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SUZUKIPictures of how I removed the Head and Cylinders from the engine on the 89-09 Suzuki GS500 motorcycle.


But first, lets pay some bills:
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  1. Head gasket leak.
    Leak


  2. Put bike on center stand. Removed seat, gas tank, and carbs.


  3. Removed breather.
    Breather


  4. Valve cover.
    Valve cover


  5. Camshaft chain tensioner.
    Tensioner


  6. Exhaust header bolts. Allen key. WD40!
    Exhaust


  7. Rear bolt on exhaust can. If you are wearing flip flops, watch it. Just sayin.
    Tensioner


  8. Cam Shaft journal holders. Removed slowly and evenly to avoid damaging the soft aluminum head or the brittle hard camshafts.
    journal holders camshafts


  9. Don't drop that timing chain. The zip tie that normally holds those cables worked well for this. If you drop the zip tie into the engine, you may want to take off the oil pan. Just sayin.
    Timing Chain


  10. Front Timing Chain Guide. It lifts straight up when there is enough room from the head moved enough or out completely.
    Chain Guide


  11. Speedometer cable.
    Speedometer cable


  12. WD40 the head bolts.
    Speedometer cable


  13. Head Bolts.
    Head Bolt 0
    Head Bolts


  14. At first I thought I would not be able to get the head out over the studs and under the frame. Slowly gently got it done.
    Cylinder


  15. Cylinder and Head.
    Cylinder and Head


  16. Head Gasket.
    Head Gasket


  17. Studs and Pistons.
    Pistons


  18. 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!


  19. Then I finished my beer.
    Beer

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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