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After my 2002 VR6 Jetta hogged space in the garage for a whole month, I have moved on to some necessary service for the Suzuki GS1100GL I bought last November. The PO had done some service to the bike but admonished me that it would need valve stem seals in not too long because there was a little bit of smoke from the left tail pipe at startup. Well, a little quickly turned into a lot and a lot quickly turned into not just at startup. To me, new stem seals means a complete head service. Because I didn't want the bike to be disabled for weeks while I waited for the valve grind, stem seals, guides, and milling, I bought a head on eBay and sent it to the machinist I have worked with for twenty years. With help from Steve, I ordered all necessary gaskets to do a reseal on the engine.
Oh, while I waited for the head, the base gasket started to weep on the right side of the engine. A weep quickly turned into a stream that made the bike unusable. In a way, I am glad that the base gasket started leaking; if it had not, I probably would not have replaced it. I have since learned that the base gasket should be replaced when the head is removed because it may not seal properly when the head is torqued down again.
Last night I began tearing into the engine. It is such a relief to work on something Japanese after a long spell of working on German cars. I actually find myself saying "thank you" out loud at the thoughtful touches Japanese engineers generally put into their work.
I texted Steve last night to ask about the removal of the timing chain tensioner because I thought I remembered a gotcha in that process. He said no gotcha to removal, so I am going to proceed with removing the tensioner, head, and cylinders tonight after work.
I will get some pics up ASAP, but for now I would like to get some information recorded here. A while ago, I asked which manual is best for my motorcycle and the answer was none. Torque specs are incorrect and details are wrong or missing.
Will somebody share correct torque specs and sequences for all relevant fasteners, i.e. head stud nuts, the two little M6 bolts at the ends of the cylinder head, cam cover, vent cover on top of cam cover?
Is there any other procedural information I should have before continuing in disassembly and beginning reassembly? Specifically, how to I handle reinstallation of the timing chain tensioner?
While the bike is torn down, I will at least clean some parts up. If time allows, I will sand and polish some engine parts. I am going to try not to fall down another rabbit hole while doing this service, as I am especially prone to the "while I'm at it" syndrome. I really want to build a set of headers for the bike, but I should wait and make that a winter project; I do not want it to be down for an extra month while I do that. I want to ride the bike that I thought was ready for spring when I bought it.
Oh, while I waited for the head, the base gasket started to weep on the right side of the engine. A weep quickly turned into a stream that made the bike unusable. In a way, I am glad that the base gasket started leaking; if it had not, I probably would not have replaced it. I have since learned that the base gasket should be replaced when the head is removed because it may not seal properly when the head is torqued down again.
Last night I began tearing into the engine. It is such a relief to work on something Japanese after a long spell of working on German cars. I actually find myself saying "thank you" out loud at the thoughtful touches Japanese engineers generally put into their work.
I texted Steve last night to ask about the removal of the timing chain tensioner because I thought I remembered a gotcha in that process. He said no gotcha to removal, so I am going to proceed with removing the tensioner, head, and cylinders tonight after work.
I will get some pics up ASAP, but for now I would like to get some information recorded here. A while ago, I asked which manual is best for my motorcycle and the answer was none. Torque specs are incorrect and details are wrong or missing.
Will somebody share correct torque specs and sequences for all relevant fasteners, i.e. head stud nuts, the two little M6 bolts at the ends of the cylinder head, cam cover, vent cover on top of cam cover?
Is there any other procedural information I should have before continuing in disassembly and beginning reassembly? Specifically, how to I handle reinstallation of the timing chain tensioner?
While the bike is torn down, I will at least clean some parts up. If time allows, I will sand and polish some engine parts. I am going to try not to fall down another rabbit hole while doing this service, as I am especially prone to the "while I'm at it" syndrome. I really want to build a set of headers for the bike, but I should wait and make that a winter project; I do not want it to be down for an extra month while I do that. I want to ride the bike that I thought was ready for spring when I bought it.
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