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How bad will this task be? Base gasket...

Jethro

Jethro

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After replacing valve cover, tensioner, head, and tach drive gaskets and seals, I'm now almost positive my base gasket is the culpret of my heinous oil leak. So obviously I have had the head off and know what that entails, and I've taken the barrels off my 81 motor (still apart), so I know how to get it apart. The problem is that the motor has awsome compression, I'm real upset to have to pull the barrels off when it's got good compression. So my questions are these:

1. How bad is it to disturb the barrels when the motor is running fine?

2. Will I absolutely have to get new rings and hone the barrels? Is it foolish not to do so? Do I just go to a machine shop and ask them to hone the barrels? Do they tell me what size rings I need?

3. Cam chain isn't stretched beyond tolerance. Is it foolish to not replace it?

4. Is there anything I haven't thought about that needs to be done at that point? New bolts, components, etc.? Everything seems healthy, other than the leak...

5. Should I just let this thing leak instead until it needs rebuilding?
 
I seem to remember having the jugs off my 83 GS750ES at around 25K miles but really don't know why I would have taken them off. There is no reason to change the chain or pistons or rings when you remove the jugs. If it ain't broke don't fix it. If the motor has signs of impending failure (low compression, chain tensioner almost at limit, bad sproket or chain, burnt pistons, etc.) then it would be good to do a complete rebuild. But if its running OK replace just the gasket and be done with it. When reinstalling the jugs BE SURE THE RINGS MOVE BACK INTO THE GROOVES AS YOU WORK THE JUGS ON.

As for the bottom gasket being the problem I'd really look carefully. The oil does not accumulate at the bottom edges of the jugs. In order for it to leak out there it would have to be splashed onto the bottom of the jug move up the outer circumference and then make its way past the gasket. You might be wise to see if the crankcave venting is OK. I guess it could leak there but it just doesn't seem likely.
 
As for the bottom gasket being the problem I'd really look carefully. The oil does not accumulate at the bottom edges of the jugs. In order for it to leak out there it would have to be splashed onto the bottom of the jug move up the outer circumference and then make its way past the gasket.
Click to expand...

I hear ya man, I thought the same thing. That's why I went to all the effort to replace all the top end gaskets, but it's still leaking, and it sure looks like the base gasket. I've got the crankcase breather routed back by the battery becasue of my pod filters, maybe the extra length of the hose is a bad idea? Ever hear of that causing a leak? I don't lose much oil, not even a noticeable amount between oil changes, just hate having a leak under my beautiful bike.

Gonna replace my cam chain tensioner gasket tonight- for $6.95 it's worth a shot, but I've checked it before. I'll keep ya posted. Thanks for the reply.
 
Howdy Jethro,

I just replaced 90 percent of my gaskets on the 850. I was hesitant to replace the base gasket because I thought I would have to replace rings and have the cylinders honed ect. But, my base broke loose when I was taking the head off. I had to replace the gasket. I decided to run with the original rings. So far I haven't been disappointed, whew.... I don't burn oil. I have don't a compression check, so I don't nknow wehere I am with that. The way it runs, I'd assume compression levels are fine.

Rick
 
Rock on, guess I'll tackle it then. This better do it, I've got over 8 manhours into trying to get this fixed already. :evil:
 
I know you mentioned you got the tensioner gasket, but have you rebuilt the tensioner itself? I had a leak that sure looked like the base - I even got a mechanic to look at it and he thought it was the base because "oil always flows back."

However, I've been cleaning the bike after every couple of rides and no oil accumulates around the base but only below the tensioner. I guess gravity and vibration overcame the wind and sent that oil forward. I have O-rings and all, I just need to get out there and get it done. I am 90% sure that will fix my leak.

I think it might be worth $5.00 and a couple man-hours to try rebuilding the tensioner if you haven't already. bwringer's site has an excellent how-to on the process.
 
Yeah, I rebuilt the tensioner a month ago. And put a new gasket on the mount flange, but I do have another new gasket, so it's worth a shot.
 
I think it's the cam chain tensioner gasket. Idiot.

Anyone need to buy a new OEM Suzuki head gasket?
 
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