1979 GS850 Oil Pan Gasket DIY

[mpidsadny]

Hi everyone,
I am nearing starting my bike for the first time in over 20 years! There's one missing piece of the puzzle though, the oil pan gasket.

I have been waiting on this part for nearly a month from japanesedreambikes on ebay. They have positive reviews from members on this site so my experience must be an anomaly. The promised delivery date came and passed about a week ago so I am now considering making my own.

Does anyone here have any experience with cutting their own oil pan gasket? I understand that there is a special pattern of holes that must be cut and I have sturdy oil rated gasket material to create the gasket. If this is possible, would anyone have a gasket they could scan and send a photo over to me?

Thanks for everyone's continued contributions to my forum posts and the posts of others. It makes reviving these old bikes possible!

[rphillips]

I just punched on ebay... suzuki part # 11489- 45001... two popped up, here in the U.S. Also looked at Suzuki Parts Monster, and found it looks like the "2V" G750's, GS850's, GS1000's and GS1100's use that same part #.... Just say'n. Good luck

[Gorminrider]

It's quite easy. get the 'karopak" gasket paper in a roll from local auto supply(get the thicker variety of the usual two choices) and some cheapo hole punches and razor-knife at the $ store.

use your sump cover as a template,tapping a bolt through holes as a marker. The holes are the most important part of the process. after that, you just cut around them using the cover as a guide and obviously without slicing a hole.. Cut the inside out first. Nobody sees inside so it just needs to not interfere. Then the outside..this needn't be too wonderful either. Firstly because nobody will see this gasket and secondly because you can trim it after installation with the razor knife. You'll have plenty left from the roll for valvecover or whatever.

[Nessism]

The sump cover gasket has round holes in it, for reasons I'm not clear about? Are they there to keep oil around the pickup when cornering? I'm not sure, but if you decide to make a gasket, I'd try to replicate the original gasket pattern.

[mpidsadny]

Took everyone’s advice and made a gasket trying to replicate the holes the best I could. The bike fired right up! Time to tackle the new problem of cylinder number 3 not firing and a high idle > . Pleased to reach this milestone though! Thanks again everyone.

[alke46]

Now, what do you think will show up in the mail early next week?