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SUZUKIPictures of how I coppered the head gasket and fixed the oil leak on my 89-09 Suzuki GS500 motorcycle.


But first, lets pay some bills:
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  1. Put bike on center stand. Removed seat, gas tank, and carbs.


  2. Removed Cylinder Head and Cylinder Block.

    Head & Cylinders


  3. The old steel gasket is a mess of burned gasket sealant and oil where it was leaking.
    Gasket


  4. I cleaned it with a wire brush, WD40, and gasket dissolver.
    Wire Brush Clean


  5. To prepare the head gasket and cylinder block base gasket to take the copper spray paint gasket adhesive, I cleaned all surfaces with ethyl alcohol, ETOH.
    Ethyl Alcohol


  6. I painted each side of both head gasket and base gasket with three coats of gasket adhesive. I waited about 30 - 60 seconds between each coat, to let the copper tack up, but still be wet enough to take the next coat.
    copper spray


  7. I have heard that it is not advisable to use cardboard cereal boxes as head gaskets. I hope the steel gasket with the copper spray will work, but if it doesn't, I now have a template to use to make cardboard gaskets if I want to try it.
    cereal box


  8. Finally, I hung up the head gasket and the cylinder block base gasket, with the copper spray gasket adhesive on both sides, to dry on nails in the garage wall.
    gaskets drying


  9. Next I sold out to make 02ยข so I can fulfill my lifelong dream of owning a 1986 944 with blown head gaskets.
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    But no minivans!


  10. Then I finished my beer.
    Beer

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Think: Cars are expensive, powerful, and heavy.   Before I start work, I face the possibility that I will destroy my vehicle, my own life, and innocent pedestrians' lives.   If anyone messes with a 4000 lb machine capable of 100 mph, these are real possibilities.   If I get in over my head, I call a professional mechanic.   The information on this website is provided only for entertainment purposes, and it is not intended as advice on how to service a vehicle.   For all you know I made this up.   Don`t believe everything you read on the internet.

Disclaimer: The technical information in these documents is provided without any warranty whatsoever and at no cost.   All information is in general terms and is not meant to apply to your particular situation, be current at the time you read it, or even be correct in the first place.   Improperly maintained vehicles can lead to serious injury, death, or unavoidable accidents. The author is not responsible for any errors on this site, and does not make any claim at all about the validity, safety, or veracity of the information contained on this website. Any work you choose to do or not to do on your vehicle is done at your own risk. The information on this site is not intended to serve as a replacement for professional advice, professional workmanship, dealer service, union labor, or psychological counseling.   The author disclaims any and all liability directly or indirectly arising from the application or use of any information or idea contained on this or any other web site.   By opening this page, you agree to never sue anyone ever or allow anyone to be sued on your behalf.   The appropriate professional should be consulted regarding your specific condition.    BeerGarage.com does not take responsibility for the information posted on other sites to which it links.

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Last modified: 11/22/2014