A 2002 GS500? I am about to take a long trip but my bike is sidelined b/c the drain plug got mauled when it was removed. Those bolt-on extractor sockets rock for emergencies.

My local shop had to order the plug, and bikebandit.com has them "on order". Either way I'll have a plug but it could be up to a week. I don't want to wait.

Will the plug from the SV650 fit? How about just going to the hardware store, finding a match and a brass/copper washer?

Or should I wait? I don't want to wait to ride anymore.

well the plug is a 17mm socket.. i am sure any 17mm should fit.. try an SV650 one.. i dont see a reason why it wont fit if its the same size.

I went up to the hardware store but didn't find anything. I guess I'll hit the bike shop and make them pull the plugs out of their warehouse for the 2004 GS500, the SV650, and maybe an older GS.

Perhaps you can match something up at an Autozone or the like.  The local Autoworks has a display of'em in blister packs, but I couldn't tell you what size you need off hand.   Either that or visiting a fastener specialty house like Fastenal.

Get the thread count for the drain plug(I don't know it, but the count for the oil filter cap is 6X1), and you can find a bolt from there.  I would put a metal and rubber gasket on it to prevent leaking, as well as checking to make sure that it won't stick too far up into the pan.  I've had problems with my filter cap nuts stripping on my GS450(only on one stud though???), so I finaly broke down and bought a package of nuts from Lowes.  They are regular nuts, not acorn style, but the keep the oil in the motor.  The same idea should work for the drain plug, hopefully without the stripping issue though
 

Don

Thanks. I went up to Autozone tonight but they didn't find anything that would work. Also, aren't they measured by the diameter and not the socket size?

I'll count the threads up (care to give me a quick explanation of what 6X1 meant?)

The only good point of this downtime is I have done a much more thorough cleaning than usual.

For metric(and most SAE), you really need to have the thread count.  That way the bolt or nut will work with the threads you have.  In my exp., with metric, you tend to end up with a certain size for the socket/wrench, but with SAE(not used on these bikes, but nice to know), thread seems to have little to do with the size of the socket/wrench used on it.

Don

It'd be nice if the drain plug could fit the under-seat toolkit's socket wrench.  I have to carry-around a 13/16 socket(*) just for that one blasted bolt.  Alternatively, if the oil drain bolt head could extend a quarter inch lower, then I could get a flat wrench on it... but I think that I would probably scratch the exhaust.

I think you should be able to change the oil with just the toolkit.

(*)13/16 inches is 20.6375mm.  That's odd, because a 13/16 socket sure seems like a snug fit.

I agree that you should be able to change the oil with the tool kit, but how many people really do change their oil on a road trip??

Don

Quote from: llamakcI'll count the threads up (care to give me a quick explanation of what 6X1 meant?)

Unkless I'm mistaken the 6 represents the diameter of the bolt, in millimeters, along the threaded part.  The 1 represents the distance, in millimeters, between the threads (from one "peak" to the next).

Quote from: ShadowhawkFor metric(and most SAE), you really need to have the thread count.  That way the bolt or nut will work with the threads you have.  In my exp., with metric, you tend to end up with a certain size for the socket/wrench, but with SAE(not used on these bikes, but nice to know), thread seems to have little to do with the size of the socket/wrench used on it.

While it is true that for standard metric thread socket size and thread size are standardized, that's less true for cars and bikes (got to optimize you revenue, that smaller head does its job just as well in that spot...), and even less for oil drain plugs.

To begin with, drain plugs often are fine threads (less pitch than is standard for the diameter.)

According to www.louis.de the drain plug of the GS is an M14x1.25.
(M-14 is an odd thread diameter to begin with, and 1.25 pitch is standard for M8, go figure...)

Oh, and this site also claims that this plug fits tons of other Suzuki types, but not a single bike of a different manufacturer.
Long live standardization.

If that thread size is correct( :dunno: ), look for an automotive drain plug of the same type.  With some shopping, you can even find one with a magnetic tip.  Just be careful of how far it sticks into the motor.

Don

Yeah that thread size appears to be correct. I found a few at a local auto parts store. There were two types: one with the magnetic tip that stuck up another 1/2 inch, and one with a tapered end that stuck up another 1/2 inch beyond the threads (I forget what this style was called). The place appeared to be out of these plugs w/o the acouterments so I am still shopping.

If worst comes to worst and my drain plugs take too long to arrive from my shop, bikebandit.com, or ronayers.com I guess I could get the magnetic strip one and grind that off.

Alternatively you could try to mount the plug and turn the motor over manually first to check if there is any interference.

I went with a M14 1.25 pilot point drain plug. At the end of the threads the bolt tapers down, then continues for a total of maybe 3 cm. Since I don't have a bench grinder, I took a hand file to it while drinking some beer. Eventually I got it down to where the taper begins, put it in the bike, refilled the oil and all is well.

It astounds me that I can't find this part in a bike shop in Georgia though. I talked with some guy at "The Cycle Shop" in Tallahassee Florida and he told me that this plug is used in all of the GS and DR models.

Anyway once my 5 plugs DO arrive: (one at local shop, two at bikebandit, two at ronayers.com) if anybody needs one, holler.

Thanx,