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Suzuki GS500E, Руководство по обслуживанию


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12

GS500EP (’93-MODEL)

CONTENTS

Содержание GS500E

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

Страница 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...

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Страница 4: ...1 GENERAL INFORMATION CONTENTS...

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

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Страница 35: ...3 ENGINE CONTENTS...

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

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Страница 112: ...5 ELECTRICAL SYSTEM CONTENTS...

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Страница 136: ...6 CHASSIS CONTENTS...

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Страница 187: ...7 SERVICE INFORMATION CONTENTS...

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

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

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

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

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

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

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

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

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

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

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Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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