SuzukiSavage.com - Head Gasket and Head Cap Install

jcharro YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 7	Head Gasket and Head Cap Install 02/27/13 at 21:23:17 Hello Everyone, Im taking on the awsome task of installing new head gasket and cap this weekend. My main question is; do I have to remove the motor from frame for the head gasket install? Or has anyone done it while motor sits in? Thanks in advance.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Head Gasket and Head Cap Install Reply #1 - 02/28/13 at 05:05:32 Why are you replacing the head gasket? The rubber plug is usually the only thing that needs replaced.
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jcharro YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 7	Re: Head Gasket and Head Cap Install Reply #2 - 02/28/13 at 06:09:53 From the looks of it, there's a good amount of oil accumulation in the fins where the head gasket sits. So, you're telling me that oil accumulates there when ONLY the head cap needs replacement?
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Re: Head Gasket and Head Cap Install
Reply #3 - 02/28/13 at 06:49:09

I am not aware of anyone having a head gasket problem. You most likely will just need to do the plug.

Have you looked at the Tech Section and looked up this process in the Index? It would help to see the process before you need to do it yourself.

I also recommed ypu get a small pastic syringe to put the sealer in...so you have better control over the applicaton. You only need a thin strip of sealant on the head cap - there is no reason to have a large amount squeezing out and blocking the oil pasages.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: Head Gasket and Head Cap Install Reply #4 - 02/28/13 at 08:09:37 Give everything a good cleaning and watch where the oil starts from. Under the head, or on top. sometimes, when the head is not retorqued (especially those 2 nuts on the underside) it can leak.
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jcharro YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 7	Re: Head Gasket and Head Cap Install Reply #5 - 02/28/13 at 08:57:34 I appreciate you guys allot. I'll go ahead and give the motor a good cleaning and replace the Cap and O-ring only. After that tighten all loosen bolts and look to see if any more oil leaks or accumulates.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Head Gasket and Head Cap Install Reply #6 - 02/28/13 at 09:25:13 Theres about the two hundredth head gasket job Ive seen that didnt need done, I wonder how many of those things got replaced before this forum came along..
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Re: Head Gasket and Head Cap Install
Reply #7 - 02/28/13 at 23:36:27

I forget what sealant Suzuki sells, but I used Yamabond on mine as suggested by my Suzuki shop. It works well where there is no gasket. But getting it in a syringe would be a real task. Just cut a small slant on the tube spout and roll it up from the end as you apply it. You have about 15 minutes to get it done, but it's no problem. I did mine in the bike, but I practiced rotating the head cap in on a couple of dry runs first.

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Head Gasket and Head Cap Install Reply #8 - 03/01/13 at 06:25:35 I used the Suzukibond - and it worked great in a syringe.....guess I will have to take some photos. I just pulled the plunger out of the back of the small plastic syringe, then squeezed the Suzukibond goo into the open syringe - then put the plunger back in. The flow was far easier to control than it is from the tube.
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mikey2004 Junior Member Offline SuzukiSavage.com Rocks! Posts: 57 Sarasota Florida Gender:	Re: Head Gasket and Head Cap Install Reply #9 - 03/03/13 at 11:08:30 i had the same problem with mine and i thought it was the head gasket. turned out that the head cap was the wrong size. but i can tell you that when the cap goes bad ALOT of oil comes out from the hole behind the exhaust pipe where it bolts into the motor. replace the cap i bet you will be good to go.
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mikey2004 Junior Member Offline SuzukiSavage.com Rocks! Posts: 57 Sarasota Florida Gender:	Re: Head Gasket and Head Cap Install Reply #10 - 03/03/13 at 11:09:39 dave i never thought of that. GREAT idea. when i replace my clutch i will do that.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18099 Camp Springs, Kentucky Gender:	Re: Head Gasket and Head Cap Install Reply #11 - 03/04/13 at 05:24:25 mikey2004 wrote on 03/03/13 at 11:09:39: dave i never thought of that. GREAT idea. when i replace my clutch i will do that. There is no reason to use sealant on the clutch cover. Get a new gasket from Suzuki.
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jcharro YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 7	Re: Head Gasket and Head Cap Install Reply #12 - 03/04/13 at 07:48:44 Everything went just as planned fellas, Thanks for all your help.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Head Gasket and Head Cap Install Reply #13 - 03/04/13 at 08:42:58 Wheres the crushed up brillo pad stuff?
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jcharro YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 7	Re: Head Gasket and Head Cap Install Reply #14 - 03/07/13 at 13:57:23 It's a no-brainer when you have a guide for all bolts and screws..
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