Re: Leaky valve cover, please some advice before I take it all apart again?

[Teek]

Yo! Everyone who posted with oil leaks today, me too. 

Did the valve adjustment Sunday, took it out today for about 25 minutes just around town this afternoon to check things out before I send the East coast kit along. I put a new valve cover gasket in and it was an SOB, it was like it was about 1/4 inch too big, did not want to stay seated even with the gasket sealer in the channel to help it stick so I could turn it upside down. Is that usual, or just poor manufactuing? I couldn't understand that, it's like it would be flat most of the way around, but then pop up. After at least 30 minutes of waiting for it to cure up some and after gently using a heat gun to help it set, my hubby and I each took an end of the cover to keep the thing in place because it still didn't want to stay in the groove, then we both checked all the way around twice before tightening her up. I have a leak about 1/2 wide on the left behind and above the plug location, and it looks like it was  almost okay ( )  and then let go probably about 5 minutes before I could get it back to the garage, so I have oil blown back down the left side of the bike and onto my riding pants and boot too. I was thinking Hey, why is my foot slipping on the shifter???  And thought, hmm, maybe I put my foot down on an oily patch at a light..  But it wasn't smoking or anything yet and I was in heavy traffic so I didn't have an uh oh moment. I had checked it while it was warming up for 8 minutes and it was fine. First thing I did after I shut it off was check the oil, the level was okay so it wasn't leaking too long, then I cleaned up all the oil, looking for an indication of where it was coming from, but all I could see was left side middle somewhere, then started it back up and now it's got a steady leak like a little smooth waterfall. Everywhere else is perfectly clean all the way around, maybe because it's leaking so nicely there.

Can sealer fix that or do I have to pop another $24. for another "oversized" PITA gasket?? 

Glad I have sense enough to test it out before I took it 30 miles from home, I was hoping to ride Thursday. Makes me feel not so smug that I was able to adjust the valves, though. I'm so careful with stuff too, pretty meticulous. Now I'm bummed.   

[beRto]

Sorry to hear about your troubles, Teek.   

I was expecting someone else to chime in, but since you've gotten no replies I'll give it a try. When I checked my valves I re-used the old gasket. I had no trouble getting the gasket back into place as it was not too big. I think that your oversized gasket is not normal. Is it possible that you were given the wrong part? i.e. did you confirm that part number against an online fiche?

Is it possible to put the old gasket back in and see if the leak goes away?

[ben2go]

You can also check it and then give everything another snug turn.Just remember it doesn't take much to break the bolts or crack the valve cover.

[Teek]

Hi beRto,

Thanks for the feedback. 
I thought my old gasket looked just fine, a couple of thinner spots that I would've used sealer on. My hubby insisted on getting a new gasket, just in case, which sounded smart to me too, and so I did. I was cleaning up prior to putting the valve cover back on, and he had already stripped the old gasket off before I could decide if I wanted to do that. (We have communication issues= his lack of communication)   . So I was stuck with doing it, because he ruined the old one before I could say wait a minute there.

No, I didn't confirm the part #. It had the exact same shape as the valve cover, I did check it against the valve cover before I actually got it dirty. It just would not lay flat all the way around.    I saved the label though, so I could confirm it now...  I am not very trusting of dealers overall, so I'll check any parts in the future. I DID check the part #s on my new jets like 10 times already though. 

I'm just going to pull the valve cover again and see what's up. The other thread got a couple of answers, I will probably just try to push the gasket around and use more of the crap sealer, it's fine everywhere else. It peeves me because I want it rideable ASAP.


Thanks for taking pity on an old fart, female to boot! 

[Teek]

Hi Ben,

Thanks for the advice, I also took note of the Edelbrock sealer you posted on the other thread, thanks for that too.   

That's what I'm going to do, I figure I'll just get more proficient at getting the tank etc. off quickly. Yeah, I had to use a pair of vise grips on the allen wrench to crack the bolts initially, so either they were too tight or just stuck. When I tightened them down I only used the allen wrench, since I had a new gasket. So I was careful not to over tighten the bolts, that's all I need is to crack something expensive! 

[ben2go]

Hi Ben,

Thanks for the advice, I also took note of the Edelbrock sealer you posted on the other thread, thanks for that too.   

That's what I'm going to do, I figure I'll just get more proficient at getting the tank etc. off quickly. Yeah, I had to use a pair of vise grips on the allen wrench to crack the bolts initially, so either they were too tight or just stuck. When I tightened them down I only used the allen wrench, since I had a new gasket. So I was careful not to over tighten the bolts, that's all I need is to crack something expensive! 

You're welcome.On a side note.There are a couple of bikes that use a gasket that looks a lot like the GS but I'm not 100% that it's the same part number.The GS400/450,GR650.and I was thinking there were a couple of others that had the same or simiular gasket.

[beRto]

I saved the label though, so I could confirm it now... 

And was it the right part after all?

[Teek]

Yes, I had to go out, came back and looked it up, I'd saved the label and had put it in the valve kit so others would know the part #. I found a  diagram here and a great price too for the gasket and O rings. It's the right part #...   

http://www.suzukipowersports.com/fiche_section_detail.asp

Don't know why it's such a sloppy fit? 

[ajaxgs]

teek

is it comming from the flat surface or the indents for the cams ? myself i lay a thin bead on the flat surfaces too and put a small bead in the cut out for the cams , but mind yo i have not bought a new gasket for the rocker cover yet .  i use the ultra gray gasket maker by permatex and have had success with that on the bike as well as the cages!

[Teek]

Hi ajax,

I used the gray permatex and was really unhappy with it the first time. I put it on the indents and in the corners, but not the flat, it would not  stick the gasket down, BUT, I went and got a new gasket, and this one fit MUCH better, and I used the black permatex and it stuck nicely as it cured. Went on MUCH easier, nice clean flatter fit all around. I think I got a crummy defective part! It actually seems to have been pinched, but we checked with flashlights 2-3 times each the first time, and it looked good, (and we were wearing our glasses!) so I'm surprised. This time it should work. My uncle said to clean both sides with laquer thinner or acetone, and just be careful of the engine paint. So I used it as a sign I should do carbs, so now I have carb questions.

I do feel the part was bad, I expect I'm just going to have to eat the cost. Suzuki messed up on that one.

It was leaking at a flat straight spot too! 

[ohgood]

maybe that larger gasket was for the infamous and rarely seen 100 HP gs500 ?

glad you got the leak sorted out. time to play now.... or are your carbs in 1,000 pieces now ?

[ajaxgs]

glad you sorted the problem with it  Teek, it's a p.i.a to take tank and associated garbage off to get at it

as for the ultra grey , there is 2 trypes , the moto ultra and just ultra ...the moto grey i find is very watery but the regular grey is more simmilar to the ultra black . i just don't like useing the black because some times it can be a pain to get off , mainly designed for oil pans ect
that are not dissassembled on a regular basis ! my 2cents

[Teek]

ohgood, I really do wonder at the difference; the second went on real neat and easy. Carbs are only in a few pieces, they look really clean so I am too chicken to do anything but swap out the jets and put it all back together and see what I messed up. 

ajaxgs, I agree about the Permatex black, but the moto guys I know best personally both insisted on it. I'm going to get pretty good at taking this stuff off and putting it back together, I suspect. Sigh.
What do valve checks and rejets run at shops these days?