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'77 GS550 oil pan replace without removing engine

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    #1

    '77 GS550 oil pan replace without removing engine

    Stripped oil plug. Tried oversize bolt. Still leaking. Can the oil pan be replaced without removing the whole engine?
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    #2
    Yes. Clear access after removing exhaust. If your exhaust has not been removed in a long time be warned that removing the bolts holding the header pipes to the head can stick. It's extremely important that you don't go and force these bolts or they will break off. Use a short handle 1/4" drive ratchet wrench and be sure to hit the bolts with PB Blaster or similar a few times before you attempt to remove them. Again, do not force them or they will break. You have been warned.
    Ed

    To measure is to know.

    Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

    Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

    Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

    KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

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      #3
      Removed oilpan on mine by removing fuel tank first then tipping bike on its side for easy access. I have a gel battery so didnt need t remove it either. Easier to see all bolts and to clean up gasket surface.

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        #4
        Yes, I have done so & documented it over in the thread linked below, but, really, heed the warnings given by nessism. As you'll see, while I had no stuck screws, I (still) suffer from PO-caused problems there.

        Here's the thread. Clicky.
        #1: 1979 GS 550 EC "Red" – Very first Bike / Overhaul thread        New here? ☛ Read the Top 10 Newbie mistakes thread
        #2: 1978 GS 550 EC "Blue" – Can't make it a donor / "Rebuild" thread     Manuals (and much more): See Cliff's homepage here
        #3: 2014 Moto Guzzi V7 II Racer – One needs a runner while wrenching
        #4: 1980 Moto Guzzi V65C – Something to chill

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          #5
          Have not done it on a 550, but on an 850. Fully agree with Nessism's cautions.

          You might want to hit the fasteners with PB Blaster as much as a week before you plan on doing the work.
          A quick burst on each fastener a couple of times a day will give it plenty of time to do its job.

          Good luck.

          .
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          hers: 1982 GS850GL - "Angel" and 1969 Suzuki T250 Scrambler
          #1 son: 1986 Yamaha Venture Royale 1300 and 1982 GS650GL "Rat Bagger"
          #2 son: 1980 GS1000G
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            #6
            Originally posted by Ike View Post
            Stripped oil plug. Tried oversize bolt. Still leaking. Can the oil pan be replaced without removing the whole engine?
            also if you remove sump don't forget o ring about 20mm size inside the oil pan it seals part of oilway from the oilpan!easily lost also blow out bolt holes before refitting as some are blind holes and you don't want to hydraulic them
            Last edited by cornishgs; 05-16-2017, 07:54 AM.

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