Katana Owners Club U.K.

Now the old girl is running ok I’m going to change the oil & filter. I thought I would do a proper job & clean the sump out at the same time so what I want to know is can I remove the sump with the standard exhaust in place?

Hi Paul, just done the same on mine!
As I have a 4-1 it has to come off to get to the filter anyway.
According to the manual the standard 4-2 has to come off for the sump to be dropped.

Just be a bit more organised than me though, I had the filters, but needed an O ring for the oil filter housing and a new crush washer for the sump drain bolt as well. More of a problem was the lack of Non Synthetic oil up here in North Norfolk

Got the o ring and washer from Robinsons, just waiting for the oil to arrive this morning!

Thanks Jim I thought it might, Ive already got the O ring and washer and I buy my Rock oil from tinternet so I’m set to go. Being basically bone idle I thought I might get away with not disturbing the exhaust system as it was a swine of a job to fit in the first place!

if youre dropping the sump to clean the sludge out, then whilst in there , pull the strainer off the oil filter and clear that out too, just in case.

johnr wrote:if youre dropping the sump to clean the sludge out, then whilst in there , pull the strainer off the oil filter and clear that out too, just in case.

Thanks John, I did the dirty deed last night. I must admit I needn’t have bothered really as there was very little crap in either the sump or the strainer. Still at least I’ve got peice of mind now. I’ll leave well alone now until I take it off the road for the winter and strip the top end off to see why it’s burning oil. I actually feel like I can trust it now so I can start going further afield on my runs.

I too have embarked on this 'dirty deed'. Dropped the oil and let it drip for a week. Went back to it today and replaced filter. Sump pan bolts out, tap with a rubber hammer and it's off. Gunked and washed, gasket surfaces cleaned, strainer cleaned. On the 'catch everything else' tray there's a random screw very reminiscent of a strainer cover screw but it can't be cos all 3 are back in. M6 thread by about 8mm long. I was wondering if it could be one of the oil pump top cover screws? Has anyone any experience of one coming loose? Would it have a clear path to the sump? Would the pump still function ok minus a screw?
Don't really want to start delving into other stuff unless really necessary as I'd like to catch the back end of the summer if possible.

Must be catching, I did the Swiss Katana last week! Though I used a Athena gasket, not Suzuki and have a small oil leak, Grrrr! I'll probably do it again over the winter but make a gasket up, as the ones I made for the 400 have worked fine.

From parts diagram the Oil pump has a bolt and screw and the screw is this:
https://www.partzilla.com/product/suzuki/02112-06258
So that looks bigger than what you have.

Cheers Rob. I've used an Athena gasket as well!
Can't think what this screw is from as there doesn't seem to be anything missing from anywhere. Beginning to wonder if it was already on the catch tray before I dropped the sump. Either way I don't remember removing it from anything

Athena gaskets are Italian made like Fiat ( fix it again tomorrow!)named after a Greek so no real surprise that they are next to useless.
Vesrah are the better aftermarket gaskets.
Nikki if the bolts hole can't be seen obviously then it must have been there before , all the oil comes through the strainer , so the gap it came down isn't very deep and would have clipped something enroute , is the bolt marked or scraped if not is was there before.

No marks on it. Looks brand new. You'd swear it was a strainer screw at first glance. Anyway its getting closed up and some oil slung in