Cylinder block leak query

user11235813 · March 23, 2016, 07:24:33 PM

A leak has suddenly developed around the cylinder block at the front. At the moment it's not enough to cause me to need to add any oil but it seems to have gotten a bit worse lately and I was wondering if I should do something about this now to stop a more serious problem. There's always been a tiny bit of seepage at this point but it has not been pooling oil in the area until recently.

The one bit of maintenance that I have not done is to re torque the cylinder head bolts and I wonder if that is probably the culprit or does this look like it's going to need a new gasket?

Iarn · March 23, 2016, 07:33:26 PM

A re-torque is certainly something that is standard maintenance. Give those heads/block a re-torque and see if that solves the issue.

user11235813 · March 23, 2016, 08:22:55 PM

OK I will give that a go, can you tell me what is the minimum I need to dismantle. It looks like I'll have to take off the breather cover and valve cover as well as tank and carbs. Or can I leave the carbs in place. Also is the breather cover removal necessary to get the valve cover off?

thanks.

Iarn · March 23, 2016, 08:47:14 PM

Seat, tank, valve cover are all that needs to come off for this, according to my manual; take off the valve cover, you don't need to touch the breather cover.

Should be a pretty simple job all things considered. Just make sure you loosen/break those bolts before you try to torque them to make sure they are properly torqued. You got this.

user11235813 · March 23, 2016, 08:48:53 PM

Okie dokie, I will report back thanks.

user11235813 · March 23, 2016, 09:32:14 PM

I can't see how the bottom of the valve cover can clear the top of the timing chain, without removing the breather cover to get some extra room. Also is there some trick to manipulate the valve cover around the carburettor cables? thx.

Iarn · March 23, 2016, 11:08:19 PM

http://forum.gs500.pl/ftp/Studi/Suzuki_GS_500_E_F_1989-2009_Service_Manual.pdf

Here is an online manual I found for you. For what you're working on, check out Section 2 page 4 (2-4) and Section 3 page 10 (3-10)

Hope this helps you. Cheers

user11235813 · March 24, 2016, 12:30:31 AM

thanks yes I have that manual, it says not to remove the breather but that must be for an engine that is not in the frame I can't see how the cover can come off otherwise. I took it off anyway and I was able to maneuver the head cover so as to access all the bolts. All seems OK now and I was thankful that somehow I was able to get the torque wrench in various configurations to fit. Fingers crossed that that has fixed the oil leak.

Big Rich · March 24, 2016, 06:05:06 AM

User, check your breather hose from the top of the engine. If there's a clog in the system (usually the drain hose from the airbox), internal pressure can build up and cause seepage from the base gasket.

user11235813 · March 26, 2016, 06:25:27 PM

Thanks Rich, looks like there was a bit of seepage still the next day, but I took the gs for for a longer ride and lo and behold the leak has completely seal up. The steel noodle packet in the breather cover fell out and I could not tell which part of the breather cover it went into, I put it in towards the rear of the cover.

All the nuts were very tight I was a bit worried forcing them open and I had to use an old deflecting pointer style pre war model torque wrench which I eyeballed to 30ft/lbs, hopefully it's accurate enough.

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Cylinder block leak query