Broken journal caps

[JackGS]

So... Today I set off to check the valve clearance and after removing the valve cover I got a big shock in the form of broken journal caps (and yes - all four of them).

Is the only solution buying a new/used engine head with good caps or does anyone have any other suggestions? Also - does anyone know if all the heads for the GS500 are the same? Mine is the 2003 model.

Thanks in advance!

[J_Walker]

you can fit a early model head, on a newer model GS, but not vise versa. I have a 1995 I believe head on my 2005.


swaps pretty easy with a brass plug for the mechanical tach.


a machine shop SHOULD be able to machine caps to fit your cam. I'm not even sure how the process works, so maybe someone with machining background can chime in. but anything can be repaired in a machine shop. 

[crackin]

My guess would be that if the cam caps are broken then the journals in the head will be damaged. Either out of round, scored or both. So they will need to be machined larger and in turn your cam ends will need enlarging. That will require machining the cam ends  and pressing bearing material onto the cams ends an machining that to size. Its expensive, I know because i had it done to my bike. It will probably be cheaper and quicker to find another head.
I'm still trying to figure out how all 4 cam caps could be broken? Over tensioning? Under tensioning? Maybe a lack of oil to the head? I'm stumped.

[mr72]

I'm still trying to figure out how all 4 cam caps could be broken? Over tensioning? Under tensioning? Maybe a lack of oil to the head? I'm stumped.

I'm with you. I'd add to the list of speculation, maybe extreme overheating and warped head.

In any case, it's unlikely IMHO that the only damage is the cam caps. I'd be shopping for a replacement head.