Blown headgasket - oil all over the place!!

[Guest]

Well I have just come back from what was to be the bikes first decent run since fitting a fresh engine, as per my previous post. Well I went to see a friend about 20miles away, when I got their my left foot was covered in oil, yuk!! Drip, drip, engine covered in oil as is the casings and the swing arm. Is it worth just re-tightening the head bolts or is it time to strip it down and do a complete re-build. Any advice welcome, I do not know the history of the engine but its compression was over 150psi on all the cylinders before I fitted it.

[JTGS850GL]

Where is the oil leak coming from? It could be something simple like a tach drive o-ring or a valve cover gasket. Pictures would help.

[hikermikem]

or a starter o-ring...

My 1100 leaked from a shot starter o-ring & the result was a left side oil leak over all the parts/foot you have noted.

[Agemax]

yeah, find the source of the leak first before you decide the way forward

[UK-GT]

How do you upload a video??

[hampshirehog]

You can upload it to a photobucket account. There might be better ways but at least I found that way simple.

[Agemax]

upload it to photobucket or similar photo sharing site, then copy and paste the link onto here

[UK-GT]

Sorry for the image size:

http://s994.photobucket.com/user/sysmanuk/media/DSCF0940_zpsa7c5f557.jpg.html

and

http://s994.photobucket.com/user/sysmanuk/media/DSCF0947_zpsc959be5b.mp4.html

[Agemax]

doesn't show where its coming from. shoot a vid from nearer the top, around the valve cover area

[JTGS850GL]

Clean off all the oil with degreaser and then start the engine. See where you get wet oil first. A leak that bad should show up pretty fast.

[UK-GT]

The oil looks like it is running down one of the head studs and then along the fins (http://i994.photobucket.com/albums/a...ps78534799.jpg).

Things to check:
1-Condition of plugs.
2-Compression Check
3-Double check what the PO had torqued the head bolts down to.
4-Buy some more Gunk and clean the head and cover in talcum powder
5-Run engine and check for the leak again.
6-?????

[49er]

On some aftermarket head gaskets (Vesrah as example), a separate seal is supplied for each of the oil ports around those 4 outer studs. If they haven't been installed correctly or have been missed all together, oil will leak out as you've described.

But, before ripping the head off, check that it has been torqued correctly. It should be 27-30 ft lbs. It's a pretty severe leak, so I'm leaning towards the seals not being installed.

You may get lucky and re-seal that area, if the torque figure is way too low.

Good luck.

[UK-GT]

My old engine has low'ish compression (120psi) and a top end rattle but cosmetically looks OK as does the gearbox etc. The new (to me) engine had high compression (over 150psi) but no rattle but cosmetically its a mess with a couple of fins on the head bent, paint peeling etc and the clutch is very heavy. I also have a spare head with a box of valves,springs etc which looks in very good condition.
I am thinking of using the bottom end (gearbox etc) from my old engine (good clutch and gears), the block and pistons etc from my new engine and the spare head. It will then keep the original engine number.
I have a Suzuki NOS Head Gasket, a complete Full OEM gasket set . New Oil Filter & 5l of Millers Oil.
I am thinking of getting a Valve Compression Tool (£13 from eBay) and a Valve Lapping Tool with Course/Fine Lapping Paste (£9). I am also considering a 51mm - 177mm honing tool (£15).
Anything else??

[hikermikem]

New OEM piston circlips

Rebuild the cam chain tensioner

New valve stem oil seals


I use aftermarket ones from Z1 here in the states with no issues, and less than half the price of OEM:

http://www.z1enterprises.com/ItemDetails.aspx?itemDescription=Valve+Stem+Seal+Suzuki&item=KL14-6386-1

[UK-GT]

Well, I've made a decision. The engine is coming out and its going to be stripped and a good engine made out of the 2 engines & spare head I have.

I have got already/on order:

• Suzuki Head Gasket.
• Complete engine OEM gasket set (has O rings, valve stem oil seals, clutch cover gasket etc..)
• 5l Oil
• Oil filter
• 8 new Gudgon Pin clips
• Torque wrench
• Valve spring compression tool
• Valve lapping tool & paste
• Normal & long reach 1/4" & 1/2" socket sets
• Loads of spanners.
• Clymer manual and associated downloaded manuals
• Compression Gauge
• Micrometer

Anything else you can think of?


Oh, I've also got an assortment of hammers, just in case

As mentioned earlier, while the engine is out the frame is going to be blasted and powder coated as well.