Suzuki 1989 GS500EK Service Manual Download Page 3 | Manualshive

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Summary of Contents for 1989 GS500EK

Page 1: ...eelbaee W 1 1410nvn Overaillength L I 2O75nWT1 Overallwidth I Kmodels L M N P and R models S TandVmodels Overall height H Seat height S Minimumgroundclearance c Weight dry Reference REF 1 FaultFinding...

Page 2: ...cycle club to join in hammers soldering iron and a workbench Service tools can usually only be purchased the putdtase equipped with a vice may be needed from a motorcycle dealer and are identifiedby A...

Page 3: ...r tool 11 A JItRneter mea8Jres and ohms 12 St1oboscope for dynwnictimingchecks 13 Hose clamp wingnuttype shown 14 Magnetic arm te escopk I pe thown 15 One man txBk8 b eederkit 7 PIastIgauge kit 10 Pis...

Page 4: ...an and smooth If for some reason the the nut or bolt Badly rusted fasteners may removed It may also be helpful to make gasket surface is gouged then a gasket sealant have to be chiselled off or remove...

Page 5: ...per cylinder Thread locking compound is an system components where clean lubricants for valves and piston rings adhesive locking compound that surfaces are absolutely necessary and prevents threaded f...

Page 6: ...rately or as part of the taillight lens V Check the condition of the headlight tail lightandtum signallenses tester particularly in view of the equipment required for some of the checks However workin...

Page 7: ...ely II Checkthatthehandlebar griprubbersare leg Onmodelssoequipped checkthatthere witOOut dragor notd1iness Steering mov nent secure Theyshouldby bondedto the barleft is nooil leakingfromthe anti dive...

Page 8: ...fromcracksandif of the bullt IHustI ation 11 check warninglight in the instrumentpanel up design all fasteners should be secure tI On drum brakes check that when the wOf1 s Spoked wheels should be che...

Page 9: ...castellated nut with a split pin or A pin can be used see Illustration 17 Wheel alignment is checked with the motorcycle off the stand and a rider seated With the front wheel pointing straight ahead t...

Page 10: ...rack its case seeIllustration6 Connecta hoseto the carburettor float chamberdrain stub arrow andunscrew the drain screw Drainthe carburettor s otherwise there is a risk of jets becoming blocked by gum...

Page 11: ...s If greasenipples are fitted to the rear suspensioncomponents not compressthe forks otherwisethe seals willrotfromcontactwiththeVaseline Applya vinylcleanerto theseat Storage ns apply lubricant to th...

Page 12: ...igh p engine1089 excessive 0 Lubrication inadequate 0 Miscellaneous causes 5 Clutch problems Clutch slipping Clutch not disengaging completely shifting problems Doesn tgo intogear or leverdoesn tretur...

Page 13: ...sis usuallycausedbywat corrosion damageor excessive wear Theswitchescanbe Starter works but engine won t turn over seized disassembled andcleanedwithelectricalcontactcleaner If 0 Seizedenginecausedbyo...

Page 14: ...3 Air bleed holes clogged Remove carburettor and blow out all passages Chapter 3 Air filter clogged poorly sealed or missing Chapter 1 Air filter housing poorly sealed Look for cracks holes or loose c...

Page 15: ...itionedor womCheckandadjustor replace Chapter 3 0 Carbonbuild upincombustionchamber Useof a fueladditive 0 Mainjet clogged Dirt wateror othercontaminants canclogthe thatwilldissolvetheadhesive bonding...

Page 16: ...iston crown and chamber is the easiest way to remove the bUlld Ch t 2 up Otherwise thecylinderheadwill haveto beremovedand passages ap er decarbonized C apter 2 Miscellaneous causes D Improperly machi...

Page 17: ...is excessive wear rangeplug Chapter1 or damage Chapter 2 0 Improperair fuelmixture Thiswillcausethecylindersto runhot andleadto detonation Cloggedjetsor anairleakcancausethis Other noIse imbalance Cha...

Page 18: ...rnandcylinder Causesoilto bepulledintothecombustionchamber Replace theheedgasket andchecktheheadfor warpage Chapter 2 0 Abnormal crankcase pressurisation whichforcesoil pastthe rings Cloggedventilatio...

Page 19: ...stembent Causedby acollision hittinga potholeor by D Fori oil leveluneven Checkandaddor drainasnecessary droppingthemachine Replace damagedpart Don ttryto Chapter 5 straighten thesteeringstem Chapter...

Page 20: ...hread size Note that the screw in type gauge adapter set up is preferable to the rubber cone type Wiring faulty Wiring grounded earthed or connections loose in ignition charging or lighting circuits C...

Page 21: ...voltage again If the battery repeatedly goes flat investigate the motorcycle s charging system Bores can be temporarily seaJed with a squirt of motor oil 10 High compression pressure indicates excess...

Page 22: ...test probes doesn t matter for continuitychecks although care should be takento follow specific test procedures if a diode or solid state component is being checked 4 A continuity tester or battery a...

Page 23: ...th the jumper wire installed the original earth circuit is faulty Check the wiring for open circuits or poor connections Clean up direct earth connections removingall tracesof corrosion andremakethejo...

Page 24: ...and temperature of a gas causedby squeezingit into a smallerspace Comprea8ion damping Controlsthe speedthe suspensioncompresseswhen hitting a b Compre88ion ratio The relationship between cylinder volu...

Page 25: ...rcycle applications brakingefficiencywill be reducedif DOT3 or 4 hydraulicfluid absorbswaterfromthe aJr care must be taken to keep new brakefluid in tightly sealedcontainers FreepiBY The amount of tra...

Page 26: ...ce with throttle position 0pen cIrcuIt An electrical ltton where there is a break in the flow of electricity no continuity high resistance O ring A type of sealing ring made of a special rubber like m...

Page 27: ...valves in relation to piston position Vemle cellper A precision measuring Instrument that measures inside and outside dimensions Not quite as accurate as a micrometer but moreconvenient VIM VehicleIde...

Page 28: ...feet Qbfft Ib ft x 12 Pounds force inches Qbfin Ib in Ibf in Ib in Pounds force feet Ibf ft Ib ft x 0 138 Kilograms force metres x 7 233 Pounds force feet Ibf ft Ib ft kgf m kg m Pounds force feet Ibf...

Page 29: ...ad replacement 6 2 6 7 seal replacement 1 21 specifications 6 1 Brake fluid type 1 2 Bulbs brake taillight 8 6 headlight 8 4 instrument 8811 side light 884 turn signal 887 wattage 882 c Ceblea choke 1...

Page 30: ...ment8 8 11 Ightingcheck 8 4 neutralswitch 8 14 011 presSl nswitch 8 12 regUator rectlfier 8 23 side 8 4 8id8starMi switch relay 8 15 specifications 8 1 a g ay8t startermotor 8 17 8 18 starterrelay 8 1...

Page 31: ...2 pulsegenerator coils 4 3 sparkplugs 1 1 1 9 1 16 specifications 4 1 timing 4 4 Ignition main switch 8 13 Instrument bulbs 8 2 8 11 checkandreplacement 8 11 drivecables 8 9 L Legalchecks 0 12 Lubrica...

Page 32: ...p 01 pan 2 37 Su8P 8iG adjustment 5 13 check 0 11 1 18 frm 1 20 5 5 5 6 rear 1 21 5 12 specifications 5 1 m inspection and replec 1 a ot 5815 removal andinstallation 5 14 SWitches brake light 8 9 clut...

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