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1983 GS 650g Valve Cover Replacement

  • Thread starter Thread starter Mop Bucket
  • Start date Start date
M

Mop Bucket

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I need to replace my valve cover with a different one. I haven't been able to locate an 83 cover. Does anyone know or have swapped with an 82 valve cover? Basically, can I bolt on the 82 without issues?
 
I believe the cover change involved a change to the bolt pattern.
 
There are two different covers for the 650 but I dont know when or how.
Maybe someone else will chime in on the specifics.
 
Nessism said:
I believe the cover change involved a change to the bolt pattern.
Click to expand...

Comparing with a cover on ebay there are extra screw holes on the 83. Looks like I am still out of action until one goes on Ebay. Thanks again Nessism.
 
Well looked at some more covers and checked gaskets, some covers look to have the same bolt pattern as the 83. Also, looking up the gasket, the same gasket is used for many years and models. Has anyone tried a different cover on the gs650 81-83? Specifically, has anyone used an 81 or 82 cover on an 83?


 
Steve has it right, no surprise. Sometime in 81, suzuki went with a 17 bolt valve cover. All 82 and 83 should use the 17 bolt pattern. Just look for the bolt hole on the front crankcase chain tunnel in the middle.
 
There is some confusion whether the change happened in '81 or '82. 1982 seems the more popular consensus around engine number 106933. But it's not important anyway. If you have the 17 bolt cylinder head then you have to use the 17 bolt cylinder head cover and gasket.

I have to ask what is wrong with the cover that you already have. Is it broken in some way?
 
Last edited:
This is a repair job that was done, but it leaks.
IMG00710.jpg
 
Is that a weld job? :eek:

It might be possible to clean out the inside and spread a layer of JB Weld to seal it up. :o

Had to do that to my Wing valve cover after it got tipped over last spring.

.
 
Mop Bucket said:
Well looked at some more covers and checked gaskets, some covers look to have the same bolt pattern as the 83. Also, looking up the gasket, the same gasket is used for many years and models. Has anyone tried a different cover on the gs650 81-83? Specifically, has anyone used an 81 or 82 cover on an 83?
Click to expand...
As others have pointed out, some cam cover change happened in 82 model year. So an 81 cover would fit some 82. Why don't you just have your existing cover repaired by a pro?
 
There is a ebay parts guy here in Vegas. He had an 81 cover for $5. Bought it and installed it today. Looks like the cover fits pretty well on the newer engine. Will fire it up after I fix the other blunders of the PO and CO(Current Owner). Basically, when I found the weld job was leaking, I also found the drain plug and generator cover was leaking. Replacing the oil pan and gasket on generator cover hopefully soon.



 
Well done. I would double check the valve cover to make sure it does not leak around the mismatch at bolt hole No. 17 on startup.
 
Make sure you know which style you are getting first.

Some 82's actually have the 81 design!
(guess how I found this out......the hard way!)

The 82's have 1 extra bolt in the front-middle, and Im positive atleast 2 other bolt positions are altered slightly to the left, if you're standing in front of the bike.

Like I said though, the easiest way to tell which style you are getting, is to look and see if there's that extra bolt near the Front-Middle area of the valve cover, it's right near the middle-nose, slightly to the left, IF you're standing in front of the bike.

Just going by memory, could be a tad fogged.
 
1_v8_merc said:
Make sure you know which style you are getting first.

Some 82's actually have the 81 design!
(guess how I found this out......the hard way!)

The 82's have 1 extra bolt in the front-middle, and Im positive atleast 2 other bolt positions are altered slightly to the left, if you're standing in front of the bike.

Like I said though, the easiest way to tell which style you are getting, is to look and see if there's that extra bolt near the Front-Middle area of the valve cover, it's right near the middle-nose, slightly to the left, IF you're standing in front of the bike.

Just going by memory, could be a tad fogged.
Click to expand...

Don't you mean when sitting on the bike.
 
Mop Bucket said:
Basically, when I found the weld job was leaking, I also found the drain plug and generator cover was leaking. Replacing the oil pan and gasket on generator cover hopefully soon.
Click to expand...

If it's just the drain plug that is leaking, there is no need to replace the oil pan. :eek:

First, make sure it's not a gasket that is leaking. Those crush washers can be re-used many times, but eventually need to be replaced.
If the threads on the pan are loose, go to Auto Zone (or whatever you have locally) and get an oversize drain plug.
They come in a couple of sizes, you should only need the "Plus 1".

.
 
Had a huge reply to explain my bike extravaganza, but, in short, stripped the plug. Put the +1 plug in crooked, and it leaks. So, found a cheap replacement pan on ebay.

Really appreciate everyone?s help so keep the suggestions coming. Hopefully get time later today to pop that sucker off. There is also a ton of crude in the bottom of the engine from the PO's imaginative try at making a gasket out of goop.
 
Thanks, but I would hate to screw up another bike :) Ran it for 10 minutes and no leaks.
 
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