Hi All,

I am new to gs500's so please ignore if you all know this but I found nothing on the forum relating to this critical issue.

I bought the original Suzuki gasket kit from Ron Ayers,  the sump gasket I received looked like the first picture, where it should have looked like the one in parts fiche below.

Notice the two large holes on the correct gasket to collect filter sludge and then notice the big oval hole on the supplied gasket. Obviously the gasket will not seal the surface around those two sludge traps.

This caused oil to bypass the filter back into the sump effectively eliminating any oil pressure in the engine. 

I know that one should CHECK EVERYTHING TWICE, but jeez, this was in the Suzuki packaging with the right model and year etc and I had taken the old gasket off and thrown it away weeks before while starting the engine rebuild!

Took me three weeks to diagnose this stupid error!

Now that I know what to look for others have had this problem as well!  http://www.gs500e.co.uk/forums/showthread.php?t=11835

I have asked Ron Ayers to investigate and find out what is going on.

I will keep you posted.

Brett

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good info! .. think thats a genuine valid warning for everyone!! 

.. perhaps Ronayers have been buying 'velly good top quality chinese knock off' pieces ?? .. some of the bits and pieces last couple years that i have bought online (not necessarily bike related) have had very good looking 'similar to genuine' packaging .. not until i started to notice minor errors and problems by using the products did i query it ...

there are a plethora or even multitude of knock off shops/factories in china and they will go to great lengths to disguise their substandard crap for the genuine thing!! ... not saying everything from china is dodgy .. but the 'super cheap price' now... always makes me wary!

Did you mention what year bike you have and what year gasket you bought?
The gasket should be different for 2004+ with the oil cooler compared to any model that does not have an oil cooler.

You should tell Ron Ayers that it took u many many man hrs to diagnose this mistake & seek some sorta compensation......that will encourage him not to repeat this basic error on other ppl.
Please keep us posted. 

Bike is a 2003 GS E , 40000 km on the clock and I recently did a top end overhaul...................

from previous bmf post and that Ron Ayers fiche page shown above is for a 04 gs500f?

suspected something like this on previous oil pump thread-

  http://gstwins.com/gsboard/index.php?topic=64727.msg772167#msg772167

Quote from: adidasguy on July 04, 2013, 12:05:59 AM
Did you mention what year bike you have and what year gasket you bought?
The gasket should be different for 2004+ with the oil cooler compared to any model that does not have an oil cooler.

Ron Ayers parts fiches don't have any 2003 GS500 parts listings since no 2003 model GS500s were sold in US.  The 2002 and 2004 fiches show different gasket parts numbers as should be.  Don't see any fault on Ron Ayers part in this matter?  I never had a problem ordering from Ron Ayers.

Still waiting for OP to come back.

1. What year is your bike?
2. Does it have the oil cooler?
3. What year gasket did you order (part number?)

You said you were new to GS500's. Possibly you ordered the wrong one thinking all were the same, unaware that the models with an oil cooler have a different oil pan (and gasket) than motors without the oil cooler.

We all have made mistakes with parts. If you tell us more then we know if you make a mistake and can put this topic to rest.

One other thing, I think most all of us compare the old gasket to the new one before we install things if for no other reason than to insure it isn't on backwards (and to be sure it is the correct one).

Hi folks,

It seems that there are two gaskets which I did not know!

It is correct that I have a 2003 without oil cooler.

I  ordered the gasket set and the part that comes with it is 11489-01D00.

However, if you look at the Ron Ayers image above (which was for the 2004) , it shows the correct gasket (two holes not the oval hole) with this part number associated to it. Unfortunately the gasket set shows no images for the parts.

Are they showing an incorrect image?

Will obvously retrack if I am wrong.

http://www.ronayers.com/OIL-FILTER-OIL-PUMP-C177718.aspx

Regards

Brett

No need to retrack, that's life, it happens.     A general thought about parts fiche pictures, their purpose is to help you locate the part and then the part number to order.  They are not to give a picture that will ID the details of the part.  The numbers change and picture details change over the years but the pictures are rarely updated.  Best example of this is the one that shows the tank and frame cocks and connecting hoses.  The frame chicken is pictured from the left side and the tank chicken from the right and hoses are shown to cross where they don't cross.  It was that way from 89-02 model years and then finally corrected with new drawings for 04 F models but never updated on older model fiches.   So when using parts fiches, buyer beware.  And be careful too!   

LOL, gotta love the way the word c-o-c-k is automatically changed to chicken.  I'm not talking about chickens, I'm talking about petcocks that are generally referred to as cocks on parts lists.

Do you think that running the bike for a total of about 20 minutes while troubleshooting this issue (with the wrong gasket) would have stuffed up my bearings  and cam journals etc? Pressure was between 4 and 15 PSI (from idle to 3000 RPM)  while I was trouble shooting?

run your engine with the correct gasket and check the oil pressure is near spec .Raced a triumph twin in the 1960s thought i would check the oil pressure one day and found it only had  4lb pressure .Ran the engine like this for rest of the season ,pulled it down in the winter bearings were totaly ok .