SUZUKIPictures of how I made a new oil pan gasket from a cereal box and fixed the oil leak on my 89-09 Suzuki GS500 motorcycle.

But first, lets pay some bills:

  1. Put bike on center stand.

  2. Removed exhaust. I already had the exhaust off for head gasket work. See Remove_Head for pics.

  3. Drained oil, Removed oil pan.
    oily oil pan

  4. Removed oil pan gasket for re use. Or not.
    You can also see the broken oil pan bolt taken off with the vice grips. That broken bolt probably contributed to the oil leak.
    Oil Pan Gasket

  5. Cleaned the oil pan.

  6. Cleaned the oil pan and engine case gasket mating surfaces.
    gasket surface

  7. Salvaged what I could of the gasket that I mangled the heck out of trying to get off. Brittle and leaking after 20k miles. Filled in the blanks as best I could for the missing pieces on the back of this cereal box.
    cereal box gasket

  8. Cut out the gasket using scissors, razor blade, and chisels for the interior circles. Made final measurements to fit the new cereal box oil pan gasket directly from the oil pan.
    cereal box gasket

  9. I reinstalled the oil pan with the new cereal box gasket with the printed side toward the engine. I read that the printed side is less likely to stick, and it is easier to clean the oil pan sitting on the bench than the engine lying on your back. I will let you know if this is true, but hopefully not for 20k more miles.
    oil pan reinstalled

  10. Then I filled it up with oil!

  11. edit: 1/2011
    About 2k miles later. The cereal box leaked quite a bit. I got some cork gasket material from the local auto parts store and cut out a new gasket. That was 2k miles ago and no more leaks.
    cork gasket material

  12. Next I sold out to make 02ยข so I can fulfill my lifelong dream of owning a 1986 944 with blown head gaskets.

    But no minivans!

  13. Then I finished my beer.


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