81-83 750 head and base removal.

[Larry D]

Okay... I know....it's '80-'82....Anyway.


I'm finally getting around to changing these gaskets. Tonight after picking up some lights, I took it apart.

Seems I'm going to be using the advise from Suzuki Don's posting.

http://www.thegsresources.com/_forum/showthread.php?t=150224&highlight=piston+carbon

Here's the base and head seperated. The gaskets have come off pretty clean to this point.

[Larry D]

Here's some close-ups of the pistons.







Here's pic of the garage. More work to do.

[tlg1100]

Nice pics, like seeing project pics

[Nessism]

If you soak those pistons in carb dip the carbon will come right off. You will have to remove the pistons from the con rods so replace the small clip. Before removing the pistons you should scratch them with the number so they get back into the proper hole.

Are you going to replace the valve stem seals and rings?

[blowerbike]

80-81 has 20 bolt valve cover..
i feel like i need to wash my hands just looking at the pictures

[Larry D]

If you soak those pistons in carb dip the carbon will come right off. You will have to remove the pistons from the con rods so replace the small clip. Before removing the pistons you should scratch them with the number so they get back into the proper hole.

Are you going to replace the valve stem seals and rings?

The valve stems seals should be here tomorrow. I wasn't going to replace the rings, however, after searching and reading several posts, I'm reconsidering........I'm going to have to get some circlips anyway.

All I wanted to do was stop the head gasket from seeping.... now, it's rings, circlips, honing, blah, blah, blah........it will be nice to know that the thick layer of carbon will be gone from the piston tops.

Anyplace less expensive than partshark for rings, they list $22.25 per piston....or $89.00 for all four.

[Nessism]

The valve stems seals should be here tomorrow. I wasn't going to replace the rings, however, after searching and reading several posts, I'm reconsidering........I'm going to have to get some circlips anyway.

All I wanted to do was stop the head gasket from seeping.... now, it's rings, circlips, honing, blah, blah, blah........it will be nice to know that the thick layer of carbon will be gone from the piston tops.

Anyplace less expensive than partshark for rings, they list $22.25 per piston....or $89.00 for all four.

You're a smart man Larry, and have learned your GSR teachings well.

An extra $100 for rings after going through all the work to tear the engine apart isn't too bad no? Provides piece of mind that the engine will be fresh with good compression. Keep up the good work.

[Larry D]

You're a smart man Larry, and have learned your GSR teachings well.

An extra $100 for rings after going through all the work to tear the engine apart isn't too bad no? Provides piece of mind that the engine will be fresh with good compression. Keep up the good work.

Thanks Ed. My lessons are expensive though.....Actually taking the top-end apart wasn't to much trouble. Everything came apart pretty easily. I am curious to see what effect it has on the performance of the engine.

The rub is that I have no idea how many miles are on this engine. It is a replacement that I bought when the original had oiling problems. So, I guess it's better to replace it all and clean it up while I'm in there.

The wife isn't going to be happy about spending ANOTHER $100 on this bike though.............

[Nessism]

The wife isn't going to be happy about spending ANOTHER $100 on this bike though.............

It's easier to get forgiveness than permission.

Regarding that oiling problem, supposedly there is a tech bulletin from Suzuki about shimming the oil pressure blow off spring to increase oil pressure a smig. Have you investigated that mod to preserve the engine? Might be worth doing, or at least investigating.

[Larry D]

It's easier to get forgiveness than permission.

Regarding that oiling problem, supposedly there is a tech bulletin from Suzuki about shimming the oil pressure blow off spring to increase oil pressure a smig. Have you investigated that mod to preserve the engine? Might be worth doing, or at least investigating.

I've read a few posts in the past on shimming the spring. Nothing more than that. I'll look into it some more.

[doctorgonzo]

Pretty much exactly what my 30K pistons looked like. I need to dip those things and sell them.

[NickNoo]

I have heard that on early models (the ET - 80/81), the original cylinder base gasket (paper), could distort and reduce the oil flow through the narrow oil passages on each side of the engine.
Later models were fitted with a more substantial metal gasket which obviously solved the problem.
Anyways - your replacement base gasket should be metal, not paper.

[Larry D]

More progress

Here's some more pics.

I got the pistons off. The pins slid out easily enough.



The pistons are soaking in a shallow bath of Berryman's in a metal paint roller tray.



Got the airbox, carbs and exhaust removed from the GK. When I took the test ride, I could tell there was an exhaust leak. I thought it was from the cross connection gaskets. However, #3 exhaust header was barely finger tight.



The exhaust has some surface rust, but it's solid and it's going to clean up nicely. I have it hanging on the garage wall for now. You can see, I took a little sandpaper to it in a couple spots.

[Larry D]

Here's the cross conection pipe.



The airbox is in great shape. Does any have a picture of the snorkel ?



The rubber boots are still in pretty good shape. All in all a good day of progress.

[hikermikem]

Keep those pics coming Larry, nice to follow what's going on...

I'll be in my 1100EX next week (or two) doing much the same.

Keep up the good work!!

Mike