I replaced my gauge cluster and put an electronic tachometer in (wired it into the RH coil like instructed on this site) and just looked at the upper part of the engine where the old manual tach cable went and can see grease and other crude all over. Is this something to worry about and if so is there anything i can do to plug this port?

I did the same thing to my bike. There was a thread somewhere around here where someone suggested using an O2 bung plug. That's what I used, but first I removed the small gear that spins the cable. Seems to be working pretty good so far.

I think that if you don't plug it up oil might be able to escape from there. When I took off mine there was a bunch of oil that came out.

-Tony

Quote from: Darkbluestar on June 20, 2011, 03:22:32 PM
I did the same thing to my bike. There was a thread somewhere around here where someone suggested using an O2 bung plug. That's what I used, but first I removed the small gear that spins the cable. Seems to be working pretty good so far.

I think that if you don't plug it up oil might be able to escape from there. When I took off mine there was a bunch of oil that came out.

-Tony

http://cgi.ebay.com/ebaymotors/O2-Oxygen-sensor-bung-02-fitting-plug-cap-bolt-_W0QQcmdZViewItemQQhashZitem4cefcb161eQQitemZ330440578590QQptZRaceQ5fCarQ5fParts#ht_941wt_732
Would that work? Also how did you remove the gear.

I have never plugged a tach cable hole.I can say from experience that you want the hole plugged.Dirt can get in and oil can get out.My cable vibrated loose once.To remove the gear,unbolt the plate that holds the tach cable and tach drive on.Then use a pair of needle nose pliers to back it out.It helps to try and spin it as you pull it out.Don't force it tho.

I didn't plug the hole on my race bike and didn't have any real issues, but I'd generally recommend it. You have a few options...

1. Remove the tach gear (may require pulling the exhaust camshaft. Can anyone comment?
2. Plug the hole.

You could probably use a standard size metric bolt. It would be up to you to figure out which one, but you could probably just bring your tach cable to the hardware store, find a nut that fit the tach cable, and a bolt that fit the nut.

Another option would be to use the OEM suzuki plug that was fit to a few generations of the GS after the move to electronic tachs. I don't recall it being horribly cheap, but it would be the 'OEM Approved' approach.

I used a M18 x 1.5 thread O2 Bung Plug.

http://gstwins.com/gsboard/index.php?topic=50448.msg584838#msg584838 This is the thread that i got the idea from. (About half way through the pictures.) The bolt you showed should work.

Quote from: burning1 on June 20, 2011, 03:54:59 PM
I didn't plug the hole on my race bike and didn't have any real issues, but I'd generally recommend it. You have a few options...

1. Remove the tach gear (may require pulling the exhaust camshaft. Can anyone comment?
2. Plug the hole.

You could probably use a standard size metric bolt. It would be up to you to figure out which one, but you could probably just bring your tach cable to the hardware store, find a nut that fit the tach cable, and a bolt that fit the nut.

Another option would be to use the OEM suzuki plug that was fit to a few generations of the GS after the move to electronic tachs. I don't recall it being horribly cheap, but it would be the 'OEM Approved' approach.

No need to remove the exhaust cam.It's a little fiddly,but it will spin out after the tach drive plate is unbolted.I have pulled mine out thinking the tach drive was bad.Turned out to be a fouled tach cable winding up and releasing.I was a noob to the GS when it happened. 

3/8 inch galvanized plug from lowes fit it...
Funny a 3/8 inch bolt was way to small, but this plug is almost a perfect fit (thread seal made it nice and snug)

Worse comes to worse and this strips out.. it is welding time.

''

That is what the finished product looked like.

Thanks everyone for the quick help... Hopefully this stops all the oil and grease buildup that i just cleaned up (goo gone is a magic magic spray)

And i fail... Checking parts stores around to see if they have a right sized one.