1. DL manuals
  2. Suzuki
  3. Motorcycle
  4. GS500E
  5. Service Manual

Suzuki GS500E Service Manual

Manual is about: Motorcycle Suzuki

Summary of GS500E

  • Page 1

    9 9 5 0 0 - 3 4 0 9 4 - 0 3 e.

  • Page 2: Group Index

    Group index general information 1 periodic maintenance and tune-up procedures 2 engine 3 fuel and lubrication system 4 electrical system 5 chassis 6 service information 7 emission control information 8 gs500el (’90-model) 9 gs500em (’91-model) 10 gs500en (’92-model) 11 gs500ep (’93-model) 12 gs500er...

  • Page 4: General

    1 general information contents.

  • Page 14: Periodic Maintenance And

    2 periodic maintenance and contents tune-up procedures.

  • Page 35: Engine

    3 engine contents.

  • Page 96: Fuel and Lubrication System

    4 fuel and lubrication system contents.

  • Page 112: Electrical System

    5 electrical system contents.

  • Page 136: Chassis

    6 chassis contents.

  • Page 187: Service Information

    7 service information contents.

  • Page 225

    8 emission control information contents.

  • Page 229: Gs500El (’90-Model)

    Gs500el (’90-model) 9 contents.

  • Page 245: Gs500Em (’91-Model)

    10 gs500em (’91-model) contents.

  • Page 256: Gs500En (’92-Model)

    11 gs500en (’92-model) contents.

  • Page 268: Gs500Ep (’93-Model)

    12 gs500ep (’93-model) contents.

  • Page 279: Gs500Er (’94-Model)

    13 gs500er (’94-model) contents.

  • Page 290: Gs500Es (’95-Model)

    14 gs500es (’95-model) contents.

  • Page 302: Gs500Et (’96-Model)

    15 contents gs500et (’96-model).

  • Page 313: Gs500Ev (’97-Model)

    16 gs500ev (’97-model) contents.

  • Page 327

    17 gs500ew/x/y (’98/’99/’00-models) note: asterisk mark (*) indicates the new specifications. Contents specifications ..................................................................................... 17- 1 service data.................................................................................

  • 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.....................................................

  • 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 h...

  • Page 341: Service Data

    Gs500k1/k2 (’01/’02-models) 18-3 service data valve + guide unit: mm (in) item standard limit valve diam. In. 39 (1.5) ——— ex. 32 (1.3) ——— valve lift in. 8.5 (0.33) ——— ex. 8.0 (0.31) ——— tappet clearance (when cold) in. & ex. 0.03 – 0.08 (0.001 – 0.003) ——— valve guide to valve stem in. 0.025 – 0....

  • Page 342

    18-4 gs500k1/k2 (’01/’02-models) camshaft + cylinder head unit: mm (in) item standard limit cam height in. 36.789 – 36.819 36.49 e-03, 18, (1.4484 – 1.4496) (1.437) 24, 28, 33 ex. 36.291 – 36.321 36.00 (1.4288 – 1.4300) (1.417) in. 36.090 – 36.130 35.80 for the (1.4208 – 1.4224) (1.409) others ex. 3...

  • Page 343

    Gs500k1/k2 (’01/’02-models) 18-5 item standard limit piston ring groove width 1st 1.21 – 1.23 (0.047 – 0.048) ——— 2nd 1.21 – 1.23 (0.047 – 0.048) ——— oil 2.51 – 2.53 (0.099 – 0.100) ——— piston ring thickness 1st 1.17 – 1.19 (0.046 – 0.047) ——— 2nd 1.17 – 1.19 (0.046 – 0.047) ——— piston pin bore 18.0...

  • 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 – 16.0 15.0 (0.62 – 0.63) (0.59) driven plate di...

  • Page 345

    Gs500k1/k2 (’01/’02-models) 18-7 carburetor item specification 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. 1 200 ±100 r/min. ← ← ← float height 13.0 ± 1.0 mm ← ← ← main jet ...

  • 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 firing order l . R spark plug type denso: x24epr-u9 ngk: dpr8ea-9 gap 0.8 – 0.9 (0.031 – 0.035) spark performance over 8 (0.3...

  • Page 347

    Gs500k1/k2 (’01/’02-models) 18-9 brake + wheel unit: mm (in) item standard limit rear brake pedal height 55 (2.2) ——— brake disc thickness front 4.5 ± 0.2 4.0 (0.177 ± 0.008) (0.16) rear 6.0 ± 0.2 5.5 (0.236 ± 0.008) (0.22) brake disc runout ——— 0.30 (0.012) master cylinder bore front 12.700 – 12.74...

  • Page 348

    18-10 gs500k1/k2 (’01/’02-models) suspension unit: mm (in) item standard limit note front fork stroke 120 (4.7) ——— front fork spring free length ——— 270 e-03, 28, 33 (10.6) ——— 336 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 s...

  • Page 349

    Gs500k1/k2 (’01/’02-models) 18-11 fuel + oil item specification note fuel type e-03, 28, 33 for the others fuel tank including reserve 19 l e-33 (5.0/4.2 us/imp gal) 20 l for the others (5.3/4.4 us/lmp gal) reserve 4.3 l (1.1/0.9 us/lmp gal) engine oil type sae 10w/40, api sf or sg engine oil capaci...

  • Page 350: Gs500K3 (’03-Model)

    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 gs500k3 (’03-model) 19-1 contents 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 fro...

  • Page 351: Specifications

    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 ..............................................

  • 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 ...................................... ...

  • Page 353: Service Data

    19-4 gs500k3 (’03-model) service data valve + guide unit: mm (in) item standard limit valve diam. In. 39 (1.5) — ex. 32 (1.3) — valve lift in. 8.5 (0.33) — ex. 8.0 (0.31) — tappet clearance (when cold) in. & ex. 0.03 – 0.08 (0.001 – 0.003) — valve guide to valve stem clearance in. 0.025 – 0.055 (0.0...

  • Page 354

    Gs500k3 (’03-model) 19-5 camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm(in) item standard limit cam height e-03, 18, 24, 28, 33 in. 36.789 – 36.819 (1.4484 – 1.4496) 36.49 (1.437) ex. 36.291 – 36.321 (1.4288 – 1.4300) 36.00 (1.417) for the others in. 36.090 – 36.130 ...

  • Page 355

    19-6 gs500k3 (’03-model) conrod + crankshaft + balancer unit: mm (in) oil pump item standard limit piston ring groove width 1st 1.21 – 1.23 (0.047 – 0.048) — 2nd 1.21 – 1.23 (0.047 – 0.048) — oil 2.51 – 2.53 (0.099 – 0.100) — piston ring thickness 1st 1.17 – 1.19 (0.046 – 0.047) — 2nd 1.17 – 1.19 (0...

  • Page 356

    Gs500k3 (’03-model) 19-7 clutch unit: mm (in) transmission + drive chain unit: mm (in) except ratio 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 (0.115 – 0.121) 2.62 (0.103) drive plate claw width 15.8 – 16.0...

  • Page 357

    19-8 gs500k3 (’03-model) carburetor carburetor item specification p-02, 09, 19, 24, 54 (gs500) p-19 (gs500-h) p-19 (gs500-u) carburetor type mikuni bsr34ss ← ← bore size 34 mm ← ← i.D. No. 01de 01df 01dg idle r/min. 1 200 ±100 r/min. ← ← float height 13.0 ± 1.0 mm ← ← main jet (m.J.) #115 #130 #115 ...

  • Page 358

    Gs500k3 (’03-model) 19-9 electrical unit: mm (in) wattage unit: w 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 type denso: x24epr-u9 ngk: dpr8ea-9 gap 0.8 – 0.9 (0.031 – 0.035) spark performance over 8 (0.3) ...

  • Page 359

    19-10 gs500k3 (’03-model) brake + wheel unit: mm (in) item standard limit rear brake pedal height 55 (2.2) — brake disc thickness front 4.5 ± 0.2 (0.177 ± 0.008) 4.0 (0.16) rear 6.0 ± 0.2 (0.236 ± 0.008) 5.5 (0.22) brake disc runout — 0.30 (0.012) master cylinder bore front * 12.700 – 12.725 (0.5000...

  • Page 360

    Gs500k3 (’03-model) 19-11 suspension unit: mm (in) tire pressure item standard limit note front fork stroke 120 (4.7) — front fork spring free length — 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 ...

  • Page 361

    19-12 gs500k3 (’03-model) fuel + oil item specification note fuel type use only unleaded gasoline of at least 87 pump octane ( ) or 91 octaneor higher rated by the research method. Gasoline containing mtbe (methyl tertiary butyl ether), less than 10% ethanol, or less than 5% methanol with appropriat...

  • Page 362

    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. • place a rag underneath the union bolt on ...

  • 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. Inspect the piston surface for any scratches or other damage. Insp...

  • 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: $ % specification and classification: dot 4 • apply brake fluid to the p...

  • 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. ( '2-16).

  • 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 ...

  • Page 367

    19-18 gs500k3 (’03-model) troubleshooting correct correct incorrect • poor connection of couplers * check that the transmission is in neutral position and 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. • ...

  • Page 368

    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 ...

  • 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 ind...

  • 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 ...

  • Page 371: Regulator/rectifier

    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...

  • 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 cont...

  • 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. • tighten the screw..

  • Page 374: Wiring Diagram

    Gs500k3 (’03-model) 19-25 wiring diagram for gs500hk3/gs500huk3 p-19 speedometer tu : turn signal indica t or light hi : high beam indica t or light oi : oil pressure indica t or light nu : neutral indica t or light sp : speedometer light t a : t a chometer light sp t a ignition switch fr ont brake ...

  • Page 375

    19-26 gs500k3 (’03-model) for gs500k3/gs500uk3 p-02, 19, 54 speedometer sp t a ignition switch fr ont brake light switch rear brake light switch st ar ter switch handleb ar switch (r) handleb ar switch (l) engine st op switch ignition coil regula t or/rectifier igniter rear turn signal light(r) rear...

  • Page 376

    Gs500k3 (’03-model) 19-27 for gs500 p-24, 28 speedometer sp t a ignition switch (onl y p-24) fr ont brake light switch rear brake light switch st ar ter switch engine st op switch ignition coil regula t or/rectifier igniter rear turn signal light(r) rear turn signal light(l) brake light/t aillight b...

  • Page 377: Wire Routing

    19-28 gs500k3 (’03-model) wire routing clamp clamp clamp clamp clamp no slack starter relay air cleaner box clamp clamp clamp side stand switch pass the lead wire underneath the frame. Make clearance between the wiring harness and fuel tank bracket. Make clearance between the helmet holder and wirin...

  • Page 378

    Gs500k3 (’03-model) 19-29 right handlebar switch lead wire brake hose wiring harness signal generator lead wire wiring harness guide left handlebar switch lead wire wiring harness pass the horn lead wire behind the wiring harness guide. Clamp ignition switch lead wire left handlebar switch lead wire...

  • Page 379: Gs500K4/fk4 (’04-Model)

    Gs500k4/fk4 (’04-model) 20-1 contents gs500k4/fk4 (’04-model) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 20 21 specifications ..................................................................................... 20- 3 service data ...................................................................

  • Page 380

    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 p-09 p-19 p-24 p-28 p-33 p-54 uk usa (except for california) colombia eu australia canada california (usa) spain.

  • Page 381: Specifications

    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 ............................................

  • 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......................................

  • Page 383: Service Data

    Gs500k4/fk4 (’04-model) 20-5 service data valve + guide unit: mm (in) item standard limit valve diam. In. 39 (1.5) — ex. 32 (1.3) — valve lift in. 8.5 (0.33) — ex. 8.0 (0.31) — tappet clearance (when cold) in. & ex. 0.03 – 0.08 (0.001 – 0.003) — valve guide to valve stem clearance in. 0.025 – 0.055 ...

  • Page 384

    20-6 gs500k4/fk4 (’04-model) camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 36.090 – 36.130 (1.4208 – 1.4224) 35.80 (1.409) ex. 36.090 – 36.130 (1.4208 – 1.4224) 35.80 (1.409) camshaft journal oil clearance in. & ex. 0.032 – 0....

  • Page 385

    Gs500k4/fk4 (’04-model) 20-7 conrod + crankshaft + balancer unit: mm (in) oil pump item standard limit piston ring groove width 1st 1.21 – 1.23 (0.047 – 0.048) — 2nd 1.21 – 1.23 (0.047 – 0.048) — oil 2.51 – 2.53 (0.099 – 0.100) — piston ring thickness 1st 1.17 – 1.19 (0.046 – 0.047) — 2nd 1.17 – 1.1...

  • Page 386

    20-8 gs500k4/fk4 (’04-model) clutch unit: mm (in) transmission + drive chain unit: mm (in) except ratio 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 (0.115 – 0.121) 2.62 (0.103) drive plate claw width 15.8 – ...

  • Page 387

    Gs500k4/fk4 (’04-model) 20-9 carburetor carburetor item specification gs500 p-02, 19, 24, 54 gs500f p-02, 19, 24, 54 gs500u p-19 gs500fu p-19 carburetor type mikuni bsr34 ← bore size 34 mm ← i.D. No. * 01dn * 01dp idle r/min 1 200 ±100 r/min ← float height 13.0 ± 1.0 mm ← main jet (m.J.) * #130 * #1...

  • Page 388

    20-10 gs500k4/fk4 (’04-model) electrical unit: mm (in) wattage unit: w 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 type denso: x24epr-u9 ngk: dpr8ea-9 gap 0.8 – 0.9 (0.031 – 0.035) spark performance ...

  • Page 389

    Gs500k4/fk4 (’04-model) 20-11 brake + wheel unit: mm (in) item standard limit rear brake pedal height 55 (2.2) — brake disc thickness front 4.5 ± 0.2 (0.177 ± 0.008) 4.0 (0.16) rear 6.0 ± 0.2 (0.236 ± 0.008) 5.5 (0.22) brake disc runout — 0.30 (0.012) master cylinder bore front * 12.700 – 12.725 (0....

  • Page 390

    20-12 gs500k4/fk4 (’04-model) suspension unit: mm (in) tire pressure fuel + oil item standard limit front fork stroke 120 (4.7) — front fork spring free length * 343 (13.5) * 336 (13.2) front fork oil level * 110 (4.3) — front fork oil type suzuki fork oil #10 or equivalent fork oil — front fork oil...

  • Page 391: Tightening Torque

    Gs500k4/fk4 (’04-model) 20-13 tightening torque engine item n·m kgf-m lb-ft cylinder head cover bolt 14 1.4 10.0 cylinder head nut 38 3.8 27.5 cylinder head bolt 10 1.0 7.0 cylinder stud bolt 15 1.5 11.0 camshaft journal holder bolt 10 1.0 7.0 cam sprocket bolt 18 1.8 13.0 cam chain tensioner mounti...

  • Page 392

    20-14 gs500k4/fk4 (’04-model) chassis item n·m kgf-m lb-ft steering stem head nut 45 4.5 32.5 front fork upper clamp bolt 23 2.3 16.5 front fork lower clamp bolt 30 3.0 21.5 front fork cap bolt * 25 * 2.5 * 18.0 front fork damper rod bolt * 28 * 2.8 * 20.0 front axle nut normal nut with cotter pin 4...

  • 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. Note: i=inspect and clean, adjust, replace or lubricate as necessary r=replace t=tighten note: (california model only) and (c.A. Only) means that th...

  • Page 394: Lower Crankcase

    20-16 gs500k4/fk4 (’04-model) lower crankcase ! 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 dowel pin position dowel pin position.

  • 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 # removal • remove the front wheel. • remove the front fender and fender brace. $ • slightly loosen the front fork cap bolt 1 to facilitate later disassembly before loosening the front fork clamp bolts. • loosen the front fork upper clamp bolt 2. 1 o-ring 2 s...

  • 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. % disassembly • remove the front fork cap bolt. • remove the spacer 1, spring retainer 2 and spring 3. • invert the...

  • 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 damper rod ring in...

  • Page 399

    Gs500k4/fk4 (’04-model) 20-21 fork spring measure the fork spring free length. If the fork spring free length is shorter than the service limit, replace the fork spring with a new one. ' front fork spring free length service limit: 336 mm (13.2 in) inner and outer anti-friction metals • inspect the ...

  • Page 400

    20-22 gs500k4/fk4 (’04-model) • insert the inner tube into the outer tube and fit a new oil seal using the special tools. & 09940-52861: front fork oil seal installer set • install the oil seal stopper ring and a new dust seal. 1 anti-friction metal (outer) 2 oil seal retainer 3 oil seal 4 oil seal ...

  • Page 401

    Gs500k4/fk4 (’04-model) 20-23 • hold the front fork vertically and adjust the fork oil level with the special tool. ' front fork oil level: 110 mm (4.3 in) & 09943-74111: front fork oil level gauge • apply fork oil lightly to a new o-ring and install it to the front fork cap bolt. ( 99000-99044-10g:...

  • Page 402: Wiring Diagram

    20-24 gs500k4/fk4 (’04-model) wiring diagram gs500k4/uk4 (p-02, 09, 19, 54) gs500fk4/fuk4 (p-02, 19, 54) speedometer tu : turn signal indica t or light hi : high beam indica t or light oi : oil pressure indica t or light nu : neutral indica t or light sp : speedometer light t a : t a chometer light ...

  • Page 403

    Gs500k4/fk4 (’04-model) 20-25 gs500k4 (p-24, 28) speedometer tu : turn signal indica t or light hi : high beam indica t or light oi : oil pressure indica t or light nu : neutral indica t or light sp : speedometer light t a : t a chometer light sp t a ignition switch fr ont brake light switch rear br...

  • Page 404

    20-26 gs500k4/fk4 (’04-model) gs500fk4 (p-03, 24, 28, 33) speedometer tu : turn signal indica t or light hi : high beam indica t or light oi : oil pressure indica t or light nu : neutral indica t or light sp : speedometer light t a : t a chometer light sp t a ignition switch (for p-28) ignition swit...

  • Page 405

    Gs500k4/fk4 (’04-model) 20-27 wiring harness and hose routing wiring harness routing clamp clamp clamp clamp clamp no slack starter relay air cleaner box clamp clamp clamp side-stand switch pass the lead wire underneath the frame. Do not allow the wiring harness to contact with the fuel tank bracket...

  • Page 406

    20-28 gs500k4/fk4 (’04-model) right handlebar switch lead wire brake hose wiring harness signal generator wiring harness guide left handlebar switch wiring harness pass the horn lead wire behind the wiring harness guide. Clamp ignition switch left handlebar switch right handlebar switch clamp left t...

  • Page 407

    Gs500k4/fk4 (’04-model) 20-29 wiring harness routing (for gs500f) lead wire guide clamp handlebar switch (r) speedometer handlebar switch (r) throttle cable clamp wiring harness ignition coil (r) clamp wiring harness handlebar switch (r) speedometer ignition coil (l) clamp handlebar switch (l) ignit...

  • 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

    Gs500k4/fk4 (’04-model) 20-31 carburetor and air cleaner hose routing air cleaner air 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) carburetor clamp p...

  • Page 410

    20-32 gs500k4/fk4 (’04-model) pair (air supply) system hose routing pair valve pipe marking (green) 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 ...

  • Page 411

    Gs500k4/fk4 (’04-model) 20-33 front brake hose 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˚ front brake hose 23 n·m (2.3 kgf-m, 16.5 lb-ft).

  • 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

    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 gs500k5/uk5/fk5/fuk5 (’05-model) 21-1 contents 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 ...

  • Page 414: Specifications

    21-2 gs500k5/uk5/fk5/fuk5 (’05-model) specifications dimensions and dry mass overall length ...................................................................................... 2 080 mm (81.9 in) overall width ....................................................................................... ...

  • 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...................................

  • Page 416: Service Data

    21-4 gs500k5/uk5/fk5/fuk5 (’05-model) service data valve + guide unit: mm (in) item standard limit valve diam. In. 39 (1.5) — ex. 32 (1.3) — valve lift in. 8.5 (0.33) — ex. 8.0 (0.31) — tappet clearance (when cold) in. & ex. 0.03 – 0.08 (0.001 – 0.003) — valve guide to valve stem clearance in. 0.025...

  • Page 417

    Gs500k5/uk5/fk5/fuk5 (’05-model) 21-5 camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 36.090 – 36.130 (1.4208 – 1.4224) 35.80 (1.409) ex. 36.090 – 36.130 (1.4208 – 1.4224) 35.80 (1.409) camshaft journal oil clearance in. & ex. 0...

  • Page 418

    21-6 gs500k5/uk5/fk5/fuk5 (’05-model) conrod + crankshaft + balancer unit: mm (in) oil pump item standard limit piston ring groove width 1st 1.21 – 1.23 (0.047 – 0.048) — 2nd 1.21 – 1.23 (0.047 – 0.048) — oil 2.51 – 2.53 (0.099 – 0.100) — piston ring thickness 1st 1.17 – 1.19 (0.046 – 0.047) — 2nd 1...

  • Page 419

    Gs500k5/uk5/fk5/fuk5 (’05-model) 21-7 clutch unit: mm (in) transmission + drive chain unit: mm (in) except ratio 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 (0.115 – 0.121) 2.62 (0.103) drive plate claw widt...

  • Page 420

    21-8 gs500k5/uk5/fk5/fuk5 (’05-model) carburetor item specification gs500 p-02, 19, 24, 54 gs500f p-02, 19, 24, 54 gs500u p-19 gs500fu p-19 carburetor type mikuni bsr34 ← bore size 34 mm ← i.D. No. 01dn 01dp idle r/min 1 200 ± 100 r/min ← float height 13.0 ± 1.0 mm ← main jet (m.J.) #130 #135 jet ne...

  • Page 421

    Gs500k5/uk5/fk5/fuk5 (’05-model) 21-9 electrical unit: mm (in) wattage unit: w 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 type denso: x24epr-u9 ngk: dpr8ea-9 gap 0.8 – 0.9 (0.031 – 0.035) spark perfor...

  • Page 422

    21-10 gs500k5/uk5/fk5/fuk5 (’05-model) brake + wheel unit: mm (in) item standard limit rear brake pedal height 55 (2.2) — brake disc thickness front 4.5 ± 0.2 (0.177 ± 0.008) 4.0 (0.16) rear 6.0 ± 0.2 (0.236 ± 0.008) 5.5 (0.22) brake disc runout — 0.30 (0.012) master cylinder bore front 12.700 – 12....

  • Page 423

    Gs500k5/uk5/fk5/fuk5 (’05-model) 21-11 suspension unit: mm (in) tire pressure fuel + oil item standard limit front fork stroke 120 (4.7) — front fork spring free length 343 (13.5) 336 (13.2) front fork oil level 110 (4.3) — front fork oil type fork oil #10 — front fork oil capacity (each leg) 380 ml...

  • Page 424

    1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 22 gs500k6/uk6/fk6/fuk6 (’06-model) 22-1 contents 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 bet...

  • Page 425: Specifications

    22-2 gs500k6/uk6/fk6/fuk6 (’06-model) specifications dimensions and dry mass overall length ...................................................................................... 2 080 mm (81.9 in) overall width ....................................................................................... ...

  • 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 .......................................................................

  • Page 427: Service Data

    22-4 gs500k6/uk6/fk6/fuk6 (’06-model) service data valve + guide unit: mm (in) item standard limit valve diam. In. 39 (1.5) — ex. 32 (1.3) — valve lift in. 8.5 (0.33) — ex. 8.0 (0.31) — tappet clearance (when cold) in. & ex. 0.03 – 0.08 (0.001 – 0.003) — valve guide to valve stem clearance in. 0.025...

  • Page 428

    Gs500k6/uk6/fk6/fuk6 (’06-model) 22-5 camshaft + cylinder head unit: mm (in) cylinder + piston + piston ring unit: mm (in) item standard limit cam height in. 36.090 – 36.130 (1.4208 – 1.4224) 35.80 (1.409) ex. 36.090 – 36.130 (1.4208 – 1.4224) 35.80 (1.409) camshaft journal oil clearance in. & ex. 0...

  • Page 429

    22-6 gs500k6/uk6/fk6/fuk6 (’06-model) conrod + crankshaft + balancer unit: mm (in) oil pump item standard limit piston ring groove width 1st 1.21 – 1.23 (0.047 – 0.048) — 2nd 1.21 – 1.23 (0.047 – 0.048) — oil 2.51 – 2.53 (0.099 – 0.100) — piston ring thickness 1st 1.17 – 1.19 (0.046 – 0.047) — 2nd 1...

  • Page 430

    Gs500k6/uk6/fk6/fuk6 (’06-model) 22-7 clutch unit: mm (in) transmission + drive chain unit: mm (in) except ratio 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 (0.115 – 0.121) 2.62 (0.103) drive plate claw widt...

  • Page 431

    22-8 gs500k6/uk6/fk6/fuk6 (’06-model) carburetor item specification gs500 p-02, 19, 24, 54 gs500f p-02, 19, 24, 54 gs500u p-19 gs500fu p-19 carburetor type mikuni bsr34 ← bore size 34 mm ← i.D. No. 01dn 01dp idle r/min 1 200 ± 100 r/min ← float height 13.0 ± 1.0 mm ← main jet (m.J.) #130 #135 jet ne...

  • Page 432

    Gs500k6/uk6/fk6/fuk6 (’06-model) 22-9 electrical unit: mm (in) wattage unit: w 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 type denso: x24epr-u9 ngk: dpr8ea-9 gap 0.8 – 0.9 (0.031 – 0.035) spark perfor...

  • Page 433

    22-10 gs500k6/uk6/fk6/fuk6 (’06-model) brake + wheel unit: mm (in) item standard limit rear brake pedal height 55 (2.2) — brake disc thickness front 4.5 ± 0.2 (0.177 ± 0.008) 4.0 (0.16) rear 6.0 ± 0.2 (0.236 ± 0.008) 5.5 (0.22) brake disc runout — 0.30 (0.012) master cylinder bore front 12.700 – 12....

  • Page 434

    Gs500k6/uk6/fk6/fuk6 (’06-model) 22-11 suspension unit: mm (in) tire pressure fuel + oil item standard limit front fork stroke 120 (4.7) — front fork spring free length 343 (13.5) 336 (13.2) front fork oil level 110 (4.3) — front fork oil type fork oil #10 — front fork oil capacity (each leg) 380 ml...

  • Page 435: Starter Button

    22-12 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 tracer.

  • Page 436: Wiring Diagram

    Gs500k6/uk6/fk6/fuk6 (’06-model) 22-13 wiring diagram gs500k6/fk6 (for p-02, 09, 19, 54) speedometer tu : turn signal indica t or light hi : high beam indica t or light oi : oil pressure indica t or light nu : neutral indica t or light sp : speedometer light t a : t a chometer light sp t a ignition ...

  • Page 437

    22-14 gs500k6/uk6/fk6/fuk6 (’06-model) gs500k6 (for p-24, 28) speedometer tu : turn signal indica t or light hi : high beam indica t or light oi : oil pressure indica t or light nu : neutral indica t or light sp : speedometer light t a : t a chometer light sp t a regula t or/rectifier igniter soleno...

  • Page 438

    Gs500k6/uk6/fk6/fuk6 (’06-model) 22-15 gs500fk6 (for p-03, 24, 28, 33) speedometer tu : turn signal indica t or light hi : high beam indica t or light oi : oil pressure indica t or light nu : neutral indica t or light sp : speedometer light t a : t a chometer light sp t a ignition switch (for p-03, ...

  • 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.