82 650g Perpetual oil leak (jug gasket)

[Guest]

I have been working on this bike off and on for quite a few years and no matter how sorted I get it I can never seem to remedy the oil leak that seems to be coming from the jug gasket. When I first got the bike I had the head off to replace the valve seals and while I was in there I replaced the jug gasket along with the head gasket. Keep in mind I used aftermarket gaskets. Being that I was still very new to working on engines and bikes in general I made a lot of mistakes so to me now its no surprise that it leaked. Fast forward several years to now I recently did the job again with factory gaskets and following the proper procedures for bolt tightening and such. Well it now appears the there is still a leak from the jug gasket on the left side of the bike. I assume this means that I will once again have to tear down the motor and do the job again but what can be done to fix this. I thought I read somewhere that this is common with these bikes but maybe I am wrong. Is there something I am missing or do I simply need to take extra measures to keep the oil in? I must also say that I am not 100% sure its coming from the jug gasket but I honestly cant imagine where else it could be coming from. Oddly thought the little rubber things in the fins are also wet with oil on the left side. Maybe the head gasket is leaking as well. Any advice here guys?

Also want to say it's good to be back. I was a regular on here quite a few years ago and you guys were extremely helpful. I even got to meet Steve when he personally came to my place to help me adjust and shim my valves. Seriously awesome guy!

[Nessism]

Obvious answer is to find the source of the leak before scheming further. My suggestion is to use some gunk engine cleaner or similar to degrease the engine really well, followed by a leaf blower or similar to dry all the rinse water. Some guys like to use foot powder spray on the engine next. Then start up the engine and watch close to find where the oil is coming from. If the cylinder/head rubber dampers are oily that suggests something towards of the top of the engine could be leaking. Most common areas are the valve cover gasket, tach drive gear, and cam chain tensioner.

And FYI, after redoing a top end it's critical to follow up after a few hundred miles and retorque the head. Suzuki called for doing this at 600 miles and then at roughly when the valve clearances are checked.

[shibby_cbs]

Yes this is a great suggestion which I went ahead and did yesterday after pulling the left side cover and applying a frugal layer of black rtv to the current gasket. I wanted to eliminate that as a source as it did seem that it might be coming from there as well. After ensuring that the rtv was properly cured I took the bike for a short ride (about 4 miles) and saw the oil starting to run down the front of the engine right about in line with the left most exhaust port. It was also running over top of the left side case. After looking just now the valve cover seems perfectly dry along with the tach drive gear. The rubber damper that is oily is on the left side as well. I had a look at the head gasket right above that and there doesnt seem to be any signs of a leak. Same with the valve cover gasket. As far ad the cam chain tensioner that seems dry at the moment but that is also on the complete opposite side of the jug where it seems my leak is coming from. Definitely seems isolated to front left corner area of the jug. The retorque was something I neglected to do the first time around and actually I doubt I even torqued it properly in the first place. This time it is certainly something I plan to do. Thought honestly I doubt I have even been able to put 600 miles on this thing since I got it somewhere back in 2009/2010. Sad really. I suppose another ride is in order (annoying ) to get a fresh look at it. I'll see about posting pics.

[Redman]

SC,

Welcome (back) to TheGSR.

Sometimes folks joke here on GSR that it is required for you to post pics before anybody can give advise. Yah, we need to know if it is the black 82 650G or the red one, as that might effect the advise given har har har

I had 82 650G for 20+ years that I had bought new. I got word that the person I sold it to moved to central Ohio, and I sometimes wonder where it went and what happened to it. So that is why I might like to see pics.

.

[shibby_cbs]

And Pictures you shall have. I decided to go ahead and mount my new tires, do the rear caliper rebuild, and install my new mixture screw o-rings first. This process also required an air compressor belt replacement. Compressor is fixed and front tire installed. Charging the impact drill and taking a beer break then i'll me right back at it. I do have to say though that I doubt this one was ever under your care. Looks like I actually picked her up in 2010. She was comatose leaning against a fence in someones backyard for years. I saw the ad for $150 and I couldn't resist. Nedless to say she has emptied my wallet for more than shes worth and then some with hours spent but i really do love this bike and i'm dying to finally get her right after nearly 10 years. Here is how she looked on the ride home.

[Big T]

Some observations

Keep the RTV away from your bike

The valve cover has many places that can leak besides the forward edge. The oil will run down among the fins and come out somewhere else

[shibby_cbs]

The RTV is fine. Was simply using it as a means to ensure the leak was not coming from the left cover. I didn't ham fist it like most who glob it everywhere. Just a thin layer to fill any voids that might be letting oil past. If you knew the history of that side cover you would understand. Also the valve cover gasket is a brand new factory gasket and i have looked all around it thoroughly. It's bone dry.

[greg78gs750]

whether its the vc gasket or not, it can be really hard to tell where a leak is coming from just by looking, when you are moving the swirling air can move oil in some mysterious ways. the foot powder trick is a good one to help narrow things down. Not sure if that bike has the orings around the head bolts under the valve cover but in mine that is a common spot for leaks. Check also the half-moons in the head...

[shibby_cbs]

This is exactly why I have always sort of second guessed myself here. I think the foot powder trick is a good one and well interestingly enough I happen to have some randomly in my garage. I am going to do this after work today. The half moons seem good and when I had them out they were still supple. I believe I replaced these with new when I initially rebuilt the bike. My bike does not have the head bolt o-rings. At lease the little oiler areas where they would go didn't seem to be as large or have the same shape as the bikes that do have them. Is there any obvious way to tell from the outside what engines are supposed to have them? I'm sure mine doesn't but may as well double check. Hopefully I can get it to start dripping with a simple idle warm-up. Seems to really only leak after a few miles of reefin on the throttle.

[tom203]

There were two camcover gaskets for this year 650.....are you using the correct one?

[shibby_cbs]

There were two camcover gaskets for this year 650.....are you using the correct one?

That's a very good question. Do you happen to know what the difference is between the two off hand?

[tom203]

Later models had extra bolt in cam tunnel area at front.....not sure why Suzuki did this. I've toyed with buying one to compare it with earlier version: not sure if this is your issue though

https://www.partsoutlaw.com/oemparts/a/suz/50d3fd93f8700230d8b4da67/cylinder-head-cover-f-no-103561

[Steve]

If he got the cam cover bolted on, he has the correct gasket.

It was not just a matter of adding a bolt, at least two others were moved to spread the load and clamping area.

Looking at the parts fiche for the various years the 650 was available, I did not see your "head bolt o-ring" on any of them.

.

[shibby_cbs]

If he got the cam cover bolted on, he has the correct gasket.

It was not just a matter of adding a bolt, at least two others were moved to spread the load and clamping area.

Looking at the parts fiche for the various years the 650 was available, I did not see your "head bolt o-ring" on any of them.

.

Hey Steve it's good to "see" you again. Thanks for taking the time to help a mechanical newbie out with his first big project all those years ago. Something I'll never forget. If you are ever back in the Columbus area again let me know and i'll take you and whoever else out for some food and drinks. The least I can do.

It does reference it with a picture in the Clymer manual but I believe that manual covers all of the displacement options or at least most. Most likely this is used only on the higher displacement models.

Unfortunately I wasnt able to get much done on the bike last night. Ended up working late and by the time I got my hands on it the mosquitoes were feasting. I did get the rear master rebuilt and back together though so 30 minutes of installation and bleeding tonight should get the job done.

[rphillips]

One of those "O" rings on the head nut on my 1100E started leaking & I almost never figured it out. But I don't see those "O" rings on the 650's.