2005 GZ Leak Starting problem leaks from cylinder near exhaust
 

Went to start bike Friday morning. Cranked and used jump starter. no luck

Today I checked gas tank seemed very strange I only went 84 miles on 3+ gallons in tank.
I added 2 gallons and started up and I ran it a minute, had other things to do.....

Later today I try cranking it over and doesn't start.
Smells of gas.
Leaks from exhaust where it attaches to head and oil and gas mix from cylinder head.

So I'm thinking I have new carb parts and needle, maybe it got stuck flooding gas into engine, looked at sight gas its full! it wasn't the other day I checked oil level when I started up bike Thursday.

Then the oil and gas coming out of head? new gaskets needed and torqued. I haven't torqued them ever. I glanced at some thread on here the bolts get loose over time and intervals

In past week I've gone to and from work a few times prior to this no issues. Also several weeks since I replaced carb parts and cleaned.

Oil from head with gas

Spldart might be a good resource for this among others. Might wait for him to check in. And he will.

Fuel tank, 84 miles, 2 more gallons?
PROBLEM
Second.
Wouldn't start added 2 gallons and then it did start. I'm guessing it wasn't full after the 2 gallons?
Is fuel getting past the petcock while bike is off?
Service manual has procedure for setting float level and inspecting needle and seat for wear.
Prolly do that before starting to throw parts at it. Choice is yours though :)
Oh! You are new parts? Did you set per factory spec? service manual and youtube are your buddies!!

Mine seems to love to leak a little from the valve clearance access plates and the head gasket.
New head gasket seems to have fixed that leak but I used gasket sealant for the access covers.

I'm kinda wondering if your motor oil in the case has a gas smell to it...

I'm thinking the same.......Is the crankcase full of gas??????.......Caution......Do NOT try to start again till you determine that the oil is free of gas.

Im going to try draining OIL. I think there is gas in it.
And yes it does smell of gas from the head with the OIL.
The day I added 2 gallons gas I checked the tank it was empty. Then when I added some gas it started right up. So I thought I'm a dummy its out of gas! So I had 2 gallons and filled with it. Then it was later I tried start up and I took pictures and leaks.
Still 84 miles city riding at 40mph or less other than a couple highway runs for some miles turn around and come back.

40 mpg is indicative of a serious problem.

More like 21mpg! I started with a full tank on the 84 miles. I'm real sad about that, I got 50 highway and 65 mpg with mostly 45mph in years past.
Yeah I'm going to check petcock over next couple days as time permits. if it leaks by. I had it in the normal position with just 2 gallons in tank. I could do a quick fix putting a valve to stop fuel going to carb when parked in meantime.

My carb months ago I replaced carb needle and brass part it seats with. And cleaned passages and removed jets too, and put back together on bike. It ran great afterward. I had issues at that time of not being able to open up throttle without issues before that cleaning and repair.

I'll try replacing head gasket if need be after I check gas in OIL and drain. Time for oil change anyway I got a 3 pack of oil filters recently and I'm scared my gz will be down and require a lot of money ever since I saw my bike like this. Hopefully it's just gas leaking from petcock into carb and into engine and that would explain the bad gas mileage.

Other problem the head/cylinder gasket. I have some rtv sealant

Update:
 

Yesterday I drained the oil and it was runny with gas. I changed oil filter too. Fresh oil in bike now.

I tightened cylinder head bolts and one of them kept turning and broke on me not using a torque wrench. They were loose bolts. Also exhaust bolts were loose.

I also checked to see if fuel petcock was working stopping gas, and it does work. I pulled off hose and had a container handy and saw fuel come out in Prime and stop in other positions.

So gas must have gotten in through carb. and its not leaking out gas tank anywhere. My carb needle and seat are a few months old. I guess all it takes is for it to get stuck open.

My next plans of action is I think I will:
1.new head bolts and get the broken one out. Hopefully it comes out and isn't stripped.
Seemed like bolt snapped when it broke on me. I can do take apart head waiting on bolts
2. Spark plug see if it needed tightening I haven't tried yet, and remove and clean.
3. Compression test (No air pushed out like before when I tried to start after tightening bolts)
4. See if bike will start. Then take apart and replace head gasket and replace bolts and get out broken one of course. I might as well take carb apart and inspect
5. Put back together and do compression test. and try to start bike.

Any suggestions? at this point I'm just putting together plans.


.

So petcock sounds goodl.
All this excess fuel is occurring while bike is running.
Sounds like float, needle, seat issue.
Or possible cracked carb housing.

Looks like i need new head gaskets as it leaks oil out front between exhaust pipes. And smoke pushing out there too.

It actually started up today! Ran a few minutes and leaks oil. Just oil and puffs of smoke turning over.

https://youtu.be/xB1MyGOVh2g

Sorry. I am sure you had nothing better to do with your spare time.

Luckily i work 3 miles away and i got my mountain bike tires swapped out and good for riding. I have a car its needed that day to go 60 miles. While i wait on head and cylinder gaskets.

On ebay about 100 bucks for a new top end rebuild kit with piston, rings and cylinder. So if it turns out worse than i think theres that, only a 100 bucks compared to trucking motorcycle to some motorcycle shop. And that extra money i dont have.

Been there, done that. Good luck with your project. Hope for minimal issues.

After several months,I got to it
 

Yesterday I finally had some days off work. I worked black Friday and the weekend so I got Monday, Tuesday, and Wednesday (today) off. My city would rather have people off than pay overtime. Like on a holiday week they'd rather have us work 4 days and paid for 5. Fine by me.....

Anyway I will be posting pictures soon, and getting back to the job. I got the head gaskets put on. Just need to put back together following the service manual.

Pictures so far

more

pics
 

pics

Last pictures from yesterday. here soon getting back to putting it back together further.
Pictures sure help to remember how the parts were.

What kind of Permatex or similar should I use for the camshaft cover?

I imagine the Suzuki kind in the service manual would take a while and cost some money

I picked up some High Temperature Permatex but it says its not for head gaskets or contact with gasoline. oh well I'll have a tube of that in stock

This exhaust Bolt been giving me hell from the beginning doing this job. Got head gaskets in. Now I might need to take off the head to get this bolt out.

Ended up taking head off and drilled out. Tried a small screw extractor and it broke off. But I was lucky I could cut it off with hacksaw and still drill larger.
Tapped out 5mm hole that's the size tap the hole is.

Forgot a broken bolt in the head one-off the green bolts.
So I got that to remove too.

Stay with it and be patient. Looks like you have made a lot of headway.

Hopefully when I get put back together and valves adjusted the compression will be good.

Found out it was bolt 12a. According to partzilla its a 6mm bolt by 50. I measured the thread on it it's 1.0 thread.
(trying advance auto and like for it with the other bolt that's good or I'll have to order and wait)
It's By spark plug hole.
Soaked in PB blaster overnight and at lunch today I used a punch and hammer to loosen it out.
Tapping it loose.
So happy it came out!

Advance auto was a success for my broken cylinder head bolt 6mm 1.0 thread 50 long!
$1.50 or so. All I did was walk in I need a 6mm bolt and guy took my good bolt and found one in a plastic package with a nut.

Granted it's shiny gold I don't care. It's a strong strength number as seen in pictures.
It will do the job .
Worked a couple hours had to stop about 530pn was too dark to see as sunset is 5pm or so now. Didn't have my head light at home.

I got the camshaft and sprocket in to 11 foot pounds and had a time bending the c shaped washer bent over.
I used antiseize on my bolt threads I want to come out again. And the off chance another bolt breaks and I have to remove it.

Update
 

I had another 6mm head bolt to replace 30mm long. Advance had it. It's the one under the valve adjust covers.

I have valve cover on and bolts finger tight with permatex black Max oil resistance sealer.
Next torque to 7 foot pounds.
I got the exhaust valves adjusted and one intake valve to adjust and turn 720 degrees and check again.
Then compression check to see what I got.
It started before puffing out the head gasket.

I had to remove the permatex from before as I realized I couldn't get that long 6mm bolt in last like I tried.
I forgot I had to take that one off last and to put it in place first.

Yesterday I torqued the cover and head to 7.
Got valves adjusted. Intake to .076mm
Exhaust at. 0.127 or 0.10. Feeler Gage. Can't remember.

Cleaned carb. Ace hardware has a good selection of metric screws and bolts and I replaced the four carburetor bowl screws. Kept original only one was stripped.
I was glad I cleaned car. I had left fuel hose off for several weeks and mud daubers plugged it up! It's good now. Also it was rusty from my negligence leaving carburetor hanging. Rain got in.
I got it in a bag out of the weather now it's clean.

It's raining here so probably next week. I'll get to put carb. back on and do a compression test.
Waiting on exhaust bolts and gaskets. Ordered from eBay seller in Norway. Lol send some Black metal cds too and death or folk metal.

Put carb. On. Tried starting with exhaust loose. I'm still waiting on exhaust bolts, I would have just searched locally and had in hand earlier.

I was so excited to try I forgot to prime the carburetor and wouldn't start after priming. Trying again when it's not in the 30s f be 50s f today.
Also might need to replace battery. It seemed weak turning over.
Will try a compression test. I wanted to see it start.

Compression test 140psi! Cold. 52f at the time
Replaced spark plug as it didn't have spark now it does.

I went to try see if it would start up and battery was dead. I forgot earlier when I did compression test I left key on.
My exhaust Bolts and gaskets from Norway came in. I got to the 2nd bolt hole and I realized I only tapped it to 5mm and not 6mm!

So here I have to tap it to 6mm.

Compression Gage and exhaust bolts and gaskets

You might need to just charge the battery and cross your fingers when trying to start er up.

Won't start.
I use jumper cables from my car running battery . It has strong turn over that way.
I have spark, I have good compression, and I've tried starter fluid in air filter and in the spark plug hole at separate times.
Could the timing be wrong? I did it by the PDF book
Camshaft notch just like it said.

Do not have car running...You will ruin the ECU...Boost from car battery with car NOT running.

Just to add.........The charging current in a car is way too high for a bike. With the car engine running, this high current will fry your bike battery. Next step is to have your bike battery tested to see if you have done any permanent damage to it.

I had my gz battery off the bike when I started with car running jumper cable.

I'll jump-start with car engine off to not fry the bikes ecu.

I'll try just some gas inside the spark plug hole.the gasoline It's fresh and it was 60f yesterday.

I'll try taking carb. Off and try starter fluid as well.

I don't get it.
Timing should be good. Top dead center and camshaft notch is facing the intake side at 9 o clock when facing bike on its right side.

Spark plug was wet so maybe it was flooded

Aside from your other issues, I would invest in a trickle charger for your bike. For $20, it would be money well spent.

That's what I have my battery on now, a 1.5amp trickle charger.

Great. I have an old variable amp charger that is at least 40 years old and is still ticking for those quicker charges as needed. I have not needed my trickle charger as my GZ is a daily rider and I invested in a lithium ion battery which has served me well for several years. It is also great because it weighs a fraction of a standard battery. Well worth the investment once you get your other problems resolved and have some spare coin IMHO.

No luck yesterday.
Found I didn't have spark.
Checked the fuses all OK.
Jiggled a wire connection to CDI and had spark again.
Tried starter fluid again in air filter hole. And even took out spark plug and let it crank to get fresh air and dry out.
Frustrated.
So I quit after 2 hours. And played drums to Misfits songs and jammed to garage days Metallica CDs.
I'll be glad once I figure this bike out so I will have more free time not messing with it. And more time playing music.

Sometimes it is good to just walk away for awhile. You tend to make more mistakes when you get frustrated. Don't worry. I know you will get it sorted out.