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Quimrider · 09-08-2008, 11:58 AM

I will probably put together a quick step by step how-to if I have time. It would have helped if I had taken some pictures before I started putting stuff back together. Here's an abbreviated rough draft:

1. Remove gas tank

2. Remove decorative chrome and their mounting brackets

3. Unbolt cylinder head from frame and remove frame to cylinder head brackets (picts will help here). The two bolts on the frame had blue thread lock making them difficult to remove.

4. Follow service manual to put the engine at TDC (so both intake and exhaust valves are fully closed.)

5. Unscrew all bolts on cylinder head cover except the two rocker arm shaft bolts (3rd pic down on page 3-24 service manual). One of the bolts has a gasket washer make note of where this goes. Thankfully for me the service manual shows where it goes on page 3-64. Service manual says to replace with new but I didn't have a new one readily available an didn't want to have to wait for a new one so I just put some liquid gasket on it during reassembly. I probably shouldn't have to mention this but don't loosen the two acorn nuts by the spark plug. You're just taking the cover off not the whole cylinder head.

NOTE: there is a bolt under each valve cover cap.

6. Tap with a rubber mallet or pull gently on the valve cover to break the gasket seal. Mine took some tapping and pulling. but came off easily with a little patience.

7. Use some gasket remover on both surfaces. Be careful not to get any in the engine. I'm not sure of the consequences but I'd image it wouldn't be a good idea to have this stuff in your engine oil. Let it soak for 15-30 minutes. The old gasket material should easily dissolve. If not put more gasket remover on and let it soak longer.

8. Wipe surfaces clean with some rags and make sure you get all the old gasket material off.

9. Remove gasket remover and oils from mating surfaces with brake cleaner or similar solvent. I sprayed some on a rag and was very careful on the cylinder head, again being careful not to get anything in the engine.

Edit 10-8-08: The original gasket material didn't hold up!

10. Apply liquid gasket maker to one of the mating surfaces. The outer area directly on the cylinder head and then for the surfaces around the inner bolt holes, apply to the cover. I suppose it really doesn't matter which surface you put it on. I just started with the cylinder head and then switched to the cover because the cam shaft was in the way. I used a rubber glove and used my finger to smear a thin layer. Thin being the operative word here you really need very very little, just enuff to cover the metal.

EDIT 10-8-08 OLD STEP TEN, SKIP THIS STEP. FOR REFERENCE ONLY.
10. Apply liquid gasket to both mating surfaces. Service manual says to use Suzuki Bond 1215. I couldn't find any specifications on this and wasn't going to pay ~$20 for some from Suzuki. The aviation gasket maker I used can go up to 400 deg. F Hopefully this is high enough temp. If anyone knows what the Suzuki temp. spec is please share. I could have used a 700 deg. F RTV silicone but the gasket remover doesn't dissolve RTV silicone. I don't want to imagine the pain in the ass it would be to remove the silicone if I had to take the cover off again.

11. Put the long bolt in the center thru the hole in the cover before you put the cover back on. Otherwise you'll be cursing like a sailor when you realize the frame doesn't allow enough clearance and you have to start over.

12. Only finger tight the bolts so you don't squeeze out all the gasket material. Wait 24hrs for gasket to cure before going to step 13.

13. snug all bolts to spec which is 7 ft-lbs. As stated above instead of using a new gasket washer, I just applied some liquid gasket to the existing washer. This is probably not necessary I see no reason why a new gasket washer would be required.

14. adjust your valves (see service manual).

15. put valve cover caps back on and enjoy your leak free engine.

16. Any questions?

Other thoughts:

EDIT 10-8-08 I ENDED UP USING THE RTV ABOVE. I LEFT THIS AS A REFERENCE INCASE SOMEONE WANTED TO TRY THIS GASKET MAKER.
Prior to this I've never used any of the gasket products shown above. I just used what I could find locally and readily available. After looking at Permatex's web page I may try this if the aviation gasket doesn't hold up. It looks similar to the aviation gasket stuff but goes up to 600 deg. F.

If you need to replace a clutch cover gasket, (surprisingly it has been more difficult that the cylinder head cover gasket!) soaking the gasket material that sticks to the clutch cover over nite with the gasket remover will make it SIGNIFICANTLY easier to remove as it is nearly impossible to remove otherwise without damaging the mating surface.

09-08-2008, 11:58 AM	#16
Quimrider Senior Member Join Date: Jun 2007 Location: Toledo, OH Posts: 198	Re: Oil Leak I will probably put together a quick step by step how-to if I have time. It would have helped if I had taken some pictures before I started putting stuff back together. Here's an abbreviated rough draft: 1. Remove gas tank 2. Remove decorative chrome and their mounting brackets 3. Unbolt cylinder head from frame and remove frame to cylinder head brackets (picts will help here). The two bolts on the frame had blue thread lock making them difficult to remove. 4. Follow service manual to put the engine at TDC (so both intake and exhaust valves are fully closed.) 5. Unscrew all bolts on cylinder head cover except the two rocker arm shaft bolts (3rd pic down on page 3-24 service manual). One of the bolts has a gasket washer make note of where this goes. Thankfully for me the service manual shows where it goes on page 3-64. Service manual says to replace with new but I didn't have a new one readily available an didn't want to have to wait for a new one so I just put some liquid gasket on it during reassembly. I probably shouldn't have to mention this but don't loosen the two acorn nuts by the spark plug. You're just taking the cover off not the whole cylinder head. NOTE: there is a bolt under each valve cover cap. 6. Tap with a rubber mallet or pull gently on the valve cover to break the gasket seal. Mine took some tapping and pulling. but came off easily with a little patience. 7. Use some gasket remover on both surfaces. Be careful not to get any in the engine. I'm not sure of the consequences but I'd image it wouldn't be a good idea to have this stuff in your engine oil. Let it soak for 15-30 minutes. The old gasket material should easily dissolve. If not put more gasket remover on and let it soak longer. 8. Wipe surfaces clean with some rags and make sure you get all the old gasket material off. 9. Remove gasket remover and oils from mating surfaces with brake cleaner or similar solvent. I sprayed some on a rag and was very careful on the cylinder head, again being careful not to get anything in the engine. Edit 10-8-08: The original gasket material didn't hold up! 10. Apply liquid gasket maker to one of the mating surfaces. The outer area directly on the cylinder head and then for the surfaces around the inner bolt holes, apply to the cover. I suppose it really doesn't matter which surface you put it on. I just started with the cylinder head and then switched to the cover because the cam shaft was in the way. I used a rubber glove and used my finger to smear a thin layer. Thin being the operative word here you really need very very little, just enuff to cover the metal. EDIT 10-8-08 OLD STEP TEN, SKIP THIS STEP. FOR REFERENCE ONLY. 10. Apply liquid gasket to both mating surfaces. Service manual says to use Suzuki Bond 1215. I couldn't find any specifications on this and wasn't going to pay ~$20 for some from Suzuki. The aviation gasket maker I used can go up to 400 deg. F Hopefully this is high enough temp. If anyone knows what the Suzuki temp. spec is please share. I could have used a 700 deg. F RTV silicone but the gasket remover doesn't dissolve RTV silicone. I don't want to imagine the pain in the ass it would be to remove the silicone if I had to take the cover off again. 11. Put the long bolt in the center thru the hole in the cover before you put the cover back on. Otherwise you'll be cursing like a sailor when you realize the frame doesn't allow enough clearance and you have to start over. 12. Only finger tight the bolts so you don't squeeze out all the gasket material. Wait 24hrs for gasket to cure before going to step 13. 13. snug all bolts to spec which is 7 ft-lbs. As stated above instead of using a new gasket washer, I just applied some liquid gasket to the existing washer. This is probably not necessary I see no reason why a new gasket washer would be required. 14. adjust your valves (see service manual). 15. put valve cover caps back on and enjoy your leak free engine. 16. Any questions? Other thoughts: EDIT 10-8-08 I ENDED UP USING THE RTV ABOVE. I LEFT THIS AS A REFERENCE INCASE SOMEONE WANTED TO TRY THIS GASKET MAKER. Prior to this I've never used any of the gasket products shown above. I just used what I could find locally and readily available. After looking at Permatex's web page I may try this if the aviation gasket doesn't hold up. It looks similar to the aviation gasket stuff but goes up to 600 deg. F. If you need to replace a clutch cover gasket, (surprisingly it has been more difficult that the cylinder head cover gasket!) soaking the gasket material that sticks to the clutch cover over nite with the gasket remover will make it SIGNIFICANTLY easier to remove as it is nearly impossible to remove otherwise without damaging the mating surface.
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