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PostPosted: Mon Apr 16, 2018 8:52 am 
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On the main road
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Joined: Sun Jan 04, 2009 7:15 pm
Posts: 157
Location: Rock Hill SC
is there a bit more cost effective oil seal/muffler seal replacment for the muffler seal on the t-500s? or does anybody have the dimensions? i searched and didnt find anything. or just the dimensions. thanks.

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PostPosted: Tue Jul 03, 2018 11:31 am 
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On the main road
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Joined: Mon Jun 12, 2017 12:01 pm
Posts: 169
Location: Galveston County, Tx.
Country: USA
Bikes owned: '75 T500M since '93 Ridden it over 100,000 mi
m in sc wrote:
is there a bit more cost effective oil seal/muffler seal replacement for the muffler seal on the t-500s? or does anybody have the dimensions? i searched and didnt find anything. or just the dimensions. thanks.
I take it you don't like the idea of paying $18.00 to $25.00 USD each for them.....me either. :wth: I have not used them for a few years now. Years ago I did start a little quest to find a suitable generic seal....heck....it amounts to nothing but a big oil seal....and I don't need it to be blue. :roll: I got sidetracked onto other things at the time but if I remember correctly, I was getting very close to finding one with the same I.D and O.D.

I don't remember the exact measurements of the stock seal and as you know it's not just a matter of measuring the I.D. of the muffler flange bore/pocket and the O.D. of the exhaust header/downpipe to get the seal measurements....ideally, there would be a certain +/- 'interference' tolerance you would want for a tight but not too tight fit of the rubber coated seal.

I might buy a single seal from Suzuki to measure but I think I have a used one that is in good enough shape to measure...just not sure right now. I've been meaning to look into searching for a generic substitute again. I'll post any positive results here if I find something.

This is what I do in lieu of the seals. I ride almost everyday of the year and this usually lasts me a few months. I'm sure if not ridden everyday the seal would last much longer and in that case the OEM seal price might be justifiable but it just seems that I remember even when I was using the stock seals, that they did not last as long as I thought they should.

This pic of my rightside muffler still has what was left of the rubber coated OEM seal less the rubber face of the seal. After cleaning, I just sealed over it. The other muffler seal is completely removed, for the better probably......a deeper 'pocket' for a little thicker bead of sealant.

All sealing area NEEDS TO BE CLEANED VERY WELL with Acetone. I then use Permatex High Temp RTV Gasket Maker for a nice thick bead. Nicely smooth out and wipe off any excess on surrounding area. Wait a full 24 hours for sealant to cure per manufacturers instructions before starting engine.

Not blue but works for me. :wink:

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For those not familiar with the T500 muffler connector seal.....

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PostPosted: Wed Jul 04, 2018 12:24 pm 
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