Head gasket GS1000G questions

[Matchless]

I plan on pulling the heads and cylinders on my GS1000G 1980 and have a full gasket set from Parts'n more. Its made by Athena and seems fairly complete with many o-rings included.
The head gasket has me a bit stumped, it seems to be made of two layers of solid metal and in some threads the issue of extra seals on the outer studs were discussed but I do not see any in the set. There are also 4 copper crush washers which I do not know where to fit.
Any suggestions on which is up or down and the outer studs sealing?

PS: I also cannot find a rectangular o-ring that fits around the camchain opening in the set.
Edit: Athena has confirmed today, 2008/07/08, that the rectangular gasket is not required on this gasket which is now according to the latest OEM part number for the head gasket. See details in post toward the end of this thread.

Thanks

 

[Matchless]

Here is a picture of the Athena head gasket if it may help. Looking at it closer it has two metal outers with some kind of black covering on the outer side and an inner with sort of shaped indentations between and this is is held together by 4 small rivets.
I have no idea how to fit this one to the GS1000G head, if anyone can help with advice I will appreciate.
Thanks

 

[focus frenzy]

I think you are missing parts.

definitely need the square one for the came chain tunnel.

I am drawing a blank on the studs, when I rebuilt the top end on my 1000G the Suzuki replacement head gasket was sandwiched metal like that but I cant remember what sealed around the oil passage studs.

the old gasket was a conventional metallic coated fiber gasket with fire rings. like found on car engines.

 

[Matchless]

Focus,
Thanks, I have carefully checked the full set I odered from the States and it seems to have just about every gasket and o-ring needed, except that rectangular one. I dont know where I am going to find one around here. Do you think it can be made up?
I also noticed that the outer stud holes are the same size as the others, not like those discussed in other threads that seem bigger to take some sort of seal.
Hopefully someone comes along that is familiar with this type of head gasket.
Keep well

 

[catbed]

no sealing rings around my studs, just the head gasket. you also need that rectangular o ring.

 

[Matchless]

Catbed,
Do you know if you had the same type of headgasket? Possibly an Athena?

I think once I have the head off I will be able to see the old rectangular gasket. It was a disappointment not finding one in the kit and I most probably will have to order one from the USA.

Thanks for the response.

 

[SqDancerLynn1]

If you haven't figured it out yet the copper washers go under the acorn head nuts, on the outer two studs as i remember

 

[Suzuki_Don]

Andre, order the rectangular "O" ring for the cam tunnel from your local Suzuki dealer. It shouldn't cost much.

EDIT: Sorry, it's about $23 US.

 

[Guest]

Andre, order the rectangular "O" ring for the cam tunnel from your local Suzuki dealer. It shouldn't cost much.

EDIT: Sorry, it's about $23 US.

23 bucks? Wow, what a rip-off!

Andre, I have several gasket sets for a GS1000. I'll send you the rectangular gasket out of one of them if you need it.

 

[catbed]

i do not know if they are the same but i had an MLS gasket. multi player steel. sounds like yours though.

 

[Matchless]

If you haven't figured it out yet the copper washers go under the acorn head nuts, on the outer two studs as i remember

Lynn,
In the kit I got very heavy copper washers and assumed that these go under the acorn nuts once the head is fitted.
I also got 4 round copper crush washers and was wondering where these go. Are these the ones you are referring to?

Thanks for your reply.

 

[Schweisshund]

If you haven't figured it out yet the copper washers go under the acorn head nuts, on the outer two studs as i remember

aren't they used for the exhaust pipes?

I just ordered exhaust gaskets and they were round thick copper crush O-ringy type things.

 

[Matchless]

Andre, order the rectangular "O" ring for the cam tunnel from your local Suzuki dealer. It shouldn't cost much.

EDIT: Sorry, it's about $23 US.

Don,
Our local people usually charge double as they again order from Belgium and it could take anything from 2 to 6 months if you are lucky!
Shipping is also going to be a killer as the last small part I ordered was nearly $20
I will see if someone from the USA cannot send me one in an envelope.
Thanks for the reply.

 

[Schweisshund]

If those copper crush o rings look like this :

http://cgi.ebay.com/ebaymotors/NEW-...42330542QQcmdZViewItem?hash=item260242330542&

they go inside the head where you attach the exhaust pipes

 

[Guest]

a good pic of the parts in question would help eliminate speculation

a good pic of the parts in question would help eliminate speculation

4 copper washers go under the head acorn nuts
if you have another set of similar size - those likely go in the head gasket where the oil passages are
rectangular gasket around the cam chain (on an 850) is an (o-ring type) rubber gasket and mine was very reusable - so i'd wait untill the barrels are off to see if you actually need one
head gasket, if the metal inserts around the cylinders are wider on one side of the gasket - then that side of the gasket faces UP

 

[Matchless]

aren't they used for the exhaust pipes?

I just ordered exhaust gaskets and they were round thick copper crush O-ringy type things.

There were just 4 in the full gasket set, and their diameter is slightly larger than the header bolts. The actual exhaust gaskets that I received are quite large and about the diameter of the header pipe.
These was a thread and pictures of a washer with rubber on one side being fitted to the outer 4 studs right in the gasket stud hole, between the head and the cylinder, but those stud holes seemed a bit larger than the others and the gasket was manufactured differently and not made by Athena.

 

[Schweisshund]

There were just 4 in the full gasket set, and their diameter is slightly larger than the header bolts. The actual exhaust gaskets that I received are quite large and about the diameter of the header pipe.
These was a thread and pictures of a washer with rubber on one side being fitted to the outer 4 studs right in the gasket stud hole, between the head and the cylinder, but those stud holes seemed a bit larger than the others and the gasket was manufactured differently and not made by Athena.

do they fit over the dowels? just a guess. You should also have an oil dowel somewhere too (I think)

 

[Matchless]

Hi All, Thanks for all the replies, my gasket has no metal inserts the 3 layers are actually loose and just held together with 4 small studs.
Here is a picture of the copper gaskets that came with the set.
Left are the exhaust gaskets, then the 4 copper crush gaskets, then the four heavy copper washers, then 4 very small copper washers.
I am sort of trying to get everyting together before I open her up.

 

[Matchless]

23 bucks? Wow, what a rip-off!

Andre, I have several gasket sets for a GS1000. I'll send you the rectangular gasket out of one of them if you need it.

Renobruce,
Thanks for the offer I have sent you a PM. I think it was just my bad luck that this was not included as the set was still sealed and had so many parts that I never checked it and going back to Parts'nmore will most probably be a waste of time as the shipping was $82 for the $61 complete set via Fedex. I got the shock of my life.
If you can, ordinary envelope via airmail like Robert Barr does please
Again thanks you guys are just great!

 

[Guest]

it's too late now, but for next time ...

it's too late now, but for next time ...

the shipping was $82 for the $61 complete set via Fedex. I got the shock of my life.

buy your parts from a smaller/customer friendlier place (such as z1enterprises) and ask them to ship "usps priority", you get a track number, gets to new zealand within a week or two and costs a lot less than fedex or ups
bigger retail places have policies in place on who they use for shipping but smaller sellers and ebay are usually happy to ship with your prefered company
ups and fedex are notoriously expensive for overseas shipping