I just ordered some left and right gaskets plus a crank oil seal for the '91 gs500.  Has anybody had oil leaking out of the right side gasket?  I have a cylmer manual and can't figure out what the torque should be on the crankcase bolts either.
I can see a '91 leaking from here or there even though it has less than 10k on the odo.
I hate taking off parts I don't need to to fix the leak cause it's so easy to break something else in the process.

Like this?



I still have the leak though...  Mine is pretty slow and the mechanic said not to worry about it unless it was "spraying oil on my leg."   

Thanks for the pic but I am pretty darn sure it's coming from the seal around the right side crankcase gasket.  When we first got the bike it looked ike it was leaking where your photo shows but it turned out to be from the speedo cable or tach cable or whatever the heck that is in the front of the heads.  I just put a new o-ring on the filler cap hoping it was that but nope.
Then again anything is possible.
Suzuki seems to have a rep for oil leaks for some reason. Bandit is the same way.
I don't think it would hurt to do all the gaskets and re-torque all the bolts if your going to keep riding it.  The exception is if it ain't broke don't fix it.

I have a leak from the Tach cable too...  I need to get that fixed.  I asked the guy about retorquing the bolts and he seemed to think it wouldn't help...   WTF do I know?

When I asked the mechanic about replacing just that gasket, he said that when you do one, you should do ALL of them.  He told me that when you loosen those bolts and take any part of, there a really high chance that you'll break the other seals and screw up those gaskets.  I dunno if that answers your question.  I'll let someone who knows what they're talking about answer it.

There is some thruth to that.  I removed and replaced a water hose clamp and did not get it just right and ended up with a leaky hose on my celica.
I think that just replacing the case gaskets will not put any undue presure on the rest of them but then again until you've seen it all you have not seen it all.

Hmm...I would say from my experience that Suzuki need more work done to the carbs, than they do to they gaskets.
If it is leaking from the right side, the same side that the ignition rotor is on, and it is part 1 in the diagram below


I would say replace part 2 with no concerns about unsettling the engine, and to be honest with you, I think unsettling the engine stuff is a bunch of  . If the engine is going to leak, it will leak its going to leak, better to find the leak earlier than later.

If it is item 1 that is leaking, it is not a major task, having a clymer's manaul(or Haynes) will help. Remember that you want good surface finish before you mate parts(i.e. no scratches, and no left over gasket). If it was me, hell I would replace the clutch disks with kevlar ones while your there.

The torque figures for the crankcase bolts are 9-13 N-m for 6mm items and 20-24 N-m for the 8mm items. The head nuts need to be 35-40 N-m. I am quoting these figures from the Genuine Suzuki service manual I have.

I got #2,15, and a crank oil seal I believe it's called.  They came today from BikeBandit.com, OEM gaskets from Japan.  I'll most likely give them a go this weekend.
Also thanks Sledge for those torque numbers.  I am one of those guys who actually uses a torque wrench, well when It's needed anyway.

Ok just did the #2 right side gasket.  Not a big deal other than removing the old gasket.  Now that was a hassle.  I have gasket remover that works pretty decent EXCEPT I thought it said will not harm paint.  May have miss read that cause it does remove paint as in on the case cover. I flat filed the cover and the case itself with a small file to get off any high spots or leftover gasket. I torqued the 6mm bolts to around 11 nh in a chris cross pattern also.
Took it for a real short test ride and no leaks yet so knock on wood.
Thanks all for your input
Took it for a 100 plus canyon ride today and the right side is sealed tight, no oil leaks.  Now for the left side...