expand...

Andre any oversize will be stamped on the top of the pistons. The rings and piston sizes go up in 0.25mm. So it will be .25, .5, .75 & 1mm. These are the four oversizes and will require new or used pistons to suit the bore oversize.
Cheers. Don.
 
psyguy said:
alphasports link in post #30 above
Click to expand...

I dont know if I am dumb or what (I probably am). When I click on the link it just takes me to the AlphaSports home page. Not to a page that shows any parts. Straighten me out please? Click on the link and tell me where I am going wrong.
Thanks PSY. Cheers. Don.
 
Suzuki_Don said:
Andre any oversize will be stamped on the top of the pistons. The rings and piston sizes go up in 0.25mm. So it will be .25, .5, .75 & 1mm. These are the four oversizes and will require new or used pistons to suit the bore oversize.
Cheers. Don.
Click to expand...

factory over sizes are .50mm and 1mm over, when I rebuilt my 1000 the .50mm first over size was not available, but the last time I checked they had made up a new batch.
 
you re not dumb suzuki don

you re not dumb suzuki don

the link doesnt work...
you can open year 1980 and scroll down to 1000g and then open the "head" link
thats the page i was talking about

Suzuki_Don said:
I dont know if I am dumb or what (I probably am). When I click on the link it just takes me to the AlphaSports home page. Not to a page that shows any parts. Straighten me out please? Click on the link and tell me where I am going wrong.
Thanks PSY. Cheers. Don.
Click to expand...
 
psyguy said:
the link doesnt work...
you can open year 1980 and scroll down to 1000g and then open the "head" link
thats the page i was talking about
Click to expand...

Thanks. I thought I was going mad and it wasn't working for me. Mind you I'm not the most computer savvy person in the world. Cheers.
 
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