Suzuki GS500E Service Manual
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Suzuki GS500E Service Manual

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Table of Contents

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Summary of Contents for Suzuki GS500E

  • Page 1 9 9 5 0 0 - 3 4 0 9 4 - 0 3 E...

  • Page 2: Table Of Contents

    FOREWORD GROUP INDEX The SUZUKI GS500E has been developed as a new generation motorcycle to the GS-models. It is GENERAL INFORMATION packed with highly advanced design concepts including a New Twin Dome Combustion Chamber, PERIODIC MAINTENANCE AND a crankshaft couter-balancer, a fully transistorized TUNE-UP PROCEDURES ignition system and a full-floater rear suspension.

  • Page 4: General Information

    GENERAL INFORMATION CONTENTS...

  • Page 14: Periodic Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES CONTENTS...

  • Page 35: Engine

    ENGINE CONTENTS...

  • Page 96: Fuel And Lubrication System

    FUEL AND LUBRICATION SYSTEM CONTENTS...

  • Page 112: Electrical System

    ELECTRICAL SYSTEM CONTENTS...

  • Page 136: Chassis

    CHASSIS CONTENTS...

  • Page 187: Service Information

    SERVICE INFORMATION CONTENTS...

  • Page 225: Emission Control Information

    EMISSION CONTROL INFORMATION CONTENTS...

  • Page 229: Gs500El ('90-Model)

    GS500EL (’90-MODEL) CONTENTS...

  • Page 245: Gs500Em ('91-Model)

    GS500EM (’91-MODEL) CONTENTS...

  • Page 256: Gs500En ('92-Model)

    GS500EN (’92-MODEL) CONTENTS...

  • Page 268: Gs500Ep ('93-Model)

    GS500EP (’93-MODEL) CONTENTS...

  • Page 279: Gs500Er ('94-Model)

    GS500ER (’94-MODEL) CONTENTS...

  • Page 290: Gs500Es ('95-Model)

    GS500ES (’95-MODEL) CONTENTS...

  • Page 302: Gs500Et ('96-Model)

    GS500ET (’96-MODEL) CONTENTS...

  • Page 313: Gs500Ev ('97-Model)

    GS500EV (’97-MODEL) CONTENTS...

  • Page 327: Gs500Ew/X/Y ('98/'99/'00-Models)

    GS500EW/X/Y (’98/’99/’00-MODELS) CONTENTS SPECIFICATIONS ..................17- 1 SERVICE DATA..................17- 2 NOTE: Asterisk mark (*) indicates the new specifications.

  • Page 339: Gs500K1/K2 ('01/'02-Models)

    GS500K1/K2 (’01/’02-MODELS) 18-1 GS500K1/K2 (’01/’02-MODELS) CONTENTS SPECIFICATIONS ..................18- 2 SERVICE DATA..................18- 3 NOTE: Asterisk mark (*) indicates the new specifications.

  • Page 340: Specifications

    18-2 GS500K1/K2 (’01/’02-MODELS) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ................2 080 mm (81.9 in) Overall width ................800 mm (31.5 in) Overall height ................1 060 mm (41.7 in) Wheelbase ................1 405 mm (55.3 in) Ground clearance ..............150 mm ( 5.9 in) Seat height ................

  • Page 341: Service Data

    GS500K1/K2 (’01/’02-MODELS) 18-3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.5) ——— (1.3) Valve lift ——— (0.33) ——— (0.31) Tappet clearance (when cold) 0.03 – 0.08 ——— IN. & EX. (0.001 – 0.003) Valve guide to valve stem 0.025 –...
  • Page 342 18-4 GS500K1/K2 (’01/’02-MODELS) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.789 – 36.819 36.49 (1.4484 – 1.4496) (1.437) E-03, 18, 24, 28, 33 36.291 – 36.321 36.00 (1.4288 – 1.4300) (1.417) 36.090 – 36.130 35.80 (1.4208 –...

  • Page 343: Oil Pump

    GS500K1/K2 (’01/’02-MODELS) 18-5 ITEM STANDARD LIMIT Piston ring groove width 1.21 – 1.23 ——— (0.047 – 0.048) 1.21 – 1.23 ——— (0.047 – 0.048) 2.51 – 2.53 ——— (0.099 – 0.100) Piston ring thickness 1.17 – 1.19 ——— (0.046 – 0.047) 1.17 –...
  • Page 344 18-6 GS500K1/K2 (’01/’02-MODELS) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 ——— (0.4 – 0.6) Clutch release screw 1/4 – 1/2 turn back ——— Drive plate thickness 2.92 – 3.08 2.62 (0.115 – 0.121) (0.103) Drive plate claw width 15.8 –...
  • Page 345 GS500K1/K2 (’01/’02-MODELS) 18-7 CARBURETOR SPECIFICATION ITEM E-02, 19, 24, 54 E-19 E-19 E-19 (GS500) (GS500-H) (GS500-U) (GS500-HU) Carburetor type MIKUNI ← ← ← BSR34SS ← ← ← Bore size 34 mm I.D. No. 01DE 01DF 01DG 01DK ← ← ← Idle r/min.
  • Page 346 18-8 GS500K1/K2 (’01/’02-MODELS) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 5° B.T.D.C. at 1 000 r/min. E-33 12° B.T.D.C. at 1 200 r/min. For the others L . R Firing order Spark plug DENSO: X24EPR-U9 Type NGK: DPR8EA-9 0.8 –...
  • Page 347 GS500K1/K2 (’01/’02-MODELS) 18-9 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height ——— (2.2) Brake disc thickness 4.5 ± 0.2 Front (0.177 ± 0.008) (0.16) 6.0 ± 0.2 Rear (0.236 ± 0.008) (0.22) Brake disc runout 0.30 ———...

  • Page 348: Tire Pressure

    18-10 GS500K1/K2 (’01/’02-MODELS) SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke ——— (4.7) Front fork spring free length ——— E-03, 28, 33 (10.6) ——— For the others (13.2) Front fork oil level E-03, 28, 33 ——— (3.9) For the others ———...
  • Page 349 GS500K1/K2 (’01/’02-MODELS) 18-11 FUEL + OIL ITEM SPECIFICATION NOTE Use only unleaded gasoline of at least 87 pump Fuel type R + M octane ( ) or 91 octaneor higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-...

  • Page 350: Gs500K3 ('03-Model)

    GS500K3 (’03-MODEL) 19-1 GS500K3 (’03-MODEL) The descriptions of GS500K3 (’03-model) are applicable to 01E, 01F and 01G, and not to 03E. This chapter describes service data, service specifications and servicing procedures which dif- 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.

  • Page 351: Dimensions And Dry Mass

    19-2 GS500K3 (’03-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 080 mm (81.9 in) Overall width ............800 mm (31.5 in) Overall height ............1 060 mm (41.7 in) Wheelbase ............1 405 mm (55.3 in) Ground clearance ..........150 mm ( 5.9 in) Seat height............
  • Page 352 GS500K3 (’03-MODEL) 19-3 CHASSIS Front suspension..........Telescopic, coil spring, oil damped Rear suspension ..........Link type, coil spring, oil damped Front suspension 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 .............
  • Page 353 19-4 GS500K3 (’03-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.5) — (1.3) Valve lift — (0.33) — (0.31) Tappet clearance (when cold) 0.03 – 0.08 IN. & EX. — (0.001 – 0.003) Valve guide to valve stem 0.025 –...
  • Page 354 GS500K3 (’03-MODEL) 19-5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.789 – 36.819 36.49 (1.4484 – 1.4496) (1.437) E-03, 18, 24, 28, 33 36.291 – 36.321 36.00 (1.4288 – 1.4300) (1.417) 36.090 – 36.130 35.80 (1.4208 –...
  • Page 355 19-6 GS500K3 (’03-MODEL) ITEM STANDARD LIMIT Piston ring groove width 1.21 – 1.23 — (0.047 – 0.048) 1.21 – 1.23 — (0.047 – 0.048) 2.51 – 2.53 — (0.099 – 0.100) Piston ring thickness 1.17 – 1.19 — (0.046 – 0.047) 1.17 –...
  • Page 356 GS500K3 (’03-MODEL) 19-7 CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/4 – 1/2 turn back — Drive plate thickness 2.92 – 3.08 2.62 (0.115 – 0.121) (0.103) Drive plate claw width 15.8 –...
  • Page 357 19-8 GS500K3 (’03-MODEL) CARBURETOR SPECIFICATION ITEM P-02, 09, 19, 24, 54 P-19 P-19 (GS500) (GS500-H) (GS500-U) Carburetor type MIKUNI ← ← BSR34SS ← ← Bore size 34 mm I.D. No. 01DE 01DF 01DG ← ← Idle r/min. 1 200 ±100 r/min. ←...
  • Page 358 GS500K3 (’03-MODEL) 19-9 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 5° B.T.D.C. at 1 000 r/min. P-28 12° B.T.D.C. at 1 200 r/min. Others Firing order L·R Spark plug DENSO: X24EPR-U9 Type NGK: DPR8EA-9 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm.
  • Page 359 19-10 GS500K3 (’03-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height — (2.2) Brake disc thickness 4.5 ± 0.2 Front (0.177 ± 0.008) (0.16) 6.0 ± 0.2 Rear (0.236 ± 0.008) (0.22) Brake disc runout 0.30 —...
  • Page 360 GS500K3 (’03-MODEL) 19-11 SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT NOTE Front fork stroke — (4.7) Front fork spring free length — P-28 (10.6) Others — (13.2) Front fork oil level — E-28 (3.9) — Others (3.6) Rear shock absorber spring 4th position among 7 —...
  • Page 361 19-12 GS500K3 (’03-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump R + M octane ( ) or 91 octaneor higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl P-28 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corro-...

  • Page 362: Front Brake Master Cylinder

    GS500K3 (’03-MODEL) 19-13 FRONT BRAKE MASTER CYLINDER REMOVAL AND DISASSEMBLY • Remove the rear view mirror 1. • Disconnect the front brake light switch couplers 2. • Remove the reservoir tank cap 3 and diaphragm. • Suck up brake fluid as much as possible. •...
  • Page 363 19-14 GS500K3 (’03-MODEL) • Pull out the dust boot 6 and remove the snap ring 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.
  • Page 364 GS500K3 (’03-MODEL) 19-15 Inspect the reservoir tank cap and diaphragm for damage. REASSEMBLY AND REMOUNTING Reassemble the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: * Wash the master cylinder components with fresh brake fluid before reassembly.
  • Page 365 19-16 GS500K3 (’03-MODEL) • Tighten the 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 reassembling the master cylinder.

  • Page 366: Ignition System

    GS500K3 (’03-MODEL) 19-17 IGNITION SYSTEM DESCRIPTION The fully transistorized ignition system consists of a signal generator, ignitor unit, ignition coils and spark plugs. The signal generator mounted at the right end of the crankshaft comprises the rotor tip and pickup coil. The induced signal in the signal generator is sent to wave-form arrangement circuit, and CPU receives this signal and calculates the best ignition timing from the signal of ceramic vibrator.

  • Page 367: Troubleshooting

    19-18 GS500K3 (’03-MODEL) TROUBLESHOOTING * Check that the transmission is in neutral position and No spark or poor spark the engine stop switch is in the RUN position. Inspect that the fuse is not blown and battery is fully-charged condition before the diagnosis. Check the ignition system couplers for Looseness •...

  • Page 368: Ignition Coil Primary Peak Voltage

    GS500K3 (’03-MODEL) 19-19 IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the fuel tank. • Disconnect the two spark plug caps. • Connect new two spark plugs to each spark plug cap and ground them. NOTE: Be sure that all couplers and spark plugs are connected properly and the battery is in fully-charged condition.
  • Page 369 19-20 GS500K3 (’03-MODEL) Inspect the No.2 ignition coil primary peak voltage in the same manner of No. 1 ignition coil inspection. No. 2 ignition coil: B/Y terminal – Ground (+ Probe) (- Probe) B/Y: Black with Yellow tracer NOTE: Do not disconnect 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...
  • Page 370 GS500K3 (’03-MODEL) 19-21 SIGNAL GENERATOR PEAK VOLTAGE • Remove the seat. • Disconnect the signal generator lead wire coupler. NOTE: Be sure that all couplers are connected properly and the battery is in fully-charged condition. Inspect the signal generator peak voltage between Brown and B/Bl lead wires on the signal generator lead wire coupler.
  • Page 371 19-22 GS500K3 (’03-MODEL) REGULATOR/RECTIFIER • Remove the seat. • Diconnect the regulator/rectifier couplers. Measure the voltage between the terminals using the multi cir- cuit tester as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.

  • Page 372: Combination Meter

    GS500K3 (’03-MODEL) 19-23 COMBINATION METER The combination is equiped with the electrical tachometer. And so the tachometer cable and tachometer 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 below.

  • Page 373: Turn Signal Light

    19-24 GS500K3 (’03-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. •...

  • Page 374: Wiring Diagram

    GS500K3 (’03-MODEL) 19-25 WIRING DIAGRAM FOR GS500HK3/GS500HUK3 P-19...
  • Page 375 19-26 GS500K3 (’03-MODEL) FOR GS500K3/GS500UK3 P-02, 19, 54...
  • Page 376 GS500K3 (’03-MODEL) 19-27 FOR GS500 P-24, 28...
  • Page 377 19-28 GS500K3 (’03-MODEL) WIRE ROUTING Clamp Ignition coil lead wire Clutch cable Throttle cable Pass the lead wire Ignition coil, left underneath the frame. Clamp Make clearance between the wiring harness and fuel tank bracket. Clamp Clamp Clamp Clamp Ignition coil, right Spark plug cap Wiring harness Neutral switch lead wire...
  • Page 378 GS500K3 (’03-MODEL) 19-29 Clamp Ignition switch lead wire Left handlebar switch lead wire Right handlebar switch lead wire Clamp Left turn signal Right turn signal Wiring harness Right handlebar switch lead wire Left handlebar switch lead wire Brake hose Wiring harness Wiring harness guide...

  • Page 379: Gs500K4/Fk4 ('04-Model)

    GS500K4/FK4 (’04-MODEL) 20-1 GS500K4/FK4 (’04-MODEL) FOREWORD This chapter describes service data, service specifications and servicing procedures which dif- fer from those of the GS500K3 (’03-MODEL). NOTE: * Any difference between the GS500K3 (’03-model) and GS500/FK4 (’04-model) in specifications and service data are clearly indicated with an asterisk (*). * Please refer to the chapter 1 through 19 for details which are not given in this chapter.

  • Page 380: Country And Area Codes

    20-2 GS500K4/FK4 (’04-MODEL) COUNTRY AND AREA CODES The following codes stand for the applicable country (-ies) and area (-s). CODE COUNTRY or AREA P-02 P-03 USA (Except for California) P-09 Colombia P-19 P-24 Australia P-28 Canada P-33 California (USA) P-54 Spain...
  • Page 381 GS500K4/FK4 (’04-MODEL) 20-3 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 080 mm (81.9 in) Overall width ............800 mm (31.5 in) Overall height ............1 060 mm (41.7 in) ....GS500/U * 1 150 mm (45.3 in) ....GS500F/FU Wheelbase ............
  • Page 382 20-4 GS500K4/FK4 (’04-MODEL) CHASSIS Front suspension ..........Telescopic, coil spring, oil damped Rear suspension ..........Link type, coil spring, oil damped Front suspension stroke........120 mm (4.7 in) Rear wheel travel ..........115 mm (4.5 in) ° Caster ..............25 05’...
  • Page 383 GS500K4/FK4 (’04-MODEL) 20-5 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.5) — (1.3) Valve lift — (0.33) — (0.31) Tappet clearance (when cold) 0.03 – 0.08 IN. & EX. — (0.001 – 0.003) Valve guide to valve stem 0.025 –...
  • Page 384 20-6 GS500K4/FK4 (’04-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.090 – 36.130 35.80 (1.4208 – 1.4224) (1.409) 36.090 – 36.130 35.80 (1.4208 – 1.4224) (1.409) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.0013 –...
  • Page 385 GS500K4/FK4 (’04-MODEL) 20-7 ITEM STANDARD LIMIT Piston ring groove width 1.21 – 1.23 — (0.047 – 0.048) 1.21 – 1.23 — (0.047 – 0.048) 2.51 – 2.53 — (0.099 – 0.100) Piston ring thickness 1.17 – 1.19 — (0.046 – 0.047) 1.17 –...
  • Page 386 20-8 GS500K4/FK4 (’04-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/4 – 1/2 turn back — Drive plate thickness 2.92 – 3.08 2.62 (0.115 – 0.121) (0.103) Drive plate claw width 15.8 –...
  • Page 387 GS500K4/FK4 (’04-MODEL) 20-9 CARBURETOR SPECIFICATION ITEM GS500 P-02, 19, 24, 54 GS500U P-19 GS500F P-02, 19, 24, 54 GS500FU P-19 Carburetor type MIKUNI ← BSR34 ← Bore size 34 mm I.D. No. * 01DN * 01DP ← Idle r/min 1 200 ±100 r/min ←...
  • Page 388 20-10 GS500K4/FK4 (’04-MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing * 5° B.T.D.C. at 1 200 r/min P-03, 28, 33 12° B.T.D.C. at 1 200 r/min Others Firing order L·R Spark plug DENSO: X24EPR-U9 Type NGK: DPR8EA-9 0.8 – 0.9 (0.031 –...
  • Page 389 GS500K4/FK4 (’04-MODEL) 20-11 BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height — (2.2) Brake disc thickness 4.5 ± 0.2 Front (0.177 ± 0.008) (0.16) 6.0 ± 0.2 Rear (0.236 ± 0.008) (0.22) Brake disc runout 0.30 —...
  • Page 390 (13.5) (13.2) Front fork oil level * 110 — (4.3) Front fork oil type SUZUKI FORK OIL #10 or equivalent fork oil — Front fork oil capacity * 380 ml — (each leg) (12.8/13.4 US/lmp oz) Front fork inner tube O.D.

  • Page 391: Tightening Torque

    GS500K4/FK4 (’04-MODEL) 20-13 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt 10.0 Cylinder head nut 27.5 Cylinder head bolt Cylinder stud bolt 11.0 Camshaft journal holder bolt Cam sprocket bolt 13.0 Cam chain tensioner mounting bolt Conrod bearing cap nut 23.0 Generator mounting rotor bolt 12.0...
  • Page 392 20-14 GS500K4/FK4 (’04-MODEL) CHASSIS ITEM N·m kgf-m lb-ft Steering stem head nut 32.5 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 21.5 Front fork cap bolt * 25 * 2.5 * 18.0 Front fork damper rod bolt * 28 * 2.8 * 20.0...

  • Page 393: Periodic Maintenance Chart

    GS500K4/FK4 (’04-MODEL) 20-15 PERIODIC MAINTENANCE CHART Interval: This interval should be judged by odometer reading or months, whichever comes first. Interval 1 000 6 000 12 000 18 000 24 000 miles 4 000 7 500 11 000 14 500 Item months Battery (Specific gravity of electrolyte)

  • Page 394: Lower Crankcase

    20-16 GS500K4/FK4 (’04-MODEL) LOWER CRANKCASE Dowel pin position Apply SUZUKI BOND to the mating surface of the lower and upper crankcase at shaded area. Dowel pin Dowel pin position position Dowel pin position ! 99104-31140: SUZUKI BOND “1207B” (USA) " 99000-31110: SUZUKI BOND “1215” (Others)

  • Page 395: Cowling (For Gs500F)

    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: Front Fork

    20-18 GS500K4/FK4 (’04-MODEL) FRONT FORK 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 ring B Oil seal C Oil seal retainer D Anti-friction metal (Outer)
  • Page 397 GS500K4/FK4 (’04-MODEL) 20-19 • Loosen the front fork lower clamp bolt 3 and remove the front fork. NOTE: Hold the front fork by the hand to prevent sliding out of the stee- ring stem. Do not operate the brake lever while the caliper is removed.
  • Page 398 20-20 GS500K4/FK4 (’04-MODEL) • Remove the dust seal 6 and oil seal stopper ring 7. • Separate the inner tube out of the outer tube. • Remove the following parts. A Oil seal B Oil seal retainer C Anti-friction metal (Outer) D Anti-friction metal (Inner) E Oil lock piece INSPECTION...
  • Page 399 Use special care to prevent damaging the teflon coated surface of the anti-friction metals when installing them. OIL SEAL • Apply fork oil lightly to the lip of a new oil seal and install it. ( 99000-99044-10G: SUZUKI FORK OIL #10 or equivalent fork oil...
  • Page 400 & 09940-34520: “T” handle 09940-34531: Attachment “A” FORK OIL • Pour specified fork oil into the inner tube. ' Front fork oil capacity (each leg): 380 ml (12.8/13.4 US/Imp oz) ( 99000-99044-10G: SUZUKI FORK OIL #10 or equivalent fork oil...
  • Page 401 • Apply fork oil lightly to a new O-ring and install it to the front fork cap bolt. ( 99000-99044-10G: SUZUKI FORK OIL #10 or equivalent fork oil • Temporarily tighten the cap bolt. INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points.
  • Page 402 20-24 GS500K4/FK4 (’04-MODEL) WIRING DIAGRAM GS500K4/UK4 (P-02, 09, 19, 54) GS500FK4/FUK4 (P-02, 19, 54)
  • Page 403 GS500K4/FK4 (’04-MODEL) 20-25 GS500K4 (P-24, 28)
  • Page 404 20-26 GS500K4/FK4 (’04-MODEL) GS500FK4 (P-03, 24, 28, 33)

  • Page 405: Wiring Harness And Hose Routing

    GS500K4/FK4 (’04-MODEL) 20-27 WIRING HARNESS AND HOSE ROUTING WIRING HARNESS ROUTING Clamp Ignition coil lead wire Clutch cable Pass the lead wire Throttle cable underneath the frame. Clamp Ignition coil (LH) Do not allow the Neutral wiring harness to switch contact with the coupler fuel tank bracket bolt.
  • Page 406 20-28 GS500K4/FK4 (’04-MODEL) For GS500/U Clamp Clamp Ignition switch Left turn signal Left handlebar switch Right turn signal Clamp Right handlebar switch Wiring harness Right handlebar switch lead wire Left handlebar switch Brake hose Wiring harness Wiring harness guide Pass the horn lead wire behind the wiring harness guide.

  • Page 407: Wiring Harness Routing (For Gs500F)

    GS500K4/FK4 (’04-MODEL) 20-29 WIRING HARNESS ROUTING (For GS500F) Lead wire guide Handlebar switch (R) Clamp Handlebar switch (R) Speedometer Throttle cable Ignition coil (R) Wiring harness Clamp To the front turn signal light (R) Wiring harness Wiring harness Clamp Handlebar switch (R) Speedometer Clamp Wiring harness...

  • Page 408: Oil Cooler Hose Routing (For Gs500F)

    20-30 GS500K4/FK4 (’04-MODEL) OIL COOLER HOSE ROUTING (For GS500F) 26 N·m (2.6 kgf-m, 19.0 lb-ft) 1 Oil cooler 2 Oil cooler hose (LH) 3 Oil cooler hose (RH)

  • Page 409: Carburetor And Air Cleaner Hose Routing

    GS500K4/FK4 (’04-MODEL) 20-31 CARBURETOR AND AIR CLEANER HOSE ROUTING Air cleaner To the fuel valve Throttle cable Air vent hose Breather hose Air cleaner Carburetor clamp position (Intake manifold side) Fuel valve vacuum hose Throttle cable Air control hose 15˚ Carburetor clamp position (Air cleaner side) Air cleaner drain hose...

  • Page 410: Pair (Air Supply) System Hose Routing

    20-32 GS500K4/FK4 (’04-MODEL) PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING Fuel valve vacuum hose No. 1 3-way joint PAIR valve vacuum hose Fuel valve vacuum hose No.2 PAIR valve Connect the thick side of the vacuum hose Marking PAIR air to the 3-way joint. (Yellow) cleaner hose Keep clearance...

  • Page 411: Front Brake Hose Routing (For Gs500F)

    GS500K4/FK4 (’04-MODEL) 20-33 FRONT BRAKE HOSE ROUTING (For GS500F) 10˚ 14˚ Front brake hose Throttle cable Throttle cable Front brake hose Clamp Clamp 28˚ 28˚ Stopper Front brake caliper After positioning the brake hose union to the stopper, tighten the union bolt. 23 N·m (2.3 kgf-m, 16.5 lb-ft)

  • Page 412: Front Turn Signal Light Installation (For Gs500F)

    20-34 GS500K4/FK4 (’04-MODEL) FRONT TURN SIGNAL LIGHT INSTALLATION (For GS500F) 14 N·m (1.4 kgf-m, 10.0 lb-ft) 1 Forward 2 Cowling 3 Front turn signal light...

  • Page 413: Gs500K5/Uk5/Fk5/Fuk5 ('05-Model)

    GS500K5/UK5/FK5/FUK5 (’05-MODEL) 21-1 GS500K5/UK5/FK5/FUK5 (’05-MODEL) This chapter describes specifications, service 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 service data are indicated with an asterisk mark (*). * Please refer to the chapter 1 through 20 for details which are not given in this chapter.
  • Page 414 21-2 GS500K5/UK5/FK5/FUK5 (’05-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................2 080 mm (81.9 in) Overall width ..................800 mm (31.5 in) Overall height ..................1 060 mm (41.7 in) .........GS500/U 1 150 mm (45.3 in) .........GS500F/FU Wheelbase ..................1 405 mm (55.3 in) Ground clearance................
  • Page 415 GS500K5/UK5/FK5/FUK5 (’05-MODEL) 21-3 CAPACITIES Fuel 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 (3.1/2.6 US/Imp qt) overhaul................
  • Page 416 21-4 GS500K5/UK5/FK5/FUK5 (’05-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.5) — (1.3) Valve lift — (0.33) — (0.31) Tappet clearance (when cold) 0.03 – 0.08 IN. & EX. — (0.001 – 0.003) Valve guide to valve stem 0.025 –...
  • Page 417 GS500K5/UK5/FK5/FUK5 (’05-MODEL) 21-5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.090 – 36.130 35.80 (1.4208 – 1.4224) (1.409) 36.090 – 36.130 35.80 (1.4208 – 1.4224) (1.409) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.0013 –...
  • Page 418 21-6 GS500K5/UK5/FK5/FUK5 (’05-MODEL) ITEM STANDARD LIMIT Piston ring groove width 1.21 – 1.23 — (0.047 – 0.048) 1.21 – 1.23 — (0.047 – 0.048) 2.51 – 2.53 — (0.099 – 0.100) Piston ring thickness 1.17 – 1.19 — (0.046 – 0.047) 1.17 –...
  • Page 419 GS500K5/UK5/FK5/FUK5 (’05-MODEL) 21-7 CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/4 – 1/2 turn back — Drive plate thickness 2.92 – 3.08 2.62 (0.115 – 0.121) (0.103) Drive plate claw width 15.8 –...
  • Page 420 21-8 GS500K5/UK5/FK5/FUK5 (’05-MODEL) CARBURETOR SPECIFICATION ITEM GS500 P-02, 19, 24, 54 GS500U P-19 GS500F P-02, 19, 24, 54 GS500FU P-19 Carburetor type MIKUNI ← BSR34 ← Bore size 34 mm I.D. No. 01DN 01DP ← Idle r/min 1 200 ± 100 r/min ←...
  • Page 421 GS500K5/UK5/FK5/FUK5 (’05-MODEL) 21-9 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 5° B.T.D.C. at 1 200 r/min P-03, 28, 33 12° B.T.D.C. at 1 200 r/min Others Firing order L·R Spark plug DENSO: X24EPR-U9 Type NGK: DPR8EA-9 0.8 – 0.9 (0.031 –...
  • Page 422 21-10 GS500K5/UK5/FK5/FUK5 (’05-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height — (2.2) Brake disc thickness 4.5 ± 0.2 Front (0.177 ± 0.008) (0.16) 6.0 ± 0.2 Rear (0.236 ± 0.008) (0.22) Brake disc runout 0.30 —...
  • Page 423 GS500K5/UK5/FK5/FUK5 (’05-MODEL) 21-11 SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT Front fork stroke — (4.7) Front fork spring free length (13.5) (13.2) Front fork oil level — (4.3) Front fork oil type Fork oil #10 — Front fork oil capacity 380 ml —...

  • Page 424: Gs500K6/Uk6/Fk6/Fuk6 ('06-Model)

    GS500K6/UK6/FK6/FUK6 (’06-MODEL) 22-1 GS500K6/UK6/FK6/FUK6 (’06-MODEL) This chapter describes specifications, service data and servicing procedures which differ from those of the GS500K5/UK5/FK5/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 (*).
  • Page 425 22-2 GS500K6/UK6/FK6/FUK6 (’06-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..................2 080 mm (81.9 in) Overall width ..................800 mm (31.5 in) Overall height ..................1 060 mm (41.7 in) ..... GS500/U 1 150 mm (45.3 in) ..... GS500F/FU Wheelbase ..................
  • Page 426 GS500K6/UK6/FK6/FUK6 (’06-MODEL) 22-3 CAPACITIES Fuel 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 (3.1/2.6 US/Imp qt) overhaul................
  • Page 427 22-4 GS500K6/UK6/FK6/FUK6 (’06-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.5) — (1.3) Valve lift — (0.33) — (0.31) Tappet clearance (when cold) 0.03 – 0.08 IN. & EX. — (0.001 – 0.003) Valve guide to valve stem 0.025 –...
  • Page 428 GS500K6/UK6/FK6/FUK6 (’06-MODEL) 22-5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.090 – 36.130 35.80 (1.4208 – 1.4224) (1.409) 36.090 – 36.130 35.80 (1.4208 – 1.4224) (1.409) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.0013 –...
  • Page 429 22-6 GS500K6/UK6/FK6/FUK6 (’06-MODEL) ITEM STANDARD LIMIT Piston ring groove width 1.21 – 1.23 — (0.047 – 0.048) 1.21 – 1.23 — (0.047 – 0.048) 2.51 – 2.53 — (0.099 – 0.100) Piston ring thickness 1.17 – 1.19 — (0.046 – 0.047) 1.17 –...
  • Page 430 GS500K6/UK6/FK6/FUK6 (’06-MODEL) 22-7 CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/4 – 1/2 turn back — Drive plate thickness 2.92 – 3.08 2.62 (0.115 – 0.121) (0.103) Drive plate claw width 15.8 –...
  • Page 431 22-8 GS500K6/UK6/FK6/FUK6 (’06-MODEL) CARBURETOR SPECIFICATION ITEM GS500 P-02, 19, 24, 54 GS500U P-19 GS500F P-02, 19, 24, 54 GS500FU P-19 Carburetor type MIKUNI ← BSR34 ← Bore size 34 mm I.D. No. 01DN 01DP ← Idle r/min 1 200 ± 100 r/min ←...
  • Page 432 GS500K6/UK6/FK6/FUK6 (’06-MODEL) 22-9 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 5° B.T.D.C. at 1 200 r/min P-03, 28, 33 12° B.T.D.C. at 1 200 r/min Others Firing order L·R Spark plug DENSO: X24EPR-U9 Type NGK: DPR8EA-9 0.8 – 0.9 (0.031 –...
  • Page 433 22-10 GS500K6/UK6/FK6/FUK6 (’06-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height — (2.2) Brake disc thickness 4.5 ± 0.2 Front (0.177 ± 0.008) (0.16) 6.0 ± 0.2 Rear (0.236 ± 0.008) (0.22) Brake disc runout 0.30 —...
  • Page 434 GS500K6/UK6/FK6/FUK6 (’06-MODEL) 22-11 SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT Front fork stroke — (4.7) Front fork spring free length (13.5) (13.2) Front fork oil level — (4.3) Front fork oil type Fork oil #10 — Front fork oil capacity 380 ml —...

  • Page 435: Starter Button

    22-12 GS500K6/UK6/FK6/FUK6 (’06-MODEL) STARTER BUTTON Color Position PUSH WIRE COLOR O/R : Orange with Red tracer O/W : Orange with White tracer Y/G : Yellow with Green tracer Y/W : Yellow with White tracer...
  • Page 436 GS500K6/UK6/FK6/FUK6 (’06-MODEL) 22-13 WIRING DIAGRAM GS500K6/FK6 (For P-02, 09, 19, 54)
  • Page 437 22-14 GS500K6/UK6/FK6/FUK6 (’06-MODEL) GS500K6 (For P-24, 28)
  • Page 438 GS500K6/UK6/FK6/FUK6 (’06-MODEL) 22-15 GS500FK6 (For P-03, 24, 28, 33)
  • Page 439 Prepared by 13th Ed. December, 2005 1st Ed. March, 1989 Part No. 99500-34094-03E Printed in Japan...
  • Page 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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