Rebuild shopping list

[Audioslave784]

I'm about to order all of the gaskets that I need for my 850 engine rebuild from Partshark. Just wanted to confirm that I'm not missing anything.

4x piston rings (12140-45121)
8x valve oil seals
1x cylinder block gasket
1x cylinder head gasket
12x copper gaskets for on top of the valve cover (4x 09168-10017, 8x 09160-10039 )
4x large o-rings for under the cylinder block
1x large rectangular o-ring for under the head

I already have a valve cover Real Gasket from my valve job, so that one's set.

The only thing I am unsure about are the 2 oval o-rings under the cylinder block. The closest ones I could find on the Partshark fiche look round (#6 below), so I don't think that's them:

http://www.partshark.com/fiche_section_detail.asp?section=95209&category=Motorcycles&make=SUZUKI&year=1980&fveh=2143

Where can I get new oval o-rings? And what are the chances I could get away with re-using the old ones?

[Big T]

The #6 is the correct one for the rear egg shaped O ring, just a bad drawing

How about the #5 O rings? If you flip your barrels over, you'll find them around the outside of the sleeves.

And, how about the cam chain guides? Soft? Hard? Worn?

[Nessism]

You only need 4 of those copper washers. Also, with the latest MLS head gaskets the rubber tunnel O-ring is not needed (I'm not sure if Suzuki changed to MLS for the 850 though).

Before you order the parts you might want to look in the Accessories section of the fishe for a complete gasket kit. You may save some money that way.

[Theo]

How about the cam chain tensioner gasket?

[tejasmud]

I had checked the bay for OEM NOS gaskets from time to time for the 700E, never found much. Then found a complete OEM NOS kit minus valve seals for $69 ($78 shipped) for an 83 750E. Copper washers are a little green............

But you are heading the right direction. OEM on gaskets seems to be the best, IMO, paper stuff doesn't really matter, but top end. Go OEM, too many swear by them.

New, new, new, clean, clean, clean.....


Oval o-rings?

Just get the round ones, and bend them.

I don't think I would "re-use".. Just buy new.

[bwringer]

The oval o-rings just look round on the fiche. They're really oval. And yes, you definitely do need them.

One detail I like to add is new dowel pins. If your old ones came out smoothly, then never mind.

[bwringer]

The complete A to Z gasket set is listed on the "optional" fiche for $186.46.

That's a deal compared to buying just a fraction of the top end gaskets individually. Plus, it'll come with a whole bunch of handy sealing washers and o-rings you didn't know you needed. It will include new o-rings for the intake boots, too. The cam chain tensioner gasket and o-rings are included, but not the seal.

If you don't want the case gaskets and bottom end stuff, you can always sell 'em (to me?) and make a few bucks back.

[Audioslave784]

No noticeable wear on the cam chain guides. The material is hard, but still a little flexible. These are the first ones I've seen, what are the signs that they might need to be replaced?

So I'll get #20 and #22 with the gasket kit, but what is the cam tensioner seal that I need to buy separately?


bwringer - I was already spending $100+ on gaskets, so I will definitely spring for the $186 complete set. Which ones do you need?

[GSJim69]

I ordered a gasket kit from partsnmore.com for $70. I plan on using an OEM head gasket though. The search function led me this way. The consinsus was that all the gaskets from partsnmore were fine except for the head gasket was suspect. So, I will order an OEM head gasket.

I am currently in the middle of doing the top end on my 850.

[Coady]

I ordered a gasket kit from partsnmore.com for $70. I plan on using an OEM head gasket though. The search function led me this way. The consinsus was that all the gaskets from partsnmore were fine except for the head gasket was suspect. So, I will order an OEM head gasket.

I am currently in the middle of doing the top end on my 850.

I've been looking at a cometic composite head gasket on ebay for $62 US. Is this of good quality or is it worth springing the extra for OEM?

[bwringer]

I've been looking at a cometic composite head gasket on ebay for $62 US. Is this of good quality or is it worth springing the extra for OEM?

The cometic gasket for the GS850/early GS750 (same gasket) is GARBAGE. Guess how I know.

Yes, spend a bit extra for OEM.

[bwringer]

No noticeable wear on the cam chain guides. The material is hard, but still a little flexible. These are the first ones I've seen, what are the signs that they might need to be replaced?

So I'll get #20 and #22 with the gasket kit, but what is the cam tensioner seal that I need to buy separately?

bwringer - I was already spending $100+ on gaskets, so I will definitely spring for the $186 complete set. Which ones do you need?

Look closely for cracking or missing bits and chunks on the plastic, especially the rear tensioner blade. I normally try to replace this one, although if the old one still seems OK, has little wear, and you're on a tight budget, it might not be worth the extra $50 or so.



Here's more info on the cam chain tensioner seal and why it's not on the fiche:

http://bwringer.com/gs/camchaintens.html

I don't actually need any of the leftover gaskets, but after you're done, let me know what you have and I'll probably buy 'em. I come in contact with quite a few GS850s, and they'll eventually find uses.

If I were you, I'd keep the clutch cover and stator cover gaskets just because it's pretty common to need to get in there.

[bwringer]

I ordered a gasket kit from partsnmore.com for $70. I plan on using an OEM head gasket though. The search function led me this way. The consinsus was that all the gaskets from partsnmore were fine except for the head gasket was suspect. So, I will order an OEM head gasket.

I am currently in the middle of doing the top end on my 850.

What brand are the PnM gaskets? Vesrah head and case gaskets are fine, but their o-rings (the oval ones and the square tunnel o-ring) and base gaskets have caused problems for me.

The aftermarket kits are also missing a lot of stuff that's in a factory kit.

[GSJim69]

What brand are the PnM gaskets? Vesrah head and case gaskets are fine, but their o-rings (the oval ones and the square tunnel o-ring) and base gaskets have caused problems for me.

The aftermarket kits are also missing a lot of stuff that's in a factory kit.

I will let you know when the kit arrives. I have not made the OEM order yet. I am waiting to see what might be missing from the kit and to see what else I might need for the head, valves etc.

[Audioslave784]

FYI about the gasket kits: I tried ordering an OEM kit from Partshark yesterday and was told that it would be an extra 3-4 weeks for them to get it. The reason being that the kits aren't stocked, but are assembled to order. Not sure why that would take 3 weeks much less 4, but I don't think I'm going to wait. If there is any site that stocks these, I would definitely like to know.

I also checked with Z1 about their Vesrah kits. The supplier who made these for Vesrah went out of business several months ago, and their gasket kits have been in short supply ever since. Dennis Kirk has 3 left, but at over $100 they are much more expensive than Z1 advertises (although shipping is free).

I ended up ordering a Vesrah kit, and I'm crossing my fingers that it doesn't come back to haunt me (and my wallet...). After looking at the kits and all the gaskets I will eventually need it just doesn't make sense to me to buy individually. Although if someone knows a site that stocks full OEM kits then I would definitely still spring for that and just return the Vesrah to DK.