Top End Tear Down

[chuck hahn]

get a service manual from BIKECLIFF website. basically you loosen them opposite the torquing pattern.

[HaggisHombre]

Could not get cylinder head off, then all of a sudden the whole thing came of in one, phew what a struggle. Here are some pictures of wear. The cam lobe that presses against the shim that appears to have the blemished finish is not scratched but it also has a mark. As you can see this piston has some markings. I have not had a chance to do a full inspection yet.

The page is not letting me upload images at the moment, not sure why.

[JTGS850GL]

Post pictures on a piture hosting site like imageshack, photobucket or tinypic and then use the insert image icon above the message window when creating the post. Use the direct link url to the picture and insert that when prompted. Works every time.

Here's a writeup on how to do in from BikeCliff's web site:

Posting Pictures To GSR

[HaggisHombre]

Here are the pics.

[Nessism]

Looks like some piece of foreign material got into the shim. I'd check it and replace the shim as necessary, or maybe flip it over.

[JTGS850GL]

Have you seperated the head from the cylinder block? Looks like they're still attached.

What do the cylinders look like inside?

What does the top of the cam lobe that has the score mark look like?
Can you feel the grove in the lobe with you finger nail?

What do the valves look like?

Do all the shim buckets turn freely? Some exhaust buckets seem to get tighter over the years and don't rotate as freely.

Pistons look normal to me but I'm sure others will chime in. The pistons could use a little decarbonizing. I would still consider new rings into the mix if you're going through all this trouble. Baring anything unusual on the cylinder jugs I'd just hone them for the new rings and be done. You may also want to run a staight edge along the head and deck at various angles to make sure everything is still flat. If not, it shouldn't cost much to have a machine shop clean them up.

[HaggisHombre]

Yeh they are still attached ha ha, now that I think about it not sure why, is there dowels? I was exhausted and thought a rest was in order before continuing. I will go out later today and report on my findings.

[JTGS850GL]

There are two (I think) locating dowels on either side of the head and one hiden bolt at the front center (exhaust side) of the engine that connects the cylinder block to the head. That bolt can not be seen from the top of the engine.

[chuck hahn]

And the two at each end of the head by the 1 and 4 spark plugs...10 MM.

[HaggisHombre]

Hi thank you, I did remove the two on the end and my engine is pre the third bolt. I have seen one engine that has the molding for the bolt but no hole, mine does not even have the molding for that third bolt. All good thoughts though. I am sure it is just the gasket, I will be going out there a bit later tonight to find out.

[chuck hahn]

Use a flat putty knife and tap it in along the seam around the head and work it to get things cut free. Dont twtst or pry..just drive it in and repeat around the perimeter. thing is to not score the surfaces as you do it.

[terrylee]

I just did this on my 850 and the new head gaskets from Suzuki should be all metal, and don't need the large o-ring around the cam chain opening. The metal gasket covers all that area. Found out the hard way when I tried to install the o-ring and it got squished out when trying to tighten head down. terrylee

[HaggisHombre]

Turns out it was a corroded dowel, at last I got it apart thank you for the suggestions. The head gasket on this bike was an aftermarket and it had no leaks. The base gasket however did leak, I do not know if that one is aftermarket. The cylinders look good, now I will measure them. The head defiantly needs a good clean lots of carbon.

[HaggisHombre]

Thank you for the information on the OEM Gasket.

[chuck hahn]

Those 3 exhaust valves look like they have gotten pretty hot. Best to check all the valves and seats as well since they are right there for the doing. Recut the seats and have the valves refaced.

Check with the local shops and take the head with you to show them what you are up against. Or if your familiar with doing the work yourself....