GS 1100G oil pan

[midwestgs]

Changing the oil in my 83 GS1100G and I decided to replace the oil pan gasket also. A pesky leak was starting to get worse so I ordered a gasket and cleaned the oil pan and per forum advice used aviation gasket sealer.
The problem came after installation when I added oil and it started running out. After I unbolted the pan I realized there is a bolt hole inside the pan bolt pattern(see pic, top R).
Suz oil pan sm.jpg
My engine is stamped U701- and after some digging I found most GS1100 pan's have this hole. I am baffled..

Obviously I unknowingly cleaned whatever was 'guped' in the hole to prevent oil from leaking out.
I considered maybe the PO changed pan's at some point, but my engine uses the outside hole which makes all 1100/850 pan's unusable on this engine.

Question:
Can anyone offer a suggestion why there is a hole where nothing bolt's?
There is no 'boss' or metal inside the engine for a bolt to bolt to.
OEM gaskets show U701 pattern outside of this hole, which seems to match my bikes pattern, but not the pan.


Thanks, "Confused in Midwest"

[Nessism]

As you said, it seems you have the wrong pan. The parts fishe illustration of the pan doesn't show that extra hole.

http://www.alpha-sports.com/suzuki_parts.htm

[midwestgs]

That was my first thought.. until a quick check on ebay showed every pan had the extra hole.
Not that ebay is a OEM reference source.. but over 40 different pan's were marked as 1100/850 and had the hole, which I see as the same PN in the online parts manual.

[Nessism]

It seems that starting in 1983 that there is a new part number for the pan. I'm not sure what's unique about it.

11511-49120

I then found this "11511-49120 SUPERCEEDED BY 11511-45300"

Looking through ebay auctions I've yet to see a pan without the extra hole. Actually, when you look at the used pans most engines use the inside hole, it's the outside hole that's just there and not used.

Good mystery.

[Nessism]

Okay, found the pan you need. Check this listing...http://www.ebay.co.uk/itm/Suzuki-GS-.../272355378509?

Your best bet will be to thread the boss and stick in a screw or welded the extra hole closed.

[JTGS850GL]

Could it be that you have the wrong gasket? Some of the pan gaskets have one hole while others had 2. Found this on ebay:

http://www.ebay.com/itm/SUZUKI-GS750-GS850-GS1000-GS1100-GS-750-850-1000-1100-OIL-PAN-GASKET-11489-45001-/311647547668?hash=item488fa43114:g:vEcAAOSwuzRXdpPW&vxp=mtr

If the bottom engine cover is cast to cover the whole then the two hole gasket would seal off that hole. Can't remember off hand. Is the pan gasket you used OEM or aftermarket?

[Buffalo Bill]

Right, like Ed said, thread the hole, then screw in a short bolt with some RTV sealer on the threads.
I suggest the bolt head should be outside the pan.

[midwestgs]

Right. Used a 5/16 tap with a safety wire head. Will drill a small hole in the cooling fin to attach a piece of safety wire. That way, no one should ever accidently unscrew it to change the pan gasket or oil. Just in case the US size doesn't make the desired impression.
Purchased High Temp RTV for the threads.
Suz oil pan tap sm.jpg

Nessism-
I hadn't found that part number, also no luck finding the difference in the pan's.

Is that the same pan as the 78 GS750? Sure looks like it to me..

[Nessism]

Nessism-
I hadn't found that part number, also no luck finding the difference in the pan's.

So I take it you didn't bother to look at the link i provided...

oil pan by [url=https://www.flickr.com/photos/18095073@N08/]

[midwestgs]

Nessism-
YOU ARE WRONG. I DID BOTHER TO LOOK AT THE PAN YOU HYPERLINKED ME.
Not only did I take the time, I wrote you back in my message congratulated you on finding a new PN and saying I couldn't find a difference either.
THEN, I opened another possibility with you- that the ebay uk pan you found and a 78'ish GS750 look very similar!

Sorry for the spice right back at ya- but I didn't appreciate the attitude.

[JTGS850GL]

Right. Used a 5/16 tap with a safety wire head. Will drill a small hole in the cooling fin to attach a piece of safety wire. That way, no one should ever accidently unscrew it to change the pan gasket or oil. Just in case the US size doesn't make the desired impression.
Purchased High Temp RTV for the threads.
[ATTACH=CONFIG]47243[/ATTACH]

Nessism-
I hadn't found that part number, also no luck finding the difference in the pan's.

Is that the same pan as the 78 GS750? Sure looks like it to me..

That doesn't look like a good thread job. Seems like the pilot hole is too large for the thread diameter used. Bolt could pull through with very little torque. Might want to consider using JB weld on the bolt threads and threading it in lightly.

[Nessism]

Nessism-
Not only did I take the time, I wrote you back in my message congratulated you on finding a new PN and saying I couldn't find a difference either.


Sorry for the spice right back at ya- but I didn't appreciate the attitude.

Your comment suggested to me that you still don't recognize a difference in the pans.

Oh well. No spice, rather just a little frustration.

[midwestgs]

JT-
Sharp Eye's! I agree, the hole dia was slightly large, but it's not going to be holding any torque, RTV'd for leaks and safety wired.

Nessism-
Thanks for the follow up.
Yea, I think you're UK ebay pan looks like an early 750 pan. I could be wrong, but..

Are all you gs1100's using the inside hole?
Makes me wonder if Suzuki went back to the early 750 pan for some reason?
Then, I wonder why?

Anyway, thanks guy's for the help!