Adfalchius goes over helicoils in the stud repair thread, skip to about 6:30:  http://www.youtube.com/watch?v=1aE_bntq_iE&context=C3d5e5a0ADOEgsToPDskKg71t1i6d-OmLfjzOfzpWY

-Jessie

Quote from: BaltimoreGS on March 01, 2012, 08:28:59 PM
Adfalchius goes over helicoils in the stud repair thread, skip to about 6:30:  http://www.youtube.com/watch?v=1aE_bntq_iE&context=C3d5e5a0ADOEgsToPDskKg71t1i6d-OmLfjzOfzpWY

-Jessie

always amazes me how helpful so many people are on this site!!! 

Really appreciate that link.

but since its an important part on the bike, I will probably take it to a machine shop to get a quote on it first.
since I have never done that before.

I watched that video and thought 3 things:

1) Very informative- good job!
2) I wish every bolt broke when the part that was holding it was eye level on a bench.......
and 3) It was kinda funny to watch somebody snap a bolt on purpose. In the back of my mind was "there are hundreds of people every day that break them on accident......."

small update.

got the work started.
took all the crap off to get to the cam shaft half moon things.
and yep, the one marked A is stripped in the female part I spoke of before.
screws in and holds it fine, it just wont tighten.

and the leak might be my own dumb mistake.
the head cover allen head bolts were not tightened all the way!!! (only hand tight)!!!
ugh enough of the mistakes!!!
Im going to check every single nut screw and bolt before im 100% finished.
even tho that was a must before this, its now imprinted in my brain.

put the 130 main jets back in and the 40 pilots in
130 because I got the K&N open air filter finally.

and stuck the front fork harley reflectors on with some added glue for extra hold instead of just the tape on it.

and thats it for now.
getting too dark out.

gonna take the half moon thingy (dont even care to look up the proper name right now) to a machine shop soon with the cover and bolt to get a quote on fixing it.

kk off I go.

I'm confused...I thought you had stripped out the threads on one of the head cover bolts?  Now you are saying that they were only finger tight.  Which bolts exactly were only finger tight?

Quote from: bombsquad83 on March 03, 2012, 01:57:17 PM
I'm confused...I thought you had stripped out the threads on one of the head cover bolts?  Now you are saying that they were only finger tight.  Which bolts exactly were only finger tight?

I stripped the one.

but the other ones were only hand tight.
I simply forgot to tighten those ones.

Supervisor at work suggested I get a metric tap set from harbor freight and see if I can retread it.
Just got back home from work and the store.
Going to go out and see if that does the trick in a min.

hopefully it does as its going to be Gorgeous out on my days off Tues Weds and Thurs.
and I am Jonesin to ride!!

but thats also if actually Tightening the other bolts I forgot to fix's the oil leak.
or the gaskets arrive at the shop tomorrow or Tues.

(edit)
and if anyone here suggested the same (retread it)
sorry, between work, the bike, the house, and new gf... i am ALLLLLLL over the place! hahaha 

Well! that didnt friggin work!

But it wasnt the cover that was leaking afterall...... 

leaking right where the middle of the jug section meets the lower part of the engine.
I couldnt stick my face right up in there because I had the bike warmed up.

heres a pic of the location on a different engine.
Just hope its a simple problem and I dont have to go and use my old cylinder section....

UGH i didnt wanna have to take this sucker apart AGAIN!

time for bed as im pretty ticked off!



(edit)
and yes I torqued it all down properly....

Is it from the cylinder base gasket?

Quote from: Big Rich on March 04, 2012, 01:25:01 PM
Is it from the cylinder base gasket?

No idea as thats why I am stuck taking it all apart yet Again! 

hopefully just a minor issue and the gasket is fine as I dont want to have to replace them yet Again either! haha

I can't speak for the GS, but my GR motors have an "over pressure" drain where you have that circled. It's there in case there is a blockage in the crank case vent (top of the motor). Buddha knows all about it on the GR as well.

How much oil is it leaking? Weeping oil stain, constant trickle, etc?

Quote from: Big Rich on March 04, 2012, 05:33:53 PM
I can't speak for the GS, but my GR motors have an "over pressure" drain where you have that circled. It's there in case there is a blockage in the crank case vent (top of the motor). Buddha knows all about it on the GR as well.

How much oil is it leaking? Weeping oil stain, constant trickle, etc?

it fills up that little area in front rather quickly.
then drip drip drip drip.

Way too much to be rideable.

Yeah, that's not that pressure release I was thinking of then.

Sounds like a new gasket may be in order then........hopefully I'm wrong though. It's weird for that gasket to be leaking that much though.......

all brand new gaskets tho.
except the head cover one that is inc now.

wont know til i take it apart i guess

(edit)
well once again I go from sick and tired of it to ticked and motivated !
ugh this bike is being worse then a Bad gf! hahahaha 

if its not raining tomorrow when I get home from work.
that engine is coming apart again and getting Fixed already!
even if I have to swap out jugs with my old ones (as long as it just gets fixed!)

                

so much for ANY plans of riding this Tues Weds and Thurs im off and supposed to be Gorgeous out ><

took the whole top of the engine off AGAIN!

new gasket above the cylinders still looks brand new. (because I bought it from the dealer!!!)

new gasket below the cylinders is a shot POS! (because I bought it off ebay!!!)
its already 25% to 40% bare metal.
the adhesive or whatever the gunk is on it was flaking off as if it was dried out to heck!
100% Garbage!!!

So now I have to call the dealer and order a new one and wait ANOTHER like 2 weeks for it to be delivered.
or find one online if I can borrow some $$ and get it shipped in a day or two.

Bad news tho.....
Cylinders cbr sent me got screwed....
Not sure exactly how.
but the one cylinder wall got 2 NICE vertical scratches in it that are WAY too deep to be useable.

Luckily and I feel bad about it.
I had my old cylinders that are perfectly fine.
and I have already honed and cleaned them up earlier.

But now I cant give them away to the rider in Pitt having bike problems that I said I was going to. (forgot the username)
^^ thats what ticked me off the most.


so!
thats why oil was leaking below the cylinder section.
the gasket was utter and total GARBAGE!

To me that's good news.  You found the problem.  Have you thought about ordering an OEM gasket from RonAyers.com.  Might be cheaper than your local dealer too.

http://www.ronayers.com/Fiche/TypeID/26/Type/CYLINDER/MakeID/2/Make/Suzuki/YearID/35/Year/1994/ModelID/6446/Model/GS500E/GroupID/268553/Group/CYLINDER

Part number 5.  Only $6.50 plus shipping.

Ring sticking out?  What would cause that nasty scratch?  Whatever it is try to figure it out before you end up with the others the same way.  Oh and ronayers has been good to me on pricing,..their shipping is a bit lengthy sometimes.

Quote from: cbrfxr67 on March 05, 2012, 01:23:30 PM
Ring sticking out?  What would cause that nasty scratch?  Whatever it is try to figure it out before you end up with the others the same way.  Oh and ronayers has been good to me on pricing,..their shipping is a bit lengthy sometimes.

I was thinking the same thing...

Quote from: cbrfxr67 on March 05, 2012, 01:23:30 PM
Ring sticking out?  What would cause that nasty scratch?  Whatever it is try to figure it out before you end up with the others the same way.  Oh and ronayers has been good to me on pricing,..their shipping is a bit lengthy sometimes.

yea I am just going to bite the bullet and order a new gasket from the dealer ><
so im down for another 2 weeks now ><
oh well, guess the gf and the house remodeling work get more of my attention.

not sure what caused the scratches. (2)
could have been one of many things im thinking.
it looked pretty fresh, so it could have been when I was pulling the cylinders.
I'll have to triple check ring clearance in the new cylinders before I put that one in.

(edit)
kk just borrowed some $$ off my dad so I dont have to wait until Friday to order a new gasket.
will be stopping by the dealer after work tomorrow and then be stuck on 4 wheels for at least a week and a half

would have waited but now that I moved, the dealer is a good 30 mins drive away.
and also because I am off Tues Weds Thurs and would have to drive there from home Friday.
vs right from work tomorrow as its closer and they open when I will be getting out of work.
so its just easier to go straight from work tom.

Now im just waiting to see what problems arise when this gets done.....

Dismantling another bike in the near future is VERY slim now!
Just tooooo many problems.
Unless I already have another bike to ride.
that is probably the only reason I am so stressed with this bike.
I WANT TO FRIGGIN RIDEEEEEEEEEEEEEE!!!!!!!!!!!!!!!!      hahahaha

kk just got back home.
Ordered 2 new lower cylinder gaskets.
Only $8 a pop, so I got an extra for my bad luck. haha 

Also might order all new piston rings.
Gotta check out everything and measurements in my old cylinders I need to use now.
Even if they are good, i still might just buy brand new as 2 sets would only be no more then $70.
and yeah I know some people say just replace them, and then some say you dont have to if they are in good shape and within spec.

all depends on specs, if I wanna be patient and better safe then sorry.
and if I have enough left after bills and paying for the cowling on Friday.

fairly good chance even if I cant buy them Friday, that I will be patient and wait 2 more weeks to purchase them.
Which if nothing goes wrong after that.
She will be up and running at the beginning of April.

(edit)
forgot to add.
yes the lower gasket I used that failed was total and utter garbage!
I suspected as much but the dealer confirmed it when I told him the material on it was "flaking" off.
vs the other new gasket above the cylinders still looks brand new.
hes like yeah, that shouldnt do or look like that.

and oh yeah.
got the best addition to the bike yesterday in the mail!
my Gstwin.com stickers  haha

At least youre ironing those things out.  You will have a sweet ride.  Keep it up brother, you can do it.