Crack in cylinder head 83 GS 1100 E

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  • Fancool
    • Feb 2026
    #1

    Crack in cylinder head 83 GS 1100 E

    I'm just about to take the cylinder head off the bike due to a crack in the housing caused by an exhaust stud being driven in to far and oil has been leaking ever since. The bike runs great and the only problem is this leak.
    I have a couple of questions and looking for advice.

    Is it worth it to send the head to a machine shop that specializes in aluminum motors and have it x-rayed, welded, and hopefully repaired, or get new/used head?

    Is there anybody on this site that would know where I can find a replacement head?

    Is there anything I should be aware of when doing this repair, I have a manual and an awesome set of tools!?

    I'm going to look on eBay and try local bike salvage but I prefer to deal with someone from this site as I have more trust here when it comes to the GS's.
    Tags: None
    • Fancool
      #2
      What is anyone's thoughts if I remove stud and use some JB weld on the stud and then reinstall?
      I'm wondering if that will make it more difficult to remove if the leak still persist?

        Comment

        • sharpy
          #3
          You sure its from the stud and not from the head nuts o-ring that leaks. is it the #4 stud from the left thats "leaking"?

            Comment

            • Fancool
              #4
              #3 exhaust port upper bolt/stud.
              But I'll recheck.

                Comment

                • Guest
                  #5
                  Sounds like a new head is in order. Put a wanted ad up.

                    Comment

                    • rapidray
                      Forum Guru
                      GSResource Superstar
                      • Oct 2006
                      • 8195
                      • So Cal
                      #6
                      It's easy to fix if you have the head off. No need to replace the head. PM me your # & I will call you.
                      Ray.

                        Comment

                        • JTGS850GL
                          Forum Guru
                          Past Site Supporter
                          • Aug 2013
                          • 9735
                          • GA
                          #7
                          JB weld will not work. The exhaust port temps are too high in that area for the JB. I'm betting that welding up the hole and re taping it is the cure.
                          http://img633.imageshack.us/img633/811/douMvs.jpg
                          1980 GS1000GT (Daily rider with a 1983 1100G engine)
                          1998 Honda ST1100 (Daily long distance rider)
                          1982 GS850GLZ (Daily rider when the weather is crap)

                          Darn, with so many daily riders it's hard to decide which one to jump on next.;)

                          JTGS850GL aka Julius

                          GS Resource Greetings

                            Comment

                            • Fancool
                              #8
                              Hi rapidray, I sent you a PM and thanks for your help.

                                Comment

                                • Fancool
                                  #9
                                  So I believe I will be removing head to get it welded. I don't trust the easy way and the bike is to good to do band aid repairs on it.

                                  Ok now the next question.

                                  Gaskets? should I replace with top end kit or just get the two main large gaskets?

                                  Dose anyone know where I can get reasonably priced kit?

                                  Again no leaks anywhere except where the stud cracked the block.

                                    Comment

                                    • TxGSrider
                                      Forum Sage
                                      Past Site Supporter
                                      • Aug 2015
                                      • 1015
                                      • Flower Mound, TX
                                      #10
                                      Originally posted by Fancool
                                      So I believe I will be removing head to get it welded. I don't trust the easy way and the bike is to good to do band aid repairs on it.

                                      Ok now the next question.

                                      Gaskets? should I replace with top end kit or just get the two main large gaskets?

                                      Dose anyone know where I can get reasonably priced kit?

                                      Again no leaks anywhere except where the stud cracked the block.



                                      If Ray gets a hold of it, it'll probably come back making another 20hp! :-)
                                      1982 GS1100E "Jolene"

                                        Comment

                                        • Fancool
                                          #11
                                          DSC_7857.jpg
                                          Already have the Mikuni flat side carbs, V+H super sport pipe, Drag clutch and more.
                                          Not my doing but certainly makes for an exciting ride!!

                                            Comment

                                            • Guest
                                              #12
                                              Make sure you update this thread on how it's fixed, it'll help others in the future. Nice looking bike!

                                                Comment

                                                • Fancool
                                                  #13
                                                  Yes I will. I took apart most of the top end today and hopefully will have the head off tomorrow. So far the motor is coming apart very well.

                                                    Comment

                                                    • Fancool
                                                      #14
                                                      Clinder head removal.

                                                      031.jpg
                                                      The cylinder head is off.
                                                      ordered new gasket kit , need to get this head checked and repaired .

                                                        Comment

                                                        • Fancool
                                                          #15
                                                          032.jpg

                                                          A lot lighter now.

                                                            Comment

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