Gs650G Katana oil pan issue

[jordraatt]

Hi folks!

I've got a 1982 Gs650G Katana, and as many of you maybe know this bike is delivered with a oil cooler.. The cooler is attached to the oil pan, so the oil pan is different from the other GS650's..

So here's the problem.. I had a little accident, and the oil pan got damaged.. So what to do?? Can i try to weld the crack?? Or should I try to find a oil pan from another Gs650 and remove the cooler?? (can't find any oil pan for the Katana).. Help anyone??

[Nessism]

I'd weld it if possible. Those Katana oil pans are hard to come by.

[jordraatt]

Yes, it might be possible to weld.. As you say, these oil pans are impossible to find..

An alternative is to mount a oil pan from another GS, and remove the oil cooler.. But I guess that's pretty stupid?? Performance loss and possible overheating on sunny days??

OR, I could mount the cooler on another place on the engine??

[Nessism]

An oil cooler is not strictly necessary. Tons of 650's on the road without one.

[jordraatt]

But I guess the performance will be reduced?? My engine is tuned with sports-exhaust, bigger carburetor jets and KN air filter.. that will propably make som more heat??

[Suzuki_Don]

But I guess the performance will be reduced?? My engine is tuned with sports-exhaust, bigger carburetor jets and KN air filter.. that will propably make som more heat??

You wont notice any difference in performance. Those mods you have will not cause the motor to operate any hotter than normal. Your motor will operate perfectly normal without the oil cooler.

But having said that I would retain the oil cooler to keep the bike standard just as it left the factory. And stop running up gutters.

Remove the sump and take it to someone that does aluminium welding. Get it welded, preferably from both sides of the crack. Check mating surface for trueness. If OK refit and connect oil lines. If not true (warped) have a machine shop true up the surface for you before refitting.

[jordraatt]

Okey, thank you very much guys.. Appreciate your help!

I'll try to save the oil cooler by welding the pan or finding a new katana pan..

[jordraatt]

okey guys, i've talked with some experienced guys.. they gave me this tip about using a type of epoxy glue called JB Weld.. they say it's perfect for repairing aluminium oil pans, as the glue itself is stronger than the aluminium and can handle oil and heat..

in many cases there's something in the aluminium that makes it impossible to weld, and in those cases they use this JB Weld, these guys told me..

I'l give it a try, so maybe it's hope for my old Katana oil pan

another alternative is to use aluminium rods, a type called HTS-2000.. http://www.youtube.com/watch?v=do2zYHwp78Y
you simply use a torch and melt these rods.. almost like soldering..

[hjfisk]

okey guys, i've talked with some experienced guys.. they gave me this tip about using a type of epoxy glue called JB Weld.. they say it's perfect for repairing aluminium oil pans, as the glue itself is stronger than the aluminium and can handle oil and heat..

in many cases there's something in the aluminium that makes it impossible to weld, and in those cases they use this JB Weld, these guys told me..

I'l give it a try, so maybe it's hope for my old Katana oil pan

another alternative is to use aluminium rods, a type called HTS-2000.. http://www.youtube.com/watch?v=do2zYHwp78Y
you simply use a torch and melt these rods.. almost like soldering..

Or just take it off and bring it to someone that knows how to weld[ a profesional ] with a Tig welder and have them do it. I don't know where you are But any welder [Profesional welder] worth his salt can weld up a pan pretty easily.

[850 Combat]

JB weld might work. A welded repair is definitely possible as well. I had a seized clutch release bearing on a cross country trip once. The pull rod shot out through the case. cover. A local guy in Upstate New York TIG welded it up for me, ground it, polished it, and it looked perfect.

If your cracks are too close to the gasket surfaces and /or the connections for the oil cooler, it may be more complicated.

I overtightened a cooling water fitting on a dual side draft intake manifold on my old car, and cracked the threaded boss on the manifold. I used JB weld on it as a temporary fix. That was about 12 years ago.

[jordraatt]

thanks guys!

looks like there are many possibilities here now.. but i've found the solution.. i'll take off the pan, clean it with aceton, use very rough sandpaper or machine on the area.. and then use aluminium rods with a propane burner..

those soldering rods are made for situations like these they produce a metal that's harder than the aluminium itself.. i might be wrong, but it seems to be a new kind of product that makes it possible to solder on places and metals where welding is impossible or difficult.. i'll make a report of the results when i'm done folks