Engine oil leak after head gasket replacement

[70pelle]

I just wrapped up a top end rebuild.  Doing my break in runs, and found a pretty good oil leak.  It seams to be coming from the front cylinder head area.  Its very hard to pin point, but looks like the whole front of the first gasket.  It only leaks at higher RPMs.  I do have a manual for the bike, its not a factory one and leaves a bit to be desired.  Do I need to re-torque the cylinder head bolts ?  Or is it possible I missed a O-ring during assembly ?  My first time in a Suzuki engine so I was schooled real fast on this engine.  I had to go back and undo a couple of steps, I was getting a little ahead of myself a couple of times.  Any help on this oil leak would be great.

Thanks Ken

[J_Walker]

Wait, its coming from the middle section of the head? OR the lower part with the "shelf that collects sand and other road crap" ? did you use OEM gaskets [the two metal gaskets]

[Bluesmudge]

You are supposed to re-torque the head bolts to the proper spec. I can't remember if this is after a certain amount of time or mileage. I just remember being very annoyed that I had to take the valve cover of yet again just to re-torque the bolts.

However, you may have a different problem than the bolts. My GS never leaked before the re-torquing. Did you replace all the copper washer type seals as well as the two metal gaskets? All of those items need to be replaced anytime you remove the head.

[J_Walker]

if you're talking about the copper washers that go inside the engine, along with the outside [under the head stud nuts] I just hit em with a torch glowing red, and drop em in a bucket of water to anneal them. never had an issue re-using those this way.


I've also re-used a metal gasket, but it was only after a couple hundred miles of use when some pistons hit some valves after a tensioner failure. OVER ALL I would say YES replace both with OEM. The Athena metal gaskets ARE NOT THE SAME AS OEM. They work, but are hit in miss as far as "working properly" I think they aren't as embossed as they should be.

[Bluesmudge]

That sounds like a neat trick with the copper washers. I've only opened the head up once so I just followed the clymer and hanes repair manuals. They both recommend replacing everything. That could get expensive if you have to do it more than once.

[70pelle]

Yes I used OEM gaskets through out the engine repairs.  I made sure all O-rings and copper washers are in there correct place.  I have no extra's laying around. I think I have found my problem, which is my fault. To much oil in the crankcase, I'm way over full by the dip stick. So I have re-torqued cylinder. And made sure all other fasteners are tight as specs call for.  Cleaned everything up.
   I'm now waiting on carb parts from the west coast. To reseal these carbs, I had a small gas drip when sitting on the left (drivers side)carb.  I order parts straight from Mikuni, been waiting since the 28th of Nov.
   I have my Jets already, because I changed the air filter to a K&N lunch box style. And added a Two Brothers muffler, I reworked the exhaust pipes myself.

Thanks Ken

[Bluesmudge]

Sounds like a nice project. Show us some pics of the custom two brothers exhaust if you get a chance.