I changed my oil and oil filter in my bike yesterday like I always do, everything going fine, I go to put the cap back on that covers the filter, screw in the screws, tightening the screws and the bottom screw decides its going to snap in half......i've been doing work to my cars and bike for many years now and have never encountered that.  I continued to finish, started the bike and the cap is now leaking oil, not bad just dripping,but I didn't even run it hot yet, I'm afraid its going to get worse when its hot. I used some jb weld solution to attach screw back, I don't think this is going to have enough pressure to hold the cap in place......Please does anyone have a suggestion, or has anyone had a similar problem. I would just replace the screw, but for you who change your own oil, the screw is part of a bigger peice. HELP!!

They same thing happened to me when i changed my oil.. Just take the other screws out and the cap off. Alot of the time the bolt will have snapped off but still have some left sticking out to unscrew out of the block.. I just got some one inch bolts to put in there. I think they were #6 but not sure on that. They work way better then those butter for bolts suzuki put in there.

The bolts are like butter!! :laugh:Thanks

Remove the cover.  Hopefully, some of the stud will still be protruding from the case.  In which case, grab it with a pair of vise grips and remove it.  Fit a new stud from Suzuki.  Fixed!

As you turn the oil filter cover nuts, feel for the compression of the O-ring.  Turn the nuts equally around the cover rather than snugging one up followed by another.  When the O-ring is fully compressed you'll feel the cover bottom and the turning resistance will suddenly increase.  Go one more flat on the nut and it'll be fine.  Use a small wrench and grip it gently between fingers for increased sensitivity.

IF you have troubles grab yourself a small set of easy outs and get that sucker out of the front of the block.  After this first service I will be replacing the oil filter studs with high tensile stainless steel studs to prevent this from happening.

Here are some related threads that may help:

• http://gstwins.com/gsboard/index.php?topic=39158.0
• http://gstwins.com/gsboard/index.php?topic=38585.0
• http://gstwins.com/gsboard/index.php?topic=23941.0
• http://gstwins.com/gsboard/index.php?topic=29786.0

Pablo's website also has a page on this topic:
http://pantablo500.tripod.com/id10.html

Good luck!

Just did the same thing.  A bolt can be a quick fix but you really want to get a new stud so that when/if you over-tighten again, the stud strips not the engine block.  The studs are easily ordered from any shop or even online like here:
http://www.bikebandit.com/houseofmotorcycles/suzuki-motorcycle-gs500en-1992/o/m6052
#12 under the oil filter section.

Good luck!

P.S. vice grips got mine out easy as pie