Suzuki GS500E Service Manual Download

Page: 1 / 440

9 9 5 0 0 - 3 4 0 9 4 - 0 3 E

Summary of Contents for GS500E

Page 1: ...9 9 5 0 0 3 4 0 9 4 0 3 E...

Page 2: ...This service manual has been produced primarily for experienced mechanics whose job is to inspect adjust repair and service SUZUKI motorcycles Apprentice mechanics and do it yourself mechan ics will a...

Page 3: ......

Page 4: ...1 GENERAL INFORMATION CONTENTS...

Page 5: ......

Page 6: ......

Page 7: ......

Page 8: ......

Page 9: ......

Page 10: ......

Page 11: ......

Page 12: ......

Page 13: ......

Page 14: ...2 PERIODIC MAINTENANCE AND CONTENTS TUNE UP PROCEDURES...

Page 15: ......

Page 16: ......

Page 17: ......

Page 18: ......

Page 19: ......

Page 20: ......

Page 21: ......

Page 22: ......

Page 23: ......

Page 24: ......

Page 25: ......

Page 26: ......

Page 27: ......

Page 28: ......

Page 29: ......

Page 30: ......

Page 31: ......

Page 32: ......

Page 33: ......

Page 34: ......

Page 35: ...3 ENGINE CONTENTS...

Page 36: ......

Page 37: ......

Page 38: ......

Page 39: ......

Page 40: ......

Page 41: ......

Page 42: ......

Page 43: ......

Page 44: ......

Page 45: ......

Page 46: ......

Page 47: ......

Page 48: ......

Page 49: ......

Page 50: ......

Page 51: ......

Page 52: ......

Page 53: ......

Page 54: ......

Page 55: ......

Page 56: ......

Page 57: ......

Page 58: ......

Page 59: ......

Page 60: ......

Page 61: ......

Page 62: ......

Page 63: ......

Page 64: ......

Page 65: ......

Page 66: ......

Page 67: ......

Page 68: ......

Page 69: ......

Page 70: ......

Page 71: ......

Page 72: ......

Page 73: ......

Page 74: ......

Page 75: ......

Page 76: ......

Page 77: ......

Page 78: ......

Page 79: ......

Page 80: ......

Page 81: ......

Page 82: ......

Page 83: ......

Page 84: ......

Page 85: ......

Page 86: ......

Page 87: ......

Page 88: ......

Page 89: ......

Page 90: ......

Page 91: ......

Page 92: ......

Page 93: ......

Page 94: ......

Page 95: ......

Page 96: ...4 FUEL AND LUBRICATION SYSTEM CONTENTS...

Page 97: ......

Page 98: ......

Page 99: ......

Page 100: ......

Page 101: ......

Page 102: ......

Page 103: ......

Page 104: ......

Page 105: ......

Page 106: ......

Page 107: ......

Page 108: ......

Page 109: ......

Page 110: ......

Page 111: ......

Page 112: ...5 ELECTRICAL SYSTEM CONTENTS...

Page 113: ......

Page 114: ......

Page 115: ......

Page 116: ......

Page 117: ......

Page 118: ......

Page 119: ......

Page 120: ......

Page 121: ......

Page 122: ......

Page 123: ......

Page 124: ......

Page 125: ......

Page 126: ......

Page 127: ......

Page 128: ......

Page 129: ......

Page 130: ......

Page 131: ......

Page 132: ......

Page 133: ......

Page 134: ......

Page 135: ......

Page 136: ...6 CHASSIS CONTENTS...

Page 137: ......

Page 138: ......

Page 139: ......

Page 140: ......

Page 141: ......

Page 142: ......

Page 143: ......

Page 144: ......

Page 145: ......

Page 146: ......

Page 147: ......

Page 148: ......

Page 149: ......

Page 150: ......

Page 151: ......

Page 152: ......

Page 153: ......

Page 154: ......

Page 155: ......

Page 156: ......

Page 157: ......

Page 158: ......

Page 159: ......

Page 160: ......

Page 161: ......

Page 162: ......

Page 163: ......

Page 164: ......

Page 165: ......

Page 166: ......

Page 167: ......

Page 168: ......

Page 169: ......

Page 170: ......

Page 171: ......

Page 172: ......

Page 173: ......

Page 174: ......

Page 175: ......

Page 176: ......

Page 177: ......

Page 178: ......

Page 179: ......

Page 180: ......

Page 181: ......

Page 182: ......

Page 183: ......

Page 184: ......

Page 185: ......

Page 186: ......

Page 187: ...7 SERVICE INFORMATION CONTENTS...

Page 188: ......

Page 189: ......

Page 190: ......

Page 191: ......

Page 192: ......

Page 193: ......

Page 194: ......

Page 195: ......

Page 196: ......

Page 197: ......

Page 198: ......

Page 199: ......

Page 200: ......

Page 201: ......

Page 202: ......

Page 203: ......

Page 204: ......

Page 205: ......

Page 206: ......

Page 207: ......

Page 208: ......

Page 209: ......

Page 210: ......

Page 211: ......

Page 212: ......

Page 213: ......

Page 214: ......

Page 215: ......

Page 216: ......

Page 217: ......

Page 218: ......

Page 219: ......

Page 220: ......

Page 221: ......

Page 222: ......

Page 223: ......

Page 224: ......

Page 225: ...8 EMISSION CONTROL INFORMATION CONTENTS...

Page 226: ......

Page 227: ......

Page 228: ......

Page 229: ...GS500EL 90 MODEL 9 CONTENTS...

Page 230: ......

Page 231: ......

Page 232: ......

Page 233: ......

Page 234: ......

Page 235: ......

Page 236: ......

Page 237: ......

Page 238: ......

Page 239: ......

Page 240: ......

Page 241: ......

Page 242: ......

Page 243: ......

Page 244: ......

Page 245: ...10 GS500EM 91 MODEL CONTENTS...

Page 246: ......

Page 247: ......

Page 248: ......

Page 249: ......

Page 250: ......

Page 251: ......

Page 252: ......

Page 253: ......

Page 254: ......

Page 255: ......

Page 256: ...11 GS500EN 92 MODEL CONTENTS...

Page 257: ......

Page 258: ......

Page 259: ......

Page 260: ......

Page 261: ......

Page 262: ......

Page 263: ......

Page 264: ......

Page 265: ......

Page 266: ......

Page 267: ......

Page 268: ...12 GS500EP 93 MODEL CONTENTS...

Page 269: ......

Page 270: ......

Page 271: ......

Page 272: ......

Page 273: ......

Page 274: ......

Page 275: ......

Page 276: ......

Page 277: ......

Page 278: ......

Page 279: ...13 GS500ER 94 MODEL CONTENTS...

Page 280: ......

Page 281: ......

Page 282: ......

Page 283: ......

Page 284: ......

Page 285: ......

Page 286: ......

Page 287: ......

Page 288: ......

Page 289: ......

Page 290: ...14 GS500ES 95 MODEL CONTENTS...

Page 291: ......

Page 292: ......

Page 293: ......

Page 294: ......

Page 295: ......

Page 296: ......

Page 297: ......

Page 298: ......

Page 299: ......

Page 300: ......

Page 301: ......

Page 302: ...15 CONTENTS GS500ET 96 MODEL...

Page 303: ......

Page 304: ......

Page 305: ......

Page 306: ......

Page 307: ......

Page 308: ......

Page 309: ......

Page 310: ......

Page 311: ......

Page 312: ......

Page 313: ...16 GS500EV 97 MODEL CONTENTS...

Page 314: ......

Page 315: ......

Page 316: ......

Page 317: ......

Page 318: ......

Page 319: ......

Page 320: ......

Page 321: ......

Page 322: ......

Page 323: ......

Page 324: ......

Page 325: ......

Page 326: ......

Page 327: ...17 GS500EW X Y 98 99 00 MODELS NOTE Asterisk mark indicates the new specifications CONTENTS SPECIFICATIONS 17 1 SERVICE DATA 17 2...

Page 328: ......

Page 329: ......

Page 330: ......

Page 331: ......

Page 332: ......

Page 333: ......

Page 334: ......

Page 335: ......

Page 336: ......

Page 337: ......

Page 338: ......

Page 339: ...18 GS500K1 K2 01 02 MODELS 18 1 GS500K1 K2 01 02 MODELS NOTE Asterisk mark indicates the new specifications CONTENTS SPECIFICATIONS 18 2 SERVICE DATA 18 3...

Page 340: ...uspension stroke 120 mm 4 7 in Rear wheel travel 115 mm 4 5 in Caster 25 05 Trail 97 mm 3 82 in Steering angle 35 Turning radius 2 7 m 8 9 ft Front brake Disk brake Rear brake Disk brake Front tire si...

Page 341: ...deflection IN EX 0 35 0 014 Valve guide I D IN EX 7 000 7 015 0 2756 0 2762 Valve stem O D IN 6 960 6 975 0 2740 0 2746 EX 6 945 6 960 0 2734 0 2740 Valve stem runout IN EX 0 05 0 002 Valve head thick...

Page 342: ...18th pin Cylinder head distortion 0 10 0 004 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Compression pressure 1 000 1 400 kPa 800 kPa 10 14 kg cm2 8 kg cm2 142 199 psi 114 psi Compress...

Page 343: ...dth 22 95 23 00 0 904 0 906 Crank pin width 23 10 23 15 0 909 0 911 Conrod big end oil clearance 0 024 0 048 0 080 0 0009 0 0019 0 0031 Crank pin O D 33 976 34 000 1 3376 1 3386 Crankshaft journal oil...

Page 344: ...in Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2 714 76 28 Final reduction ratio 2 437 39 16 Gear ratios Low 2 461 32 13 2nd 1 777 32 18 3rd 1 380 29 21 4th 1 125 27 24 5th 0 961 25 26 T...

Page 345: ...Needle jet N J P 5M Throttle valve Th V 105 Pilot jet P J 17 5 Pilot screw P S PRE SET PRE SET PRE SET PRE SET 2 turns back 25 8 turns back 2 turns back 25 8 turns back Throttle cable play 3 6 mm 0 1...

Page 346: ...More than 220 V For H HU models voltage Generator Max output Approx 200 W at 5 000 r min Generator no load voltage More than 75 V AC at 5 000 r min Regulated voltage 13 5 15 5 V at 5 000 r min Starte...

Page 347: ...cylinder piston diam Front 12 657 12 684 0 4983 0 4994 Rear 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Rear 38 180 38 256 1 5031 1 5061 Brake caliper pis...

Page 348: ...For the others 13 2 Front fork oil level 99 E 03 28 33 3 9 91 For the others 3 6 Rear shock absorber spring 4th position among 7 adjuster Rear wheel travel 115 4 5 Swingarm pivot shaft runout 0 3 0 01...

Page 349: ...erhaul 3 200 ml 3 4 2 8 US lmp qt Front fork oil type Fork oil 10 Front fork oil capacity 382 ml E 03 28 33 each leg 12 9 13 5 US Imp oz 389 ml For the others 13 1 13 7 US Imp oz Brake fluid type DOT...

Page 350: ...fer from those of the GS500K2 02 MODEL NOTE Please refer to the chapter 1 through 18 for details which are not given in this chapter Any difference between the GS500K2 02 model and GS500K3 03 model in...

Page 351: ...13 in Stroke 56 6 mm 2 228 in Displacement 487 cm3 29 7 cu in Compression ratio 9 0 1 Carburetor BSR34 twin Air cleaner Non woven fabric element Starter system Electric Lubrication system Wet sump Idl...

Page 352: ...y 12 V 39 6 kC 11 Ah 10 HR Generator Three phase A C generator Fuse 20 A Headlight 12 V 60 55 W Position light 12 V 4 W Except P 24 28 Turn signal light 12 V 21 W P 24 28 12 V 18 W Others Brake light...

Page 353: ...lection IN EX 0 35 0 014 Valve guide I D IN EX 7 000 7 015 0 2756 0 2762 Valve stem O D IN 6 960 6 975 0 2740 0 2746 EX 6 945 6 960 0 2734 0 2740 Valve stem runout IN EX 0 05 0 002 Valve head thicknes...

Page 354: ...0 10 0 004 Cam chain pin at arrow 3 18th pin Cylinder head distortion 0 10 0 004 ITEM STANDARD LIMIT Compression pressure 1 000 1 400 kPa 10 14 kg cm2 142 199 psi 800 kPa 8 kg cm2 114 psi Compression...

Page 355: ...nd width 22 95 23 00 0 904 0 906 Crank pin width 23 10 23 15 0 909 0 911 Conrod big end oil clearance 0 024 0 048 0 0009 0 0019 0 080 0 0031 Crank pin O D 33 976 34 000 1 3376 1 3386 Crankshaft journa...

Page 356: ...th 60 8 2 39 ITEM STANDARD LIMIT Primary reduction ratio 2 714 76 28 Final reduction ratio 2 437 39 16 Gear ratios Low 2 461 32 13 2nd 1 777 32 18 3rd 1 380 29 21 4th 1 125 27 24 5th 0 961 25 26 Top 0...

Page 357: ...DH41 3rd 5DH41 2nd Needle jet N J P 5M Throttle valve Th V 105 Pilot jet P J 17 5 Pilot screw P S 2 turns back 2 turns back 2 turns back Throttle cable play 3 6 mm 0 1 0 2 in ITEM SPECIFICATION P 19 G...

Page 358: ...and more Generator Max output Approx 200 W at 5 000 r min Generator no load voltage More than 75 V AC at 5 000 r min Regulated voltage 13 5 15 5 V at 5 000 r min Starter motor brush length N D Limit 9...

Page 359: ...70 0 4972 0 4988 Rear 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Rear 38 180 38 256 1 5031 1 5061 Brake caliper piston diam Front 30 150 30 200 1 1870 1...

Page 360: ...270 10 6 P 28 336 13 2 Others Front fork oil level 99 3 9 E 28 91 3 6 Others Rear shock absorber spring adjuster 4th position among 7 Rear wheel travel 115 4 5 Swingarm pivot shaft runout 0 3 0 01 CO...

Page 361: ...ermissible P 28 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Others Fuel tank including reserve 20 L 5 3 4 4 US lmp gal reserve 4 3 L 1 1 0 9 US lmp gal Engin...

Page 362: ...as possible Place a rag underneath the union bolt on the master cylinder to catch any spilt brake fluid Remove the brake hose union bolt and disconnect the brake hose Remove the master cylinder Remove...

Page 363: ...7 Remove the piston and return spring 8 Piston cup set 9 Return spring INSPECTION Inspect the master cylinder bore for any scratches or other dam age Inspect the piston surface for any scratches or o...

Page 364: ...ing 2 Piston cup set 3 Return spring When remounting the brake master cylinder onto the handle bars align the master cylinder holder s mating surface A with punch mark B on the handlebars and tighten...

Page 365: ...union bolt Brake hose routing 7 16 Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft The seal washers should be replaced with the new ones to prevent fluid leakage Bleed air from the system after rea...

Page 366: ...s connected to the primary windings of the ignition coil which is turned OFF and ON accordingly thus it induces the secondary current on the ignition coil second ary windings and produce the spark bet...

Page 367: ...connection Inspect the spark plug Inspect the battery voltage between input lead wires O W and B W at the ignitor unit with the ignition switch ON position Correct Inconnect Correct Faulty ignition co...

Page 368: ...primary wire 09900 25008 Multi circuit tester set Shift the transmission into the neutral Turn the ignition switch to the ON position Squeeze the clutch lever Crank the engine a few seconds with start...

Page 369: ...nnect the ignition coil primary wire Tester knob indication Voltage Ignition coil primary peak voltage More than 100 V If they are lower than the specified values inspect the ignition coil signal gene...

Page 370: ...g starter button and then check the signal generator peak voltage Repeat the above test procedure a few times and measure the highest signal generator peak voltage Tester knob indication Voltage Signa...

Page 371: ...ified value replace the regulator rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode test More than 1 4 V tester s battery voltage NOTE If the tester reads unde...

Page 372: ...r driven gear are eliminated INSPECTION Remove the headlight Disconnect the combination meter couplers Using the multi circuit tester check the continuity between lead wires in the diagram as shown be...

Page 373: ...3 MODEL TURN SIGNAL LIGHT BUIB REPLACEMENT Loosen the screw Release the bulb socket 1 by turning it clockwise Replace the bulb and lock the bulb socket Hook the claw A on the turn signal light body Ti...

Page 374: ...W W B B W Br Lg B W Lg B W Br B W Br B W Y B W W B B W B B W B Bl B Bl B Bl G G O O O Bl G B W G B W Br B Bl G Y R O G O W O B W B W Y G R Y Y Y Y Y Y R B W B W B W R B W Br B Bl G Y G Bl R B Bl G Bl...

Page 375: ...R O G O W O B W B W Y G R Y Y Y Y Y Y R B W B W B W R B W Br B Bl G Y Bl Bl B Bl B W Lg Lbl B O W Y O B Y Y G B Bl B W Lg Lbl B O R W Y Y W B Y B Y O G Y Bl B B W Lg B Y B W O O B R O G Y Bl B B W Lg...

Page 376: ...B W Br B Bl G Y Bl Bl B Bl B W Lg Lbl B O W Y O B Y Y G B Bl B W Lg Lbl B O R W Y Y W B Y B Y O G Y Bl B B W Lg B Y B W O O B R O G Y Bl B B W Lg B Y B W O Gr R O O Br R O Gr Br R O Gr R O Gr O Bl O...

Page 377: ...fender No slack Clamp Clamp Clamp Clamp Ignition coil left Ignition coil right Spark plug cap Ignition coil lead wire Clutch cable Throttle cable Wiring harness Neutral switch lead wire Regulator lead...

Page 378: ...d wire Left handlebar switch lead wire Right handlebar switch lead wire Clamp Left turn signal Right turn signal Wiring harness VIEW OF A Frame Clamp Clamp Clamp Signal generator lead wire Battery lea...

Page 379: ...26 WIRING HARNESS AND HOSE ROUTING 20 27 WIRING HARNESS ROUTING 20 27 WIRING HARNESS ROUTING For GS500F 20 29 OIL COOLER HOSE ROUTING For GS500F 20 30 CARBURETOR AND AIR CLEANER HOSE ROUTING 20 31 PA...

Page 380: ...UNTRY AND AREA CODES The following codes stand for the applicable country ies and area s CODE COUNTRY or AREA P 02 P 03 P 09 P 19 P 24 P 28 P 33 P 54 UK USA Except for California Colombia EU Australia...

Page 381: ...r cooled DOHC Number of cylinders 2 Bore 74 0 mm 2 913 in Stroke 56 6 mm 2 228 in Displacement 487 cm3 29 7 cu in Compression ratio 9 0 1 Carburetor BSR34 twin Air cleaner Non woven fabric element Sta...

Page 382: ...C 11 Ah 10 HR Generator Three phase A C generator Fuse 20 A Headlight 12 V 60 55 W Position light 12 V 4 W GS500 U 12 V 5 W GS500F FU Turn signal light 12 V 21 W Brake light Taillight 12 V 32 3 cp 2 p...

Page 383: ...flection IN EX 0 35 0 014 Valve guide I D IN EX 7 000 7 015 0 2756 0 2762 Valve stem O D IN 6 960 6 975 0 2740 0 2746 EX 6 945 6 960 0 2734 0 2740 Valve stem runout IN EX 0 05 0 002 Valve head thickne...

Page 384: ...distortion 0 10 0 004 ITEM STANDARD LIMIT Compression pressure 1 000 1 400 kPa 10 14 kgf cm2 142 199 psi 800 kPa 8 kgf cm2 114 psi Compression pressure difference 200 kPa 2 kgf cm2 28 psi Piston to c...

Page 385: ...end width 22 95 23 00 0 904 0 906 Crank pin width 23 10 23 15 0 909 0 911 Conrod big end oil clearance 0 024 0 048 0 0009 0 0019 0 080 0 0031 Crank pin O D 33 976 34 000 1 3376 1 3386 Crankshaft journ...

Page 386: ...ngth 60 8 2 39 ITEM STANDARD LIMIT Primary reduction ratio 2 714 76 28 Final reduction ratio 2 437 39 16 Gear ratios Low 2 461 32 13 2nd 1 777 32 18 3rd 1 380 29 21 4th 1 125 27 24 5th 0 961 25 26 Top...

Page 387: ...3rd Needle jet N J P 5M Throttle valve Th V 105 Pilot jet P J 17 5 Pilot screw P S 3 turns back Throttle cable play 2 0 4 0 mm 0 08 0 16 in ITEM SPECIFICATION GS500 P 09 28 GS500F P 03 28 GS500F P 33...

Page 388: ...ry peak voltage 100 V and more Probe W or B Y Probe Ground Generator Max output Approx 200 W at 5 000 r min Generator no load voltage More than 75 V AC at 5 000 r min Regulated voltage 13 5 15 5 V at...

Page 389: ...diam Front 12 630 12 670 0 4972 0 4988 Rear 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Rear 38 180 38 256 1 5031 1 5061 Brake caliper piston diam Front 3...

Page 390: ...225 2 25 33 REAR 250 2 50 36 280 2 80 41 ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane R 2 M 2 or 91 octane or higher rated by the research method Gasoline c...

Page 391: ...Generator mounting rotor bolt 120 12 0 87 0 Starter clutch bolt 18 1 8 13 0 Signal generator bolt 20 2 0 14 5 Crankcase bolt 6 mm 11 1 1 8 0 8 mm 22 2 2 16 0 Counter balancer shaft setting bolt 40 4...

Page 392: ...mounting bolt 43 4 3 31 0 Front footrest bolt 23 2 3 16 5 Brake hose union bolt 23 2 3 16 5 Air bleeder valve 8 0 8 6 0 Front and rear disc bolt 23 2 3 16 5 Swingarm pivot nut 72 7 2 52 0 Rear shock...

Page 393: ...000 km 2 000 miles and replace every 12 000 km 7 500 miles Cylinder head nuts and exhaust pipe bolts T T T T T Tappet clearance I I I I I Spark plugs I R I R Fuel line I I I I I Replace every 4 years...

Page 394: ...CASE 99104 31140 SUZUKI BOND 1207B USA 99000 31110 SUZUKI BOND 1215 Others Apply SUZUKI BOND to the mating surface of the lower and upper crankcase at shaded area Dowel pin position Dowel pin position...

Page 395: ...GS500K4 FK4 04 MODEL 20 17 COWLING For GS500F 1 Screen 2 Front cowling cover Center 3 Front cowling 4 Front cowling cover LH 5 Front cowling cover RH 6 Cowling brace...

Page 396: ...fork upper clamp bolt 2 1 O ring 2 Spacer 3 Spring retainer 4 Front fork spring 5 Damper rod ring 6 Damper rod 7 Rebound spring 8 Inner tube 9 Anti friction metal Inner 0 Dust seal A Oil seal stopper...

Page 397: ...ork cap bolt Remove the spacer 1 spring retainer 2 and spring 3 Invert the front fork and stroke it several times to drain out the fork oil Hold the fork inverted for a few minutes Remove the damper r...

Page 398: ...l B Oil seal retainer C Anti friction metal Outer D Anti friction metal Inner E Oil lock piece INSPECTION DAMPER ROD RING Inspect the damper rod ring for wear or damage If damper rod ring is worn or d...

Page 399: ...als for wear and damage Replace the metal s if necessary REASSEMBLY Reassembly is in the reverse order of disassembly Pay atten tion to the following points ANTI FRICTION METALS Clean the inner tube m...

Page 400: ...eal DAMPER ROD Install a new gasket 1 Apply THREAD LOCK to the damper rod bolt and tighten it to the specified torque 99000 32050 THREAD LOCK 1342 USA 99000 32110 THREAD LOCK 1322 Others Damper rod bo...

Page 401: ...he front fork assembly align the upper sur face A of the inner tube with the surface B of the steering upper bracket Tighten the front fork upper clamp bolt 1 to the specified tor que Front fork upper...

Page 402: ...B R Lg B W Lg B W B B W B B W W B B W Br Lg B W Lg B W Br B W Br B W Y B W W B B W B B W B Bl B Bl B Bl G G O O O Bl G B W G B W Br B Bl G Y B B B B B B W Y G R Y Y Y Y Y Y R B W B W B W R B W Br B Bl...

Page 403: ...B W Br Lg B W Lg B W B B Br B W Y B W W B B W B B W B Bl B Bl B Bl G G O O O Bl G B W G B W Br B Bl G Y B W Y G R Y Y Y Y Y Y R B W B W B W R B W Br B Bl G Y G Bl R B Bl G Bl R B Bl B Bl B W Lg Lbl B...

Page 404: ...B Bl R G Bl O W B R Lg B W Lg B W B B W B B W W B B W Br Lg B W Lg B W Y B W W B B W B B W B Bl B Bl B Bl G G O O O Bl G B W G B W Br B Bl G Y B W Y G R Y Y Y Y Y Y R B W B W B W R B W Br B Bl G Y G B...

Page 405: ...coil RH Spark plug cap Ignition coil lead wire Clutch cable Throttle cable Wiring harness Neutral switch Regulator Pass the regulator lead wire under the wiring harness Clamp the wiring harness at blu...

Page 406: ...dlebar switch Right handlebar switch Clamp Left turn signal Right turn signal Wiring harness VIEW A previous page Frame Clamp Clamp Clamp Signal generator Battery lead wire Generator Battery lead wire...

Page 407: ...itch R Speedometer Ignition coil L Clamp Handlebar switch L Ignition switch Horn Front turn signal light L Clamp Clamp Wiring harness To the front turn signal light R Starter cable Handlebar switch L...

Page 408: ...20 30 GS500K4 FK4 04 MODEL OIL COOLER HOSE ROUTING For GS500F 1 Oil cooler 2 Oil cooler hose LH 3 Oil cooler hose RH 26 N m 2 6 kgf m 19 0 lb ft...

Page 409: ...r vent hose To the fuel valve Throttle cable Breather hose Air cleaner Air cleaner drain hose Air control hose Throttle cable Fuel valve vacuum hose Carburetor clamp position Intake manifold side Carb...

Page 410: ...en Marking Red PAIR valve vacuum hose Fuel valve vacuum hose No 2 Connect the thick side of the vacuum hose to the 3 way joint PAIR air cleaner hose Marking Yellow PAIR valve PAIR valve vacuum hose Fu...

Page 411: ...E ROUTING For GS500F Throttle cable Front brake hose Clamp Front brake caliper Stopper After positioning the brake hose union to the stopper tighten the union bolt 28 28 10 Throttle cable Clamp 14 Fro...

Page 412: ...20 34 GS500K4 FK4 04 MODEL FRONT TURN SIGNAL LIGHT INSTALLATION For GS500F 1 Forward 2 Cowling 3 Front turn signal light 14 N m 1 4 kgf m 10 0 lb ft...

Page 413: ...e data and servicing procedures which differ from those of the GS500K4 FK4 04 MODEL NOTE Any differences between the GS500K4 FK4 04 MODEL and GS500K5 UK5 FK5 FUK5 05 MODEL in specifications and servic...

Page 414: ...Final reduction ratio 2 437 39 16 Drive chain D I D 520VM 110 links CHASSIS Front suspension Telescopic coil spring oil damped Rear suspension Link type coil spring oil damped Front suspension stroke...

Page 415: ...5 0 4 2 US Imp gal P 33 20 0 L 5 3 4 4 US Imp gal Others reserve 4 3 L 1 1 0 9 US Imp gal Engine oil oil change 2 600 ml 2 7 2 3 US Imp qt with filter change 2 900 ml 3 1 2 6 US Imp qt overhaul 3 200...

Page 416: ...on IN EX 0 35 0 014 Valve guide I D IN EX 7 000 7 015 0 2756 0 2762 Valve stem O D IN 6 960 6 975 0 2740 0 2746 EX 6 945 6 960 0 2734 0 2740 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN...

Page 417: ...head distortion 0 10 0 004 ITEM STANDARD LIMIT Compression pressure 1 000 1 400 kPa 10 14 kgf cm2 142 199 psi 800 kPa 8 kgf cm2 144 psi Compression pressure difference 200 kPa 2 kgf cm2 28 psi Piston...

Page 418: ...big end width 22 95 23 00 0 904 0 906 Crank pin width 23 10 23 15 0 909 0 911 Conrod big end oil clearance 0 024 0 048 0 0009 0 0019 0 080 0 0031 Crank pin O D 33 976 34 000 1 3376 1 3386 Crankshaft...

Page 419: ...ee length 60 8 2 39 ITEM STANDARD LIMIT Primary reduction ratio 2 714 76 28 Final reduction ratio 2 437 39 16 Gear ratios Low 2 461 32 13 2nd 1 777 32 18 3rd 1 380 29 21 4th 1 125 27 24 5th 0 961 25 2...

Page 420: ...3rd Needle jet N J P 5M Throttle valve Th V 105 Pilot jet P J 17 5 Pilot screw P S 3 turns back Throttle cable play 2 0 4 0 mm 0 08 0 16 in ITEM SPECIFICATION GS500 P 09 28 GS500F P 03 28 GS500F P 33...

Page 421: ...rimary peak voltage 100 V and more Probe W or B Y Probe Ground Generator Max output Approx 200 W at 5 000 r min Generator no load voltage More than 75 V AC at 5 000 r min Regulated voltage 13 5 15 5 V...

Page 422: ...ton diam Front 12 630 12 670 0 4972 0 4988 Rear 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Rear 38 180 38 256 1 5031 1 5061 Brake caliper piston diam Fro...

Page 423: ...50 36 280 2 80 41 ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane R 2 M 2 or 91 octaneor higher rated by the research method Gasoline containing MTBE Methyl Ter...

Page 424: ...FUK5 05 MODEL NOTE Any differences between the GS500K5 UK5 FK5 FUK5 05 MODEL and GS500K6 UK6 FK6 FUK6 06 MODEL in specifications and service data are indicated with an asterisk mark Please refer to t...

Page 425: ...Final reduction ratio 2 437 39 16 Drive chain D I D 520VM 110 links CHASSIS Front suspension Telescopic coil spring oil damped Rear suspension Link type coil spring oil damped Front suspension stroke...

Page 426: ...tank including reserve 19 0 L 5 0 4 2 US Imp gal P 33 20 0 L 5 3 4 4 US Imp gal Others reserve 4 3 L 1 1 0 9 US Imp gal Engine oil oil change 2 600 ml 2 7 2 3 US Imp qt with filter change 2 900 ml 3 1...

Page 427: ...on IN EX 0 35 0 014 Valve guide I D IN EX 7 000 7 015 0 2756 0 2762 Valve stem O D IN 6 960 6 975 0 2740 0 2746 EX 6 945 6 960 0 2734 0 2740 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN...

Page 428: ...head distortion 0 10 0 004 ITEM STANDARD LIMIT Compression pressure 1 000 1 400 kPa 10 14 kgf cm2 142 199 psi 800 kPa 8 kgf cm2 144 psi Compression pressure difference 200 kPa 2 kgf cm2 28 psi Piston...

Page 429: ...big end width 22 95 23 00 0 904 0 906 Crank pin width 23 10 23 15 0 909 0 911 Conrod big end oil clearance 0 024 0 048 0 0009 0 0019 0 080 0 0031 Crank pin O D 33 976 34 000 1 3376 1 3386 Crankshaft...

Page 430: ...ee length 60 8 2 39 ITEM STANDARD LIMIT Primary reduction ratio 2 714 76 28 Final reduction ratio 2 437 39 16 Gear ratios Low 2 461 32 13 2nd 1 777 32 18 3rd 1 380 29 21 4th 1 125 27 24 5th 0 961 25 2...

Page 431: ...jet N J P 5M Throttle valve Th V 105 Pilot jet P J 17 5 Pilot screw P S 3 turns back Throttle cable play 2 0 4 0 mm 0 08 0 16 in ITEM SPECIFICATION GS500 P 09 GS500 P 28 GS500F P 03 28 GS500F P 33 Car...

Page 432: ...rimary peak voltage 100 V and more Probe W or B Y Probe Ground Generator Max output Approx 200 W at 5 000 r min Generator no load voltage More than 75 V AC at 5 000 r min Regulated voltage 13 5 15 5 V...

Page 433: ...ton diam Front 12 630 12 670 0 4972 0 4988 Rear 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Rear 38 180 38 256 1 5031 1 5061 Brake caliper piston diam Fro...

Page 434: ...50 36 280 2 80 41 ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane R 2 M 2 or 91 octaneor higher rated by the research method Gasoline containing MTBE Methyl Ter...

Page 435: ...GS500K6 UK6 FK6 FUK6 06 MODEL STARTER BUTTON O W Y G O R Y W PUSH WIRE COLOR Color Position O R Orange with Red tracer O W Orange with White tracer Y G Yellow with Green tracer Y W Yellow with White t...

Page 436: ...Br B W Y B W W B B W B B W B Bl B Bl B Bl G G O O O Bl G B W G B W Br B Bl G Y B B B B B B W Y G R Y Y Y Y Y Y R B W B W B W R B W Br B Bl G Y G Bl R B Bl G Bl R B Bl B Bl B W Lg Lbl B O R W Y Y W B...

Page 437: ...B Bl G Y G Bl R B Bl G Bl R B Bl B Bl B W Lg Lbl B O R W Y Y W B Y B Y O G Y Bl B B W Lg B Y B W O O B R O G Y Bl B B W Lg B Y B W O Gr R O O Br R O Gr Br B Y W O W G B B W R B B R G Bl B B Bl Bl Br...

Page 438: ...er Black with White tracer Black with Yellow tracer Blue with Black tracer Green with Black tracer Green with Yellow tracer Orange with Blue tracer Orange with Red tracer Orange with White tracer Whit...

Page 439: ...Prepared by 13th Ed December 2005 1st Ed March 1989 Part No 99500 34094 03E Printed in Japan 448...

Page 440: ...Printed in Japan K L M N P R S T V W X Y K1 K2 K3 K4 K5 K6...

Search results

Summary of Contents for GS500E

Reviews:

Related manuals for GS500E

Brands by name

Popular brands

Suzuki GS500E, Service Manual

Search results

Summary of Contents for GS500E

Reviews:

Related manuals for GS500E

Brands by name

Popular brands