SuzukiSavage.com - Head gasket repair, by a newbie

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Head gasket repair, by a newbie
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?

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Re: Head gasket repair, by a newbie
Reply #1 - 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.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Head gasket repair, by a newbie Reply #2 - 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.
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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 repair, by a newbie Reply #3 - 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.
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S-P Serious Thumper Offline Back in the saddle again Posts: 816 Phoenix, AZ Gender:	Re: Head gasket repair, by a newbie Reply #4 - 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.
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BalingWire Full Member Offline "The savage in man is never quite eradicated." HDT Posts: 238 Wauseon, Ohio Gender:	Re: Head gasket repair, by a newbie Reply #5 - 07/04/14 at 05:25:54 Ode to an oil plug leak. ♫ Leakage from a basket case, Smudges from "head gasket" trace, Makes the bike so cheap to buy, "Oil plug" fix easy as pie. ♪ Fellows, do you think I could make my living as a song writer in Nashville?
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Re: Head gasket repair, by a newbie
Reply #6 - 07/04/14 at 10:47:18

BalingWire wrote on 07/04/14 at 05:25:54:

Ode to an oil plug leak.

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

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

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

Dave

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Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28660 Tucson Az Gender:	Re: Head gasket repair, by a newbie Reply #7 - 07/04/14 at 10:49:46 I'd keep my day job... ...
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NickGann Junior Member Offline SuzukiSavage.com Rocks! Posts: 75	Re: Head gasket repair, by a newbie Reply #8 - 07/04/14 at 10:55:05 I live near Nashville, that's as good as anything I've heard here.
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BlackCorona YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 6	Re: Head gasket repair, by a newbie Reply #9 - 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?
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Re: Head gasket repair, by a newbie
Reply #10 - 07/05/14 at 05:02:31

BlackCorona wrote 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?

It's #24 in the exploded view shown in this link...
http://www.suzukipartspitstop.com/oemparts/a/suz/50d32e9df8700232d0b3d66e/cyl...
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

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BalingWire

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Re: Head gasket repair, by a newbie
Reply #11 - 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.)

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"The satisfactions of manifesting oneself concretely in the world through manual competence have been known to make a man quiet and easy."
Shop Class as Soulcraft: An Inquiry Into the Value of Work

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Head gasket repair, by a newbie Reply #12 - 07/05/14 at 06:49:33 It's one of those things that are not always just one way or the other.
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BlackCorona YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 6	Re: Head gasket repair, by a newbie Reply #13 - 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!!!
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BlackCorona YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 6	Re: Head gasket repair, by a newbie Reply #14 - 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.
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