Suzuki gsx 600 1991 oil leak front of the engine just above the exhaust from a nut or pipe not sure thanx

too big on the main jets , take them back to the rebuilder and tell him to fix it.

1. Raise the front of the vehicle and support it safely using jackstands. Remove the plug and drain the engine oil from the pan and crankcase.
2. Disconnect the fasteners from the exhaust manifold flange and the pipe rear flange, then remove the front exhaust pipe and gaskets from the vehicle.
3. Remove the engine stiffening bracket and the flywheel cover.
4. Remove the right wheel and splash shield, then loosen the 4 front motor mount bolts. Back the bolts out about 1 / 2 in. (12mm).
5. Remove all the oil pan bolts. For vehicles with a manual transaxle, an 8mm flex socket may be used to access the rear oil pan bolts located next to the flywheel.
6. Using SA9123E, or an equivalent RTV cutter tool, separate the oil pan from the engine. Drive the tool around the pan to shear the RTV seam, then tap the pan sideways with a rubber mallet to loosen.
7. Pry the engine mount away from the engine as necessary and remove the oil pan. Be careful not to damage or score component surfaces when prying.

To install:

1. Carefully clean the gasket mating surfaces with a scraper and solvent.
2. Apply a 0.16 in. (4mm) bead of RTV sealer to the pan flange. Make sure the RTV is applied to the inner side of the flange from the bolt holes as shown.
3. Install the oil pan within 3 minutes of RTV application and tighten the bolts to 80 inch lbs. (9 Nm).
4. Tighten the front mount bolts to 37 ft. lbs. (50 Nm).
5. Install the right splash shield and wheel.
6. Install the engine stiffening bracket and the flywheel cover.
7. Install the exhaust pipe. Tighten the pipe to manifold nuts in a crosswise pattern to 23 ft. lbs. (31 Nm) and the pipe to converter bolts to 33 ft. lbs. (45 Nm).
8. Remove the jackstands and carefully lower the vehicle, then fill the engine crankcase with clean engine oil immediately in order to prevent an attempt to start the engine without oil.
9. Start the engine and check for leaks.

2.0L Engine

1. Disconnect the negative battery cable.
2. Drain the engine oil.
3. Remove or disconnect the following:
   Engine undercover Front exhaust pipe Lower oil pan bolts and lower pan Cover Upper oil pan bolt and upper pan Baffle plate
   
   Fig. Oil pan and related components-2.0L engine
   
   

To install:

1. Clean all gasket surfaces of the cylinder block and the upper and lower oil pan.
2. Install or connect the following:
   Baffle plate
   
3. Apply a 0.16 in. (4mm) bead of sealant to the gasket surfaces of the upper oil pan.
   Upper oil pan onto the cylinder block within 15 minutes after applying sealant. Tighten the bolts as shown in the accompanying figure.
   
   Fig. Upper oil pan bolt location and torque sequence-2.0L engine
   
   
4. Apply 0.16 in. (4mm) bead of sealant to the gasket surfaces of the lower oil pan.
   Lower oil pan and tighten the bolts, in the sequence shown, to 88-106 inch lbs. (10-12 Nm)
   
   Fig. Lower oil pan bolt tightening sequence-2.0L engine
   Front exhaust pipe Engine undercover Oil drain plug with a new gasket and tighten to 29 ft. lbs. (40 Nm)
   
   Fig. Make sure to the install the new drain plug gasket as shown, or leaks will occur
   
   
5. Lower the vehicle and fill the crankcase to the proper level with clean engine oil.
6. Connect the negative battery cable. Start the engine and check for leaks.

Non-Turbo Engine

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Drain the engine oil into a suitable container.
4. Once the oil has completely drained, install the plug and tighten to 25 ft. lbs. (34 Nm).
5. Remove the front exhaust pipe.
6. Remove the engine oil dipstick and tube assembly.
7. Remove the front plate.
8. Unfasten the oil pan mounting bolts, then remove the oil pan and gasket.
   
   Fig. Exploded view of the oil pan and related components-1999 2.0L non-turbo engine
   

To install:

1. Apply sealant at the point where the engine block meets the oil pump.
2. Use a new gasket and install the oil pan. Tighten the mounting bolts to 8.9 ft. lbs. (12 Nm).
   
3. Install the front plate.
4. Install the front exhaust pipe.
5. Install the dipstick and tube assembly.
6. Safely lower the vehicle to the floor.
7. Refill the crankcase with oil to the proper level.
8. nnect the negative battery cable.
9. Start the engine and check for leaks.

Turbo Engine

1. Disconnect the negative battery cable.
2. Safely raise and support the vehicle.
3. Remove the front exhaust pipe.
4. Remove the exhaust pipe and muffler assembly.
5. Drain the engine oil into a suitable container. Once the oil has drained completely, tighten the plug to 29 ft. lbs. (39 Nm).
6. Remove the dipstick and tube.
7. For AWD vehicles, remove the transfer case assembly as follows:
   1. With the propeller shaft still installed, remove the transfer mounting bolt.
   2. Insert a suitable prytool in between the transfer case and transaxle, then remove the transfer case from the center shaft.
   3. Remove the transfer case from the center shaft. Do NOT tilt the transfer assembly to the rear or oil will leak out.
   4. After removing the transfer assembly, insert tool MB991193 or equivalent, to prevent the oil from leaking out. Use a piece of wire to suspend the transfer case from the body.
      
      
      Fig. View of the transfer case with the tool installed to prevent oil from leaking out-1999 2.0L turbo engines
      
8. Remove the bell housing cover.
9. Disconnect the oil return pipe from the oil pan.
10. Remove the oil pan mounting bolts. Tap the oil pan seal breaker MB998727 or equivalent between the oil pan and the engine block to break the seal and remove the oil pan.
    
    Fig. Exploded view of the oil pan and sealant application-1999 2.0L Turbo engine
    

To install:

1. Clean the sealing surface on the oil pan and engine block. Apply a continuous bead of sealant MD970389 or equivalent to the oil pan.
2. Clean the oil pan mounting bolt holes in the oil seal case.
3. Install the oil pan to the engine block. Tighten the mounting bolts to 5.1 ft. lbs. (6.9 Nm).
4. Use a new gasket and connect the oil return pipe to the oil pan.
5. Install the bell housing cover.
6. If equipped with AWD, install the transfer case assembly.
7. Install the dipstick and tube assembly.
8. Install the front exhaust pipe.
9. Install the exhaust pipe and muffler.
10. Install a new oil filter.
11. Safely lower the vehicle to the floor and add five quarts of oil to the crankcase.
12. Connect the negative battery cable.
13. Start the engine and check for leaks.

Good luck (remember rated this help).

If yo ucan see all the bolts on the bottom of the pan, it will be as easy as changing your oil. Make sure you get a torque wrench for the install though so you don't strip the bolts out, and just follow the directions with the gasket.



Fig. 1: Exploded view of the oil pan and related components for the 1990-94 1.6L engine-2.2L engine is similar



Fig. 2: Exploded view of the oil pan and related components for the 1.8L engine


Make sure all old sealer is removed from the bolts prior to installation. Installing a bolt coated with old sealer could result in cracking of the bolt holes.

1. On 1990-94 323 1.6L (B6E) and 1994 Protege 1.8L (BPD) engines, install the integrated stiffener to the engine block and transaxle. Tighten the bolts to 38 ft. lbs. (52 Nm).
2. 1990-94 Protege 1.8L (BPE) and 1994 MX3 1.8L (BPD) engines, install the transverse member. Tighten the bolts to 93 ft. lbs. (1 Nm).
3. Install the front exhaust pipe bracket, if equipped. Install the front exhaust pipe, using new gaskets. Tighten the exhaust manifold flange nuts to 34 ft. lbs. (46 Nm).
4. Install the oil pan drain plug using a new gasket. Tighten the drain plug to 30 ft. lbs. (41 Nm).
5. Install the engine undercover and lower the vehicle.
6. Fill the engine with the proper type and quantity of oil.
7. Connect the negative battery cable. Start the engine and bring to normal operating temperature. Check for leaks.

Hope helped with this (remember rated this help). Good luck.

REMOVAL & INSTALLATION

The radio may contain a coded theft protection circuit. Always obtain the code number before disconnecting the battery.
2.2L, 2.3L and 2.7L Engines

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Drain the engine oil into a sealable container.
4. Install the drain bolt with a new gasket. Tighten the bolt to 33 ft. lbs. (44 Nm).
5. Remove the front wheels and the splash shield.
6. Remove the center beam.

Fig. To gain access to the oil pan, remove the center beam-2.2L and 2.3L engines

1. Detach the Oxygen sensor (O 2 S) electrical connector.
2. Remove the bolts from the support bracket on the exhaust pipe.
3. Remove the nuts attaching the exhaust pipe to the exhaust manifold and the catalytic converter.
4. Remove the exhaust pipe and discard the gaskets.
5. If equipped with an automatic transaxle, remove the converter cover.
6. If equipped with a manual transaxle, remove the clutch cover.
7. Remove the oil pan nuts and bolts (in a criss-cross pattern) and the oil pan; if necessary, use a mallet to tap the corners of the oil pan. DO NOT pry on the pan to get it loose.
8. Clean the oil pan mounting surface of old gasket material and engine oil.

To install:

1. Install a new oil pan gasket to the oil pan. Apply liquid gasket to the corners of the curved section of the gasket.
2. Install the oil pan to the engine.
3. Install the oil pan nuts and bolts and tighten the nuts and bolts in sequence. Tighten the nuts and bolts in 2 steps to 10 ft. lbs. (14 Nm).
4. If equipped with an automatic transaxle, install the torque converter cover. Tighten the bolts to 108 inch lbs. (12 Nm).
5. If equipped with a manual transaxle, install the clutch cover. Tighten the bolts to 108 inch lbs. (12 Nm).
6. Install the exhaust pipe with new gaskets and new locknuts. Tighten the nuts attaching the exhaust pipe to the manifold to 40 ft. lbs. (54 Nm)and tighten the nuts attaching the exhaust pipe to the catalytic converter to 25 ft. lbs. (33 Nm). Install the bolts to the exhaust pipe support bracket and tighten the bolts to 13 ft. lbs. (18 Nm).
7. Attach the Oxygen sensor (O 2 S) electrical connector.
8. Install the center beam and tighten the mounting bolts as follows:
   
   Prelude: 43 ft. lbs. (60 Nm) Accord: 37 ft. lbs. (50 Nm)
   
9. Install the splash shield and tighten the mounting bolts to 84 inch lbs. (10 Nm).
10. Install the front wheels.
11. Lower the vehicle and fill the engine with oil.
12. Connect the negative battery cable and enter the radio security code.
13. Start the engine and check for leaks.

Fig. Oil pan mounting bolt tightening sequence-2.2L and 2.3L engines



Fig. Oil pan tightening sequence-2.7L engines


3.0L Engine



Fig. Tighten the oil pan bolts in three steps, in sequence, to 8.7 ft. lbs. (12 Nm)

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Remove the engine undercover.
4. Drain the engine oil and replace the drain plug.
5. Remove the front exhaust pipe.
6. Remove the oil pan mounting bolts.
7. Hammer a seal cutter between the engine block and oil pan to break the seal.
8. Remove the oil pan.

To install:

1. Clean the oil pan flange and engine block mounting surface.
2. Apply sealant to the oil pan flange. Be sure to apply sealant toward the inside of the bolt holes.
3. Install the oil pan on the engine. Tighten the bolts in sequence to 8.7 ft. lbs. (12 Nm).
4. Install the exhaust pipe.
5. Install the undercover.
6. Lower the vehicle.

WARNING Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

1. Refill the engine with the correct amount of oil.
2. Connect the negative battery cable.
3. Start the engine and check for leaks.

I really hope help you with this (remember rated this help) Good luck.

exhaust will not cause vibration, maybe a fluttering sound if they are loose. engine vibration at high rpms is detrmined how well the engine was balanced at the factory, thats why performance and racers take apart the engine and have it balanced better than factory. only thing you could do is make sure engine mounts are all tight. anything else means taking engine apart 13k is way fast rpm,so if it doesnt shake at 10k, not to worry.

Just screw the cap onto the lead if it falls off cut about 6mm off the lead and try again, a standard socket for a plug of your size should fit be sure to use a proper plug socket
smoke from the front of the engine could be from the exhaust where they bolt to the head,
Get your self a good degreaser and wash down the engine then run up the bike and look for oil leak dont ride the bike as a little oil will go a long way and it will be harder to see where its leaking, usual suspects rocker cover gasket if the oil is high up,

That is a lot of oil - is it blowing smoke? Is there any indication of where the oil is going?
The GSX engine is bulletproof - normally - and doesn't use much oil at all. I have serviced 35,000 mile bikes after 7500 miles and the oil has been spot on.
Looking on the net, it seems the 1400 is a bit vulnerable to oil-cooler damage. With an air/oil cooled bike this could be an indication of where the problem lies. The engine won't leak oil while stationary - well, maybe a drop... but when it is warm and under revs any hole in the oil cooler could be a direct exit point for oil. Look for stains on the exhaust headers - if you are driving and there is a leak, that'll be the first place the oil will go.
It would be the first place I would look - as well as oil cooler, pipes, connectors...
Run the bike for a while and try to inspect it to see if there are any leaks you can spot while the engine is running.

Removal Procedure
1. Disconnect the negative battery cable.
2. Drain the engine oil from the engine crankcase.
3. Remove the exhaust flex pipe retaining nuts from
the exhaust manifold.
4. Remove the exhaust flex pipe retaining nuts from
the catalytic converter or the connecting pipe.
5. Remove the exhaust flex pipe.
6. Remove the oil pan flange–to–transaxle retaining
bolts.
7. Remove the oil pan retaining bolts.
8. Remove the oil pan from the engine block.
Cleaning Procedure
1. Clean the oil pan sealing surface.
2. Clean the engine block sealing surface.
3. Clean the oil pan retaining bolts.
4. Clean the oil pan attaching bolt holes in the engine
block.
5. Clean the oil pan scraper.
Installation Procedure
1. Coat the new oil pan gasket with sealant.
Important : Install the oil pan within 5 minutes after applying
the liquid gasket to the oil pan.
2. Install the oil pan to the engine block.
3. Install the oil pan retaining bolts.
Tighten
Tighten the oil pan retaining bolts to 10 NSm (89 lb–in).
4. Install the oil pan flange–to–transaxle retaining
bolts.
Tighten
Tighten the oil pan flange–to–transaxle bolts to 40
NSm (30 lb–ft).
5. Install the exhaust flex pipe.
6. Install the exhaust flex pipe retaining nuts to the
exhaust manifold.
Tighten
Tighten the exhaust flex pipe–to–exhaust manifold
retaining nuts to 35 NSm (26 lb–ft).
7. Install the exhaust flex pipe retaining nuts to the
catalytic converter or the connecting pipe.
Tighten
Tighten the exhaust flex pipe–to–catalytic converter
or connecting pipe retaining nuts to 35 NSm (26 lb–ft).
8. Connect the negative battery cable.
9. Install the oil pan drain plug.
Tighten
Tighten the oil pan drain plug to 35 NSm (26 lb–ft).
10. Refill the engine crankcase with engine oil.