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SUZUKIPictures of how I installed the head, gaskets, and cylinders after fixing the head gasket leak on my 89-09 Suzuki GS500 motorcycle.


But first, lets pay some bills:
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  1. I had the head and cylinder block off to fix the gasket leak and clean up the carbon deposits on the head and pistons. That done, and the pistons reinstalled, now it is time to reassemble the top end. Here is the engine case with the newly coppered cylinder base gasket just installed.
    pistons


  2. I do not have a piston ring compressor, so I tried a lot of things with cut up aluminum cans. These ideas, though keeping true to the cheap, creative, and pig headed stubborn traditions of the BeerGarage, only worked if you want the pistons to stay out of the cylinders and the blood out of your fingers. That was a fail.
    aluminum


  3. I ended up just pushing the rings in to the cylinders one at a time with my hands and a small screwdriver. Not that bad. I put some regular engine oil on the inside of the cylinders to provide some initial lubrication for the pistons the first time I start it. Then I cleaned off the mating surface and put on the o rings and the coppered gasket.
    cylinder block


  4. Then the tight fit of getting the head in over the studs and under the frame. I was nervous about scratching the freshly machined mating surface, but it seemed to go in a lot more easily than it came out. No worries!
    cylinder head


  5. Then I pulled the timing chain up through the head.
    timing chain


  6. Then hand tight installed the washers and nuts that hold on the top end, cylinder block and cylinder head.
    nuts


  7. Then torqued them in order. What order? I don't remember. It's in the Factory Service Manual. Do you have your manual? You can probably find one for download on the GSTwins forum.
    torque


  8. The front nut torque is so low, I do not think my wrench is accurate at that low level, so I guesstimated that I could not do too much damage with just one finger.
    finger torque


  9. I started to reinstall the camshafts, but hey! Don't forget the front timing chain guide!
    timing chain guide


  10. Setting the timing is another page by itself, there is or will soon be a link for that on the left.


  11. Timing chain tensioner. That is a little screwdriver in my hand. I held the tensioner and screwdriver with one hand, and installed the bolts hand tight with my other hand.
    Timing Chain Tensioner


  12. Filled these little reservoirs with engine oil to provide initial lubrication to the cams.


  13. Someone send me a free head and I will do a port and polish writeup. Until then, I will just ride it as is.
    Exhaust Ports


  14. Used my homemade garage creeper to scoot the exhaust under without scratching it (again).
    garage creeper


  15. I put some anti seize on the exhaust bolts before tightening those. WTF, I thought it was i before e. You suck, "Charlie Brown Enters the Spelling Bee."
    anti seize


  16. Put valve cover on, filled up with oil, put carbs on, gastank, whatever else.


  17. Started her up! Let the engine heat up gently just sitting there for 15 minutes. Definitely not by racing a mini cooper around a vineyard. Then I LET IT COOL and then retorqued all the bolts. They were all loose by ~10 lbs.
    retorqueing the head nuts


  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