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SUZUKIPictures of how I machined the head and cylinder block to fix the head gasket 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. I filled the head with WD40 for a few hours. The valves held the WD40, so the valves seal well enough that I am not going to reseat them. And the WD40 softened up all the black crud burned onto the heads. Maybe I forgot to turn the choke off once or twice, what of it.
    WD40


  4. Cleaned up the head pretty nicely. Used a brass or copper wire brush and a flat head screwdriver. AND WD40!
    Clean Head


  5. Can you believe that bashing that wire brush around in there changed the spark plug gap?
    Spark Plug Gap


  6. Big pliers, paper towels, and patience got these alignment pins out of the head (This is an after pic, but you get the idea). Don't let the pliers put a bur on the pins or they will be murder (scroll down to # 18) to get off next time.
    alignment pins


  7. Cleaned up the Cylinder block mating surface.
    Cylinder


  8. Cleaned the stud holes. They are open to the air and sand can get caught in there. Yeah, I said stud holes. What? That's what they are.
    studs


  9. High Tech head milling machine. Glass, tape, sandpaper. 220? 400? I don't know. I am no expert here. I read in one forum to sand it smooth enough that the copper gasket spray will fill the scratches, and rough enough to grip the gasket.
    Head milling machine


  10. Before and after on the block. Why yes, I did deglaze (and or hone) the cylinders myself, thank you for noticing. And no, I did not leave the o ring in the block when I started sanding, completely destroying the o ring. Shut up.
    Before After


  11. 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!


  12. 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