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:

  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.

  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.

    But no minivans!

  10. Then I finished my beer.


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Last modified: 11/22/2014