OK what do I do before installing the head gasket. Also do I put sealant or something on either side
Do I clean it with gasoline before reinstalling prolly I think, its got carbon a plenty.
Any other tips guys ... its a savage not a GS BTW.
Cool.
Srinath.

Most head gaskets don't require any sealant. I'd clean off the carbon with some brake cleaner (or any solvant) and a fine scotchbright pad before assembling. Also check to make sure the head isn't warped with a straight edge and feeler gauges.

Oftentimes a if a head gasket blows, it's because the head has warped so it's always a good idea to check it before re assembly, otherwise you'll probally blow it again soon. If it's warped you'll have to have a machine shop mill it down slightly.

also now is a good time to check how well your valves are sealing, set the head upside down and fill the combustion chambers with gas, then see if any leaks past the valves. If much leaks, then you'll want to grind or lap your valves.

Torque the head down according to the sequence in the manual, usually it's best to do it in 2 or 3 steps. Also usually you want to use oil on the threads, but check the manual it should specify.

Clean the carbon check - do I use that power wire brush ... or os that brass material too hard for the aluminum in the head and case.
However this bike didn't blow the head gasket. It had a cam chain tensioner that was loose and the Idjit rode it like that with the damn thing scraping to glory and it sawed a trench in the cases after eating through the guides. It was till running when I opened it.
I believe its still true and I believe valves are sealing up well. That was all just done before we bought that motor whcih we put in the frame after aforementioned Idjit blew up what it had by breaking an exhaust valve by never checking it ... ever, or never checking the decompression guage either.
Cool.
Srinath.

Clean with lacquer thinner, once metal gasket is clean and shiny and cylinder and head mating surfaces are clean of all old residue, you may begin next phase.
Spray gasket with K&W copper coat or permatex copper spray a gasket. http://permatex.carshopinc.com/product_info.php/products_id/42287/80697
Dont use an abrasive on the gasket lacquer thinner will clean it off, keep rag soaking wet in lacquer thinner and just keep working it.

Oh, OK. Easier.
Cool.
Srinath.

I got the head and gasket material cleaned off the cylinder, and there is some weird non metallic crap in the gaps between the piston and rings. I dont think I can clean it off cos its like in there and I am not planning to take off the jugs to do it. Can anyone tell me if that crap (not much maybe 10-20 little things all very small in size) will hurt.
Like I said, non metallic, I never got anything metallic in the cleaning process.
Also if the head gasket has been torqued down but never run (no heat cycle) will it be re useable.
Cool.
Srinath.

and you are the all knowing budda of everything GS.........

That's just John's cruel joke ...
Now you have any idea or just here to harass me ... 
Cool.
Srinath.

herass you of course....for a while


I thought you were re-ringing the turd
that should be unburnt hydrocarbons...COKE....
it needs to come out if you want the thing to seal up properly

or are you refering to the ring of crap at the top of the clyinder above the top ring during travel....
same stuff
that is your cheap non detergent superl ow grade fuel you love..... sticking inside your engine

This is the savage not the GS.
The crap ring is barely visible (OK its visible but its not feelable really) and its not been removed by me. The previous owner of that motor re built it I think ...
Cool.
Srinath.

The gasket should be okay if it was only torqued down once.  I compressed mine twice before finally installing it for good.  No problems.

Someone, I believe it was dgyver, told me that he's compressed the head gasket 5+ times without problems.

OK Then, I am going to split it and clean it cos I believe I am yanking the motor out anyway ...
Cool.
Srinath.