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General Category >> Rubber Side Down! >> Head gasket repair, by a newbie
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Message started by BlackCorona on 07/03/14 at 18:14:57

Title: Head gasket repair, by a newbie
Post by BlackCorona on 07/03/14 at 18:14:57

So I bought a quite new '88 Savage for $400. The only problem was what Suzuki said was a blown head gasket. My friend is helping me fix it (he has done these sorts of repairs on smaller bikes) but I have not. We do have the service manual but I was wondering if anyone would be able to post a video showing how to take the engine down properly, just to ease my nerves. If not what about a walk through in more common speak?

EDIT: are there any other repairs I should absolutely make sure to do while I have it taken down?

Title: Re: Head gasket repair, by a newbie
Post by engineer on 07/03/14 at 18:48:09

Typing out an engine tear down walk through would be a lot of work. Take a look in the tech section. There is even a table of contents, actually several of them, grouped by category. Plus, there is a series of very good photos you can download that show various stages of disassembly. Valuable stuff. Good luck and when you have more specific questions there are lots of guys here who can give you some good answers.

As far as what else you might want to do while you have it torn down depends on what it needs and how much you want to spend. How many miles are on the bike?

The cam chain tensioner may need the Versy upgrade. You will want to pay special attention to torque values and sealing the plastic plug when reassembling.

Title: Re: Head gasket repair, by a newbie
Post by justin_o_guy2 on 07/03/14 at 20:01:29

You're the hundredth to think it's the head gasket. None have been right.
Look in the tech section for head plug leak.

Title: Re: Head gasket repair, by a newbie
Post by verslagen1 on 07/03/14 at 20:27:15

tech section index
go down to engine
1st couple of titles

our mantra...
we never believe what the stealership says.
we always watch what the stealership does.
Johnie still in high school seems to always work on our bike.
we always ask our brothers for a 2nd opinion.
we need pictures.

Title: Re: Head gasket repair, by a newbie
Post by S-P on 07/03/14 at 21:43:14

You can do the head plug fix without completely removing the motor. It's tricky but a lot easier than pulling the motor out of the chassis.

Title: Re: Head gasket repair, by a newbie
Post by BalingWire on 07/04/14 at 05:25:54

Ode to an oil plug leak.

[ch9835] Leakage from a basket case,
Smudges from "head gasket" trace,
Makes the bike so cheap to buy,
"Oil plug" fix easy as pie. [ch9834]

Fellows, do you think I could make my living as a song writer in Nashville? ;D

Title: Re: Head gasket repair, by a newbie
Post by Dave on 07/04/14 at 10:47:18

0625282D2A23132D3621440 wrote:

You didn't mention your dog, Momma, Trains, Prison.....or drinkin'!

Dave

Title: Re: Head gasket repair, by a newbie
Post by Serowbot on 07/04/14 at 10:49:46

I'd keep my day job... ;D...

Title: Re: Head gasket repair, by a newbie
Post by NickGann on 07/04/14 at 10:55:05

I live near Nashville, that's as good as anything I've heard here.

Title: Re: Head gasket repair, by a newbie
Post by BlackCorona on 07/04/14 at 17:42:36

Thanks all very much! Just a question about the head plug though, does it need to be completely replaced? That can be done, but I'm just curious. Like I said, not a ton of experience with small engine repair.

Edit: Does anyone have a link to a replacement head plug or a part number?

Title: Re: Head gasket repair, by a newbie
Post by Gerry on 07/05/14 at 05:02:31

654B46444C644855484946270 wrote:

It's #24 in the exploded view shown in this link...
http://www.suzukipartspitstop.com/oemparts/a/suz/50d32e9df8700232d0b3d66e/cylinder-head
This is where I bought all my parts, there are many other sources as well, some of the other fellas will chime in.

Also, did you go thru the tech section? This thread is pretty good for what you are going to do...
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1099227295

HTH
Gerry

Title: Re: Head gasket repair, by a newbie
Post by BalingWire on 07/05/14 at 05:39:27

[...] the head plug though, does it need to be completely replaced?

In my opinion, no.

If you have an older style steel head plug, I think the old steel plug is superior to the newer rubber plug. I bought the new part, but after looking at the parts, I put in the old part again. Just squirt some goop in the groove that is begging for some sealant.

The newer rubber plug also has a groove for goop, but it looks and feels like it would seal without it.

(If you have a newer rubber plug in yours, and it is getting hard and cracked, it might need replaced.)

Title: Re: Head gasket repair, by a newbie
Post by justin_o_guy2 on 07/05/14 at 06:49:33

It's one of those things that are not always just one way or the other.

Title: Re: Head gasket repair, by a newbie
Post by BlackCorona on 07/05/14 at 11:44:51

Thanks all for helping a young guy with his first bike! These are all fantastic sources that I have been looking for but have been unable to find!!!

Title: Re: Head gasket repair, by a newbie
Post by BlackCorona on 07/08/14 at 01:26:27

Edit: Head cover refuses to be removed. We don't want to pry, any ideas? I routinely feel incompetent with these sorts of things, so feel free to assume the obvious.

Title: Re: Head gasket repair, by a newbie
Post by justin_o_guy2 on 07/08/14 at 02:48:32

I Gay Ron Tee you've left a bolt in it. Look at a diagram,count and compare.

Title: Re: Head gasket repair, by a newbie
Post by Dave on 07/08/14 at 04:38:22

Did you remove the bolts that are under the covers for setting the valve clearance? Those are sneaky ones......they are.

Dave

Title: Re: Head gasket repair, by a newbie
Post by Bubba on 07/08/14 at 13:20:51

yeah, and check the underside of the headcover ...there are 2 bolts (front/back of cylinder) you can only access from below...

Title: Re: Head gasket repair, by a newbie
Post by Dave on 07/08/14 at 13:47:47

201700000353525A51620 wrote:

yeah, and check the underside of the headcover ...there are 2 bolts (front/back of cylinder) you can only access from below...

Those nuts hold the cylinder head onto the cylinder......not the head cover onto the cylinder head. You need to remove those nuts when you take the head off the cylinder.

Dave

Title: Re: Head gasket repair, by a newbie
Post by Bubba on 07/08/14 at 14:58:30

Thanks for the correction Dave,
I recalled those because I ripped apart a savage engine a couple years ago and remember thinking "what the hell" when I was tearing it down... :-[

Title: Re: Head gasket repair, by a newbie
Post by BlackCorona on 07/10/14 at 12:03:42

I shall check those! Thanks all for so much help!!!

Title: Re: Head gasket repair, by a newbie
Post by S-P on 07/11/14 at 16:08:35

032D20222A022E332E2F20410 wrote:

Edit: Head cover refuses to be removed. We don't want to pry, any ideas? I routinely feel incompetent with these sorts of things, so feel free to assume the obvious.

First be SURE you have ALL the bolts out. There are a couple hidden ones. The next thing is either a rubber mallet or block of wood with a hammer and a LIGHT tap tap tap around the head at different points to break the sealant free.

Title: Re: Head gasket repair, by a newbie
Post by LANCER on 07/12/14 at 04:39:56

Did you get the bolt that is in the center of the head cover; directly under the frame backbone ? That is sometimes overlooked, along with the 2 that Dave mentioned, inside the little valve access covers.

Title: Oh no :(
Post by BlackCorona on 07/22/14 at 01:34:42

Okay, so thanks to everyone's help I fixed my blown head plug. Unfortunately it still won't start. The electric start works fine, just no starting. I can post a video of this if you think it will help!

Title: Re: Head gasket repair, by a newbie
Post by verslagen1 on 07/22/14 at 08:57:45

I spliced your 2 threads together... it helps us to know previous history.

You might try...

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1403194022

Title: Re: Oh no :(
Post by S-P on 07/22/14 at 16:55:19

143A37353D153924393837560 wrote:

Mine wouldn't start after I did some engine work on it. Try a couple second blast of starting fluid into the air cleaner, wait a few seconds for it to vaporize then try starting it. If it runs then you have a fuel/air related issue. That will eliminate most electrical and "no spark" issues.