Popping a head off GS1000

[Suzuki Mad]

A little while ago my cylinder head started leaking through the cam chain tunnel and through the head gasket on No1 piston side where the 'O' ring is situated. Usual things for these to go and I used to swap them out in the 1980's in an hour or so.

Now, nearly 35 years later I have to do it again.

So my question is any tricks or tips on getting a 36 year old cylinder head off without popping the barrels and having to get new rings, base gaskets, 'O' rings and all when I just need to do the cylinder head.

Cheers

[CrazyCloud]

Most will advise to do the base gasket when you are doing the head gasket; more than likely it will be disturbed and start to leak if you don't. I would check compression (after valve adjust)to see if it needed rings before tearing into it.
I think you can leave out the cam tunnel o-ring if you get the newer style mls head gasket.

[gsrick]

If you want to take the chance, you could run a strap around the cylinders so that it fits into the fins and then run a strap from one side to the other under the frame to try and eliminate any movement. Just be really careful with those fins. I'm thinking of trying that to replace the gasket on my 1000, let me know how that works out.

[Suzuki Mad]

In just doing a head gasket only it's a lot cheaper than the whole lot. Here in the UK you are looking at a little over £1000 just for the rings alone which is more than the bikes worth.

[gsrick]

In just doing a head gasket only it's a lot cheaper than the whole lot. Here in the UK you are looking at a little over £1000 just for the rings alone which is more than the bikes worth.

You don't have to replace the rings when doing the gaskets or removing the cylinders, unless there is a lot of smoking going on when it's running and they just need to be replaced.

[Nessism]

In just doing a head gasket only it's a lot cheaper than the whole lot. Here in the UK you are looking at a little over £1000 just for the rings alone which is more than the bikes worth.

Order the rings from the USA. They are about $38USD/hole.

[Rijko]

Most will advise to do the base gasket when you are doing the head gasket; more than likely it will be disturbed and start to leak if you don't. I would check compression (after valve adjust)to see if it needed rings before tearing into it.
I think you can leave out the cam tunnel o-ring if you get the newer style mls head gasket.

agreed, this is a totally different situation than the one 35 years ago,
the bike has had a long life since then.

You don't have to replace the rings when doing the gaskets or removing the cylinders, unless there is a lot of smoking going on when it's running and they just need to be replaced.

Agreed, if compression is ok and no smoke, just leave the rings on.
If the engine runs well, there is no reason it would not do so after
a gasket refresh.

In just doing a head gasket only it's a lot cheaper than the whole lot. Here in the UK you are looking at a little over £1000 just for the rings alone which is more than the bikes worth.

New rings and clips will set you back £200 ish.

https://www.cmsnl.com/suzuki-gs1000s-1979-n-usa-e03_model15993/partslist/95522.html

Cost may be higher if you find a worn cam chain, cracked cam chain
guides, etc so i understand your reluctance to open the engine more than necessary.

On the other hand, if you invest time and money and find out you
have to open the engine again ... i would at least replace base gasket,
cylinder o-rings and oil stud o-rings.
Think Murphy will make sure it will leak if you don't

Lap valves and replace valve seals while the head is off .. just
to be sure. Low cost, best practice.

[Suzuki Mad]

Order the rings from the USA. They are about $38USD/hole.

I did buy from the USA 10 years ago as it was cheaper but few companies now ship to the UK especially the Suzuki dealers. So I dont have any options on doing that now.

[Suzuki Mad]

She's only done 40,000 miles from new. NO smoke, starts first time in the button and runs like a dream even with the oil leaks.

But as she's my bit of fun bike the cost of what you guy's are suggesting this will get rolled back into the back of the garage and be left till another time in the future, read that as never.

[2BRacing]

Maybe you can first try to re-torque the head. Increased clamping force may slow down the oil leaks.

[fastbysuzuki]

Personaly I would do the base gasket and all the orings as well.
if you were to just do the head gasket and then find out you have leaks on the base it's do it all again along with the extra cost.

[Rijko]

She's only done 40,000 miles from new. NO smoke, starts first time in the button and runs like a dream even with the oil leaks.

But as she's my bit of fun bike the cost of what you guy's are suggesting this will get rolled back into the back of the garage and be left till another time in the future, read that as never.

don't give up on a nice bike that runs like a dream !

Sounds like you have the front fork sorted with NOS tubes and all that,
a base gasket and small parts will only set you back £50.

And if that puts it over the top, try re-torque the head like 2BRacing suggests,
it may slow down or stop the leak.
Forget about new rings if it runs well.
These bikes run forever even with a small oil leak, hope you find the
motivation to help her on the road and enjoy a great GS1000.

[hannibal]

The base gasket (at least on my 750) is 10% of what a head gasket costs. Why not go ahead and replace it for just a little more money?

With that said, I currently have my engine apart. This is the only motor I've ever touched, but I'm convinced I could simply replace the head gasket and be OK. I think these are the original 40 yr old gaskets. The amount of effort required to lift the cylinder off suggests to me the base gasket was unaffected when I pulled off the head. Fab up some kinda spreader as shown in the manual instead of beating on it with a mallet and the base gasket would be even better off.

My last twist is that I have the motor off the bike, moved up a flight of stairs, and sitting in my apartment. I NEVER want to do this again and I needed to install an endless cam chain so I did pull the cylinders. I'm replacing the rings and honing the cylinders. The difference in price is about $150 ($130 for rings plus $20 for gasket and O rings). I guess the hone itself is another $25. Seems worth it to ensure I won't have to do this again, at least until I have a nice garage to play in.