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 Post subject: Head Gasket Leak
PostPosted: Tue Jun 04, 2019 11:11 am 
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Still in the Driveway

Joined: Tue Jun 12, 2012 1:26 pm
Posts: 6
Country: usa
Bikes owned: T500 Titan
Hello All. Cannot get my left side head to seal and I'm out of ideas. The bike had a stripped head bolt when purchased and I helicoiled it no problem. I don't think it was leaking prior to teardown but the center main seal was which has since been repaired.

The leak is occurring in the same general area as the broken bolt. Relapped the head and jug, fresh gasket, still leaking. No cracks found, bolts are not bottoming out, torque is correct. In my frustration I even tried Permatex Copper Spray - still nada.

The sleeve is slightly higher than the casting but as I recall so was the right side. This is something I have never seen on any of my 2 strokes but this is my first Suzuki. Should it be higher or could the sleeve have slipped?


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 Post subject: Re: Head Gasket Leak
PostPosted: Wed Jun 12, 2019 9:57 am 
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Expert racer

Joined: Wed Jul 10, 2013 12:04 pm
Posts: 1003
Country: England, UK
Bikes owned: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
Suggest you skim the block (with liners fitted). Be cautious doing this. You will need to check deck height to ensure piston will not hit head afterwards. If it is too high, you will need to get the squish band re-cut. Chris Applebee did this on a GT250 for me a while back.


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 Post subject: Re: Head Gasket Leak
PostPosted: Tue Jul 23, 2019 8:10 am 
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Still in the Driveway

Joined: Tue Jun 12, 2012 1:26 pm
Posts: 6
Country: usa
Bikes owned: T500 Titan
The leak is occurring between the 2 bolts nearest the opposite cylinder, one of which had been broken when I bought the bike. Base gasket is sealing well I believe.

For some reason the head is bowing in this area when torqued down. Both surfaces are flat, fresh aluminum gasket. I am at the point where I am going to buy another head to see if it would make a difference. Possibly from having that broken bolt there and having been run that way for however long the metal has just fatigued too much? Really have no other explanation.


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 Post subject: Re: Head Gasket Leak
PostPosted: Fri Jul 26, 2019 4:25 pm 
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Expert racer

Joined: Wed Jul 10, 2013 12:04 pm
Posts: 1003
Country: England, UK
Bikes owned: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
I'm confused; in one post you say the sleeve is slightly higher than the casting, but in another you say both surfaces are flat. Which is correct?


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