Head removal ??

[Russ' GS1000E]

I have all the nuts off the head, mercifully without breaking anything,
but the head seems stuck-fast to the block.

Used a rubber mallet to no avail.

Help, hints? Figured I'd find similar in a search....

Yes, 8 nuts, 4 acorns, and 3 bolts. ( 1 in front and one on each end)

[Billy Ricks]

On some models there is an external bolt at the front of the head where it meets the block. See if you have one.

[Big T]

Some others have had the same problem - just a case of properly applied force

I used a piece of 1" x 2" at the corners and center and hit that with a dead blow hammer

This degree of adhesion means you'll have to pull the barrels also


And, tie up the cam chain to save yourself some time later on

[Billy Ricks]

On some models there is an external bolt at the front of the head where it meets the block. See if you have one.

Just saw your edit, looks like you got the one that runs from the block upwards into the head.

[Nessism]

If you look in the factory service manual they use a special tool to pry the head loose against the cylinder. The parts have special slots that the tool can pry against without breaking off any fins. Obviously, finding a tool like that is difficult but look for the pry points and don't bang on the fins or you will risk snapping some of them off. You can get the head loose without breaking anyting if you pry carefully.

[blowerbike]

throw the cam chain into the bottom end....no biggie.
remove the head and cylinders and then take a couple equal length pieces of wood and put in the end cylinders.
have someone hold the head while you lift and drop the assy. against the wood pieces while holding the cylinders.
the head will then separate from the cylinder.
oh,
as for the cam chain i said to toss out of the way...
its call a stick or flexible magnet..reaches right down into the bottom end and retrieves the cam chain.
don't sweat the small stuff.
note:
the cam chain on GS's will not fall off of the crank sprocket like a 900/1000 kawi...no worries.

[Russ' GS1000E]

Thanks everybody !

I have time on my side, so it will come apart!

I checked the factory service manual I have downloaded,
but I don't see pry points listed.

So far the motor work has been fun....

[Dogma]

Be patient, and you will get it.

I have some plastic "scrapers" that look like chisels. I got them from HF for a few bucks. I drove one of these into the edge of the head gasket, and that got mine loose.

[Russ' GS1000E]

Got the head off tonight.

I used a rubber mallet as a buffer and a big hammer as the force.
Struck on the Intake side outside, and top front of the outside of the head. Both areas look reinforced in the fins.

My first look at any used cylinder, but I think they look good.
Is that still cross-hatching I see?

Where do I find a Valve Spring Compressor?

[Nessism]

Looks pretty good. You got lucky if they all look that way.

[BassCliff]

Where do I find a Valve Spring Compressor?

Hi,

Check out Mr. Steve's video:

http://s25.photobucket.com/albums/c96/Tiggrbike/GS%20stuff/?action=view&current=ValveSpringCompressor.flv

Mr. Steve shows us how to replace the valves and springs in his GS motor. He also demonstrates the valve spring compressor gizmo he fabricated from simple PVC pipe.


Thank you for your indulgence,

BassCliff

[80GS1000]

Looks pretty good. You got lucky if they all look that way.

+1. Might want to run a quick ball hone through there to knock off any glaze before reassembling.

[Russ' GS1000E]

Quote:
Originally Posted by Nessism
Looks pretty good. You got lucky if they all look that way.

+1. Might want to run a quick ball hone through there to knock off any glaze before reassembling.

Yes, hone for sure, at a minimum. I do like the dingleberry (ball) hones.
Does one of our site sponsers sell the right size?

Been fighting with the cylinder block this morning.
1/4" up off the base so far.


Cool !! A Valve spring tool viddy. The one at Autozone for $20 didn't look like it would work.

[Nessism]

Yes, hone for sure, at a minimum. I do like the dingleberry (ball) hones.
Does one of our site sponsers sell the right size?

Been fighting with the cylinder block this morning.
1/4" up off the base so far.


Cool !! A Valve spring tool viddy. The one at Autozone for $20 didn't look like it would work.

Crud gets down into the stud holes and makes removing the cylinder a pain sometimes.

Regarding that ball hone, we don't have any site sponsors here (good thing) so you might want to search using google. I need to get one too so please post your search results so I can leach off your hard work.

[67fire]

This will do a fine job also.
Available at Sears and most Automotive stores.
I believe, that you want a 120 degree cross-patten for best sealing. Ray?



Eric