3 - Forum o Suzuki GS 500
Contents
1. 19981 enjg 29i 8 OE HJIALLOJH HOLVINOJH g 222 yo Amuvo ODD ES m 22 m ueej 67 ng UBIT Kei 20 e 2 E los 9 z 25 2 D m mom o 22 eng 18 eg g 307109 m m m 27 TYNDIS NYNL TYNDIS NYNLINOHYA 4 T 1 34 ws ER wa a E 8 s IZ s T wa8 a AHOITTIVL LHON JMVHA 18 NOLLISOd 4 JA ag M SM A AH9ITAVIH mw 51 BE1 51 6 EZ 57 d 1H9 I1 TYNDIS r4 d 1H9 I1 TYNDIS NHNLINOHA m m 220 m Lv IV DO w on lt B 200 S 25 8 20m E ee 8 9 5 29 S sa 5 208 HOLIMS LHOIT JMVHA 14 TYNDIS NYNL zu Y 10 Y 109 NOLLINDI O AHO HILINOHOVL VL HOSN3S 5 NOILISOd HON HO1VOIGNI TVHLNAN ITLLOHHL HOLIMS LHOIT HO1VOIGNI SHNSS3Hd 3 vu8 INOHA OfO HON HO1VOIGNI HON TYNDIS NYNL GION310S HOLIMS bz d 103 juo HOLIMS NOLLINDI YILINOGIIdS 1 HOLIMS HOLIMS HOLIMS2. GS500F FU iiic epe ies 1 405 mm 55 3 in Ground 150 mm 5 9 in GS500 U 120 mm 4 7 in GS500F FU Seat height 5 ue nei etn ie 790 mm 31 1 in BIMBI DER 174 kg 383 Ibs GS500 U 180 kg 396 Ibs GS500F FU ENGINE TYPEN Four stroke air cooled DOHC Number of cylinders 2 aaa tuan 74 0 mm 2 913 in Stroke side eh FERE 56 6 mm 2 228 in Displacement us tete 487 cm 29 7 cu in Compression ratio 9 0 1 Carburetor BSR34 twin Aitcleaner i dude Non woven fabric element Starter Systema anh ea Electric Lubrication System Wet sump Idle Sp680 cie ey NE 1 200 100 r min DRIVE TRAIN Clute Wet multi plate type Recta ciui E 6 speed constant mesh Gearshift pattern 1 down 5 up Primary reduction ratio 2 714 76 28 Ge rratios LOW NA a n 2 461 32 13 Pio 1 777 32 18 A M 1 380 29 21 Ath aie eee t tenis 1 125 27 24 Shas 0 961 25 26 0 851 23 27 Final reduction ratio 2 437 39 16 Drive chaiB
3. 12 GS500KA FK4 04 MODEL SUSPENSION ITEM STANDARD Unit mm in Front fork stroke 120 4 7 Front fork spring free length 943 13 5 Front fork oil level 110 4 3 Front fork oil type SUZUKI FORK OIL 410 or equivalent fork oil Front fork oil capacity each leg 880 ml 12 8 13 4 US Imp oz Front fork inner tube O D 36 9 1 45 Rear shock absorber spring adjuster 4th position among 7 Rear wheel travel Swingarm pivot shaft runout TIRE PRESSURE COLD INFLATION SOLO RIDING DUAL RIDING TIRE PRESSURE kPa kgf cm psi kPa kgf cm psi FRONT 225 2 25 33 225 2 25 33 REAR 250 FUEL OIL 2 50 36 280 2 80 41 SPECIFICATION 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 containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corro sion inhibitor is permissible P 03 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Fuel tank including reserve 19L 5 0 4 2 US Imp gal 201 5 3 4 4 US Imp reserve 4 3L 1 1 0 9 US Imp gal Engine oil type SAE 10W 40 API SF or SG Engine oil capacity 2 600 ml 2 7 2 3 US Imp gt Change 2 900 ml
4. IVNSIS NYNL HOLIMS 3unssaud 26 GS500K4 FK4 04 MODEL GS500FK4 P 03 24 28 33 4808 RIM HOLIMS DER bz d 104 IM MOLES HOS HOLIMS NOILISOd HOLIMS OD 190811 S M aNv1S 3dis HAS SMUM HILNTI ONISSVd NOLLNG NHOH 19981 oBUBIO OTO OTO OTO 18981 n g 2922 USAID o HOLIMS 19981 Y TYHLNSN 19981 HOLOW Ju 18981 UMA Av13H HJLHVIS HJIHVIS AVTIH 19981 x 19081 xoelg voz NIVW OL 15 3 15 19981 X2elg 3aoia 4991 enig xoelg Molek HJIALLIJH HOLVINIJH g w s tki 222 5 EG 9 Sed dq Kava x 29 s6ueo Y s s MO won 6 eng 1 s e 9 E o EA 2000 ouw 9o soct amp f5 up 9 gt 4g m lt lt lt eng 18
5. S 36 SUZUKI MOTOR CORPORATION Printed in Japan K4
6. 238 SHIM w 27 AHO TYNDIS NYNL uvas LHONM TYNDIS NYNLLNOHA wa ZO va r a a E a 8 Lia e _ A LHOITTIVL LHOI Sve 18 18 M I am S M EI ele 51 E21 51 1 8 51 u 1H5nr1 NHNLHVJH TYNDIS NHNLLNOHA o 9 o 2 o2 5 3 5 o o o o HB zea 26 225093328258 2 895928 902 e 9 HOLIMS LHOIT uva AvT3H e IVNSIS NYNL 5 87 d 104 Y HOLIMS NOILINDI Lww 1109 NOLLINDI OO HJLJNOHOVL VL HOSN3S 5 dS NOILISOd HOLV9IGNI TYHLNAN JILLOHHL YALINDI HOLIMS HOLVSIGNI JHNSSIHA Ave INOHA OFO HSNd 4015 1 HOLVDIANI 1H9T1 HOLVOIGNI TYNDIS NHi GION310S HOLIMS HILYVIS HOLIMS HV8371 NVH vz d 103 HOLIMS NOLLINDI 33130093345 GS500K4 FK4 04 MODEL 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 5 Do not allow the wiring harness to lo contact with the fuel tank bracket bolt LA Neutral switch coupler Clamp Wiring harness Rear turn signal Battery light LH lead wire Ignition coil RH Clamp Wiring har
7. Drive chain l Clean and lublicate every 1 000 km 600 miles Brakes hose Replace every 4 years Brake fluid Replace every 2 years Tires Steering Front forks Chassis bolts and nuts T T T T T 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 the item or the maintenance interval to be applied for the California model 16 05500 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 position Dowel pin position sd MER Dowel pin position 99104 31140 SUZUKI BOND 1207B USA 99000 31110 SUZUKI BOND 1215 Others GS500K4 FK4 04 MODEL 17 COWLING For GS500F O Screen Front cowling cover Center Front cowling Front cowling cover LH Front cowling cover RH Cowling brace 18 GS500K4 FK4 04 MODEL FRONT FORK S JE USA Others B REMOVAL Remove the front wheel Remove the front fender and fender brace Make sure that the motorcycle is supported securely Slightly loosen the front fork cap bolt 1 to facilitate later dis assembly before loosening the
8. Filter change 3 1 2 6 US Imp gt 3 200 ml Overhaul 3 4 2 8 US Imp qt Brake fluid type DOT 4 TIGHTENING TORQUE ENGINE ITEM GS500K4 FK4 04 MODEL 13 Cylinder head cover bolt Cylinder head nut Cylinder head bolt Cylinder stud bolt Camshaft journal holder bolt Cam sprocket bolt Cam chain tensioner mounting bolt Conrod bearing cap nut Generator mounting rotor bolt Starter clutch bolt Signal generator bolt Crankcase bolt 6 mm 8 mm Counter balancer shaft setting bolt Oil pump mounting screw Oil pressure regulator Oil drain plug Oil pan bolt Clutch sleeve hub nut Clutch spring set bolt Oil cooler hose bolt crankcase side For GS500F Exhaust pipe bolt Muffler mounting bolt Engine mounting bolt 14 GS500K4 FK4 04 MODEL CHASSIS ITEM Steering stem head nut Front fork upper clamp bolt Front fork lower clamp bolt Front fork cap bolt Front fork damper rod bolt Front axle nut Normal nut with cotter pin Self lock nut Front axle pinch bolt Handlebar set bolt Handlebar holder set nut Front brake master cylinder mounting bolt Front brake caliper mounting bolt Front footrest bolt Brake hose union bolt Air bleeder valve Front and rear disc bolt Swingarm pivot nut Re
9. SUZUKI GS500 F SUPPLEMENTARY SERVICE MANUAL USE THIS MANUAL WITH GS500E SERVICE MANUAL 99500 34091 01E 99501 34150 01E GS500K4 FK4 04 MODEL 1 GS500K4 FK4 04 MODEL FOREWORD This manual describes service data service specifications and servicing procedures which dif fer from those of the GS500K3 03 MODEL NOTE Any differences between the GS500K3 03 model and GS500K4 FK4 04 model in specifications and service data are indicated with an asterisk mark Please refer to the GS500K3 Service Manual for details which are not given in this man ual CONTENTS e E ivana 3 SERVICE DATA eR 5 TIGHTENING TORQUE cion add 13 ENGINE inuit M 13 ills AN 14 PERIODIC MAINTENANCE CHARTT 15 LOWER CRANK CASE reke 16 COWLING For 4S500F iia 17 FRONT FORK quem 18 REMOVAL 18 IPtlllpm M 19 INSPECTION 2 2 a is S A 20 HEASSEMBLY 2 iine iii EEE 21 INSTALLATION ici ii aaa ea ica 23 WIRING DIAGRAM x iii 24 GS500K4 UK4 02 09 19 54 24 GS500FK
10. 010 Idle r min 1 200 100 r min Float height 13 0 1 0 mm Main jet 130 Jet needle 5DH91 Needle jet P 5M Throttle valve 105 Pilot jet HITS Pilot screw PRE SET 3 turns back Throttle cable play 2 0 4 0 mm 0 08 0 16 in 10 GS500KA FKA 04 MODEL ELECTRICAL ITEM SPECIFICATION Unit mm in 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 NGK DPR8EA 9 0 8 0 9 0 031 0 035 Spark performance Over 8 0 3 at 1 atm Signal generator resistance 250 420 Q Ignition coil resistance Primary 3 60 Terminal Terminal Secondary 18 30 Plug cap Terminal Signal generator peak voltage 1 8 V and more Probe Br Probe Ignition coil primary peak voltage 100 V 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 relay resistance 3 50 designation CB10L B2 Capacity 12 V 39 6 KC 11 Ah 10 HR Standard electrolyte S G 1 28 at 20 68 Fuse size WATTAGE 20 SPECIFICATION Unit W
11. face of the inner tube with the surface of the steering upper bracket Tighten the front fork upper clamp bolt to the specified torque V Front fork upper clamp bolt 23 N m 2 3 kgf m 16 5 Ib ft Tighten the front fork lower clamp bolt 2 to the specified torque V Front fork lower clamp bolt 30 N m 3 0 kgf m 21 5 Ib ft Tighten the front fork cap bolt to the specified torque V Front fork cap bolt 25 N m 2 5 kgf m 18 0 Ib ft Recheck that the surface is flush with the surface B Install the front fender and front wheel NOTE Before tightening the front fender brace mounting screws move the front forks up and down several times GS500K4 FK4 04 MODEL 23 WIRING DIAGRAM 24 GS500K4 FK4 04 MODEL 19 54 GS500K4 UKA 02 09 19 54 GS500FK4 FUK4 P 02 19081 SUM WA 19981 USSIE MOJA D A 1994 OUM A M 19081 SYM U 19981 Y O 18984 eng 18 0 1908 U99J5 A D MORJE YIM ueeJ5 9 9 Jeoenxoelg 19981 13981 UUM 199811 J DEN UJE 49984 MOIRA BUM M AHILIVE o u a yf eng 14 197 kein 19 e O u 19 5 wog gt eng 18 2 40709 SHIM a TYNDIS NYNLYUVIY lt lt Za Yal411939 401V1N938 HOLVHANID HO
12. front fork clamp bolts Loosen the front fork upper clamp bolt 2 O ring Spacer Spring retainer Front fork spring Damper rod ring Damper rod Rebound spring Inner tube Anti friction metal Inner Dust seal Oil seal stopper ring Oil seal Oil seal retainer Anti friction metal Outer Oil lock piece Outer tube Front fork cap bolt D 2 9 4 D 8 9 0 4D B Damper bolt 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 steer ing stem CAUTION Do not operate the brake lever while the caliper is removed DISASSEMBLY Remove the front fork cap bolt Remove the spacer 1 spring retainer and spring 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 rod bolt using the special tools and 7 mm hexagon wrench 09940 34520 handle 09940 34531 Attachment A Remove the damper rod and rebound spring GS500K4 FK4 04 MODEL 19 20 GS500K4 FKA 04 MODEL Remove the dust seal and oil seal stopper ring Separate the inner tube out of the outer tube Remove the following parts Oil seal O
13. 046 0 047 Piston pin bore 18 002 18 008 0 7087 0 7090 Piston pin O D 17 995 18 000 0 7085 0 7087 CONROD CRANKSHAFT BALANCER ITEM STANDARD Unit mm in Conrod small I D 18 006 18 014 0 7089 0 7092 Conrod big end side clearance 0 1 0 2 0 004 0 008 Conrod 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 Crank pin O D 33 976 34 000 1 3376 1 3386 Crankshaft journal oil clearance 0 020 0 044 0 0008 0 0017 Crankshaft journal O D 31 976 32 000 1 2589 1 2598 Crankshaft thrust bearing thickness 2 950 2 975 0 1161 0 1171 Crankshaft runout Balancer journal oil clearance 0 020 0 044 0 0008 0 0017 Balancer journal O D 31 984 32 000 1 2592 1 2598 Balancer spring free length OIL PUMP ITEM STANDARD Oil pump reduction ratio 1 879 76 28 x 27 39 Oil pressure at 60 C 140 F Above 200 kPa 50 kgf cm 28 psi Below 500 kPa 5 0 kgf cm 71 psi at 3 000 r min 8 05500 04 MODEL CLUTCH Unit mm in ITEM STANDARD Clutch lever play 0 4 _ 06 Clutch release screw 1 4 1 2 turn back Drive plate thickness 2 92 3 08 0 11
14. 4 FUKA4 02 19 54 J 24 GS500K4 P 24 28 EEE 25 GS500FK4 P 03 24 28 33 26 WIRING HARNESS AND HOSE ROUTING 27 WIRING HARNESS ROUTING 27 WIRING HARNESS ROUTING For 5500 29 OIL COOLER HOSE ROUTING For GS500P 30 CARBURETOR AND AIR CLEANER HOSE ROUTING 31 PAIR AIR SUPPLY SYSTEM HOSE ROUTING eere enn n nn 32 FRONT BRAKE HOSE ROUTING For GS500F 33 FRONT TURN SIGNAL LIGHT INSTALLATION For GS500F 34 COPYRIGHT SUZUKI MOTOR CORPORATION 2004 SUZUKI MOTOR CORPORATION 2 5500 04 MODEL COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area 5 COUNTRY or AREA UK USA Except for California Colombia EU Australia Canada California USA Spain GS500K4 FK4 04 MODEL 3 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length 2 080 mm 81 9 in Overall Width lia 800 mm 31 5 in Overall height 1 060 mm 41 7 1 GS500 U 1 150 mm 45 3 in
15. 5 0 121 Drive plate claw width Driven plate distortion Clutch spring free length TRANSMISSION DRIVE CHAIN Unit mm in Except ratio ITEM STANDARD 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 0 851 23 27 Shift fork to groove clearance 0 1 0 3 0 004 0 012 Shift fork groove width Shift fork thickness 5 7 3 9 0 20 Countershaft length 114 7 01 Low to 2nd 4 516 z Drive chain Type 0 1 0 DID520VM Links 110 20 pitch length Drive chain slack 20 30 0 8 1 2 CARBURETOR ITEM SPECIFICATION GS500K4 FK4 04 MODEL 9 GS500 P 02 19 24 54 GS500F 02 19 24 54 GS500U 19 GS500FU P 19 Carburetor type MIKUNI BSR34 Bore size 34 mm 1 0 No 01DN Idle r min 1 200 100 r min Float height 13 0 1 0 mm Main jet 130 Jet needle 5DH57 3rd Needle jet P 5M Throttle valve 105 Pilot jet 17 5 Pilot screw 3 turns back Throttle cable play CARBURETOR ITEM 2 0 4 0 mm 0 08 0 16 in SPECIFICATION GS500 P 09 28 GS500F P 03 28 GS500F P 33 Carburetor type MIKUNI BSR34 Bore size 34 mm 1 0 No
16. 9 US Imp gal 2 600 ml 2 7 2 3 US Imp qt 2 900 ml 3 1 2 6 US Imp qt 3 200 ml 3 4 2 8 US Imp qt 380 ml 12 7 13 4 US Imp oz These specifications are subject to change without notice SERVICE DATA VALVE GUIDE GS500K4 FK4 04 MODEL 5 STANDARD Unit mm in Valve diam 39 1 5 32 1 3 Valve lift 8 5 0 33 8 0 0 31 Tappet clearance when cold 0 03 0 08 0 001 0 003 Valve guide to valve stem clearance 0 025 0 055 0 0010 0 0022 0 040 0 070 0 0016 0 0028 Valve stem deflection Valve guide 1 0 7 000 7 015 0 2756 0 2762 Valve stem O D 6 960 6 975 0 2740 0 2746 6 945 6 960 0 2734 0 2740 Valve stem runout Valve head thickness Valve seat width Valve head radial runout Valve spring free length IN amp EX Valve spring tension IN amp EX 10 9 12 5 kgf 24 0 27 6 Ibs at length 31 0 mm 1 22 in 20 3 23 3 kgf 44 8 51 4 Ibs at length 35 0 mm 1 38 in 6 GS500K4 FK4 04 MODEL CAMSHAFT CYLINDER HEAD Unit mm in ITEM STANDARD LIMIT Cam height IN 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 IN amp EX 0 032 0 066 0 008 i 0 0013 0 0026 0 0060 Camshaft journ
17. GS500 U GS500F FU 02 09 19 24 54 02 19 24 54 03 28 33 Headlight 60 lt 55 4 Position light 4 Brake light Taillight Turn signal light 21 Tachometer light 1 7 Speedometer light 1 7 Turn signal indicator light 1 7 High beam indicator light 1 7 Neutral indicator light 1 7 Oil pressure indicator light TETTE TIT T 1 7 WHEEL ITEM GS500K4 FK4 04 MODEL STANDARD 11 Unit mm in Rear brake pedal height 55 Brake disc thickness Brake disc runout Master cylinder bore Front 12 700 12 725 0 5000 0 5010 Rear 12 700 12 743 0 5000 0 5017 Master cylinder piston 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 30 150 30 200 1 1870 1 1890 Rear 38 098 38 148 1 4999 1 5019 Wheel runout Axial Radial Wheel axle runout Front Rear Wheel rim size Front 17 x MT3 00 17M C x MT3 00 Rear 17 x MT3 50 17M C x MT3 50 Tire size Front 110 70 17M C 54H Rear 130 70 17M C 62H Tire tread depth Front Rear
18. LHOIT TVYNDIS NYNL LAL HOLIMS LHOI HOLIMS JMVHA INOHA OO 4015 HOLIMS HJLHVLS 4AILINOGIIdS 9 LH917 TYNDIS NYNL 1NOH3 HON HILINOHIVL VL 1H5r1H313A0033dS HON TVHINJN HOLVDIONI JHNSSIHd NO HO1VOIGNI AHOIT TYNDIS NYNL NL GS500K4 FK4 04 MODEL 25 GS500K4 24 28 48981 18981 9 D A 18981 SYYM G M 19981 49984 uj 0 19981 anig 0 18981 19981 YOR G 18981 49921 48981 SPYM 49981 19981 yM pelg HOLIMS JHNSSJHd HO1VH3N39 15 3 15 HOLOW Av3H HJIHVIS HILYVIS VOZ OL GNVLS 3AIS 7 HOLIMS HV831 NVH HOLIMS HOLIMS OHIO HOLIMS LHOIT TYNDIS NYNL NOLLISOd HJAJI HILNTI NOLLNA NHOH
19. LIMS HV831 NVH HOLIMS HOLIMS LHOIT TYNDIS NYNL HOLIMS JHNSSJUd HOLIMS HOIVUJNJO HOLIMS NOILISOd ONVLS 301S OJ OD HOLIMS LI 9 V TYHLNAN HOLOW p Av13H HJIHVIS HJIHVIS Avis voz NIYIN CL 15 3015 F1 EE EO lt 93 257 zo mi omg HOLIMS AH9I1 SNISSVd NOLLNA NHOH 18 au 19 0 N A A M uo 8 197 51 18 8 D A o A Mw o 8 197 51 19 9 NHOH DLHOTI TYNDIS NYNL LNOH3 A1H9ITIVI IH9TI Aves NOLLISOd 18 M M wa am S N T A EI wa T wa EXI wa 61 51 51 LxI 51 9 LH917 TYNDIS NYNLYVIY u 18 9 8 WO gm 18 9 v ww HOSN3S NOILISOd 3T1LLOHHL GION310S 18 18 18 8 9 8 18 9 ua 8 9 197 o M ANO o SM o ANO 18 0 19 HOLIMS HOLIMS 25 85328 HOLIMS
20. Oil cooler hose RH ONIS GS500K4 FK4 04 MODEL 31 CARBURETOR AND AIR CLEANER HOSE ROUTING Air cleaner To the fuel valve Throttle cable Air vent hose Air cleaner Carburetor clamp position Intake manifold side Air control hose Carburetor clamp position Air cleaner side LH lt gt gt RH 32 GS500KA 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 Marking Connect the thick side of the vacuum hose Yellow PAIR air to the 3 way joint cleaner hose Keep clearance between the hose clips and the frame PAIR valve vacuum hose NES Marking Green Marking Red PAIR valve pipe GS500K4 FK4 04 MODEL 33 FRONT HOSE ROUTING For GS500F Front brake hose Throttle cable SIDE Throttle cable Front brake hose VI JA positioning the brake hose union to the stopper tighten the union bolt 23 2 3 kgf m 16 5 lb ft 34 GS500K4 FK4 04 MODEL FRONT TURN SIGNAL LIGHT INSTALLATION For GS500F tt 7 0 l e pre 10 0 Ib ft 3 Forward Cowling Front turn signal light e G Prepared SUZUKI MOTOR CORPORATION January 2004 Part No 99501 34150 03E Printed in Japan
21. al holder I D 22 012 22 025 IN amp EX 0 8666 0 8671 Camshaft journal O D IN amp EX 0 9825 a Camshaft runout IN amp EX 0 004 Cam chain pin at arrow 3 18th pin Cylinder head distortion 0 10 0 004 CYLINDER PISTON PISTON RING ITEM STANDARD Unit mm in LIMIT Compression pressure 1 000 1 400 kPa 10 14 kgf cm 142 199 psi 800 8 kgf cm 144 psi Compression pressure difference 200 kPa 2 kgf cm 28 psi Piston to cylinder clearance 0 050 0 060 0 0020 0 0024 0 120 0 0047 Cylinder bore 74 000 74 015 2 9134 2 9140 74 080 2 9165 Piston diam 73 945 73 960 2 9112 2 9118 Measure at 15 mm 0 6 in from the skirt end 73 880 2 9087 Cylinder distortion 0 10 0 004 Piston ring free end gap Approx 7 0 0 28 5 6 0 22 Approx 11 0 0 43 8 8 0 35 Piston ring end gap 0 10 0 25 0 004 0 010 0 70 0 028 0 10 0 25 0 004 0 010 0 70 0 028 Piston ring to groove clearance 0 180 0 0071 0 150 0 0059 STANDARD GS500K4 FK4 04 MODEL 7 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 1 19 0
22. ar shock absorber upper and lower mounting nut Rear cusion lever rod mounting nut Rear cusion lever mounting nut Front amp Center Rear brake caliper mounting bolt Rear brake caliper housing bolt Rear brake master cylinder rod lock nut Rear brake pedal bolt Torque link nut Front amp Rear Rear brake master cylinder mounting bolt Rear nut Normal nut with cotter pin Self lock nut PERIODIC MAINTENANCE CHART Item Interval GS500K4 FK4 04 MODEL 15 Interval This interval should be judged by odometer reading or months whichever comes first km 1 000 6 000 12 000 18 000 24 000 miles 600 4 000 7 500 11 000 14 500 months 2 12 24 36 48 Battery Specific gravity of electrolyte Air cleaner element Clean every 3 000 km 2 000 miles and replace every 12 000 km 7 500 miles Exhaust pipe bolts and muffler bolts T T T T T Tappet clearance Spark plugs Eom Replace every 4 years Engine oil and filter Idle speed Throttle cable play Throttle valve synchronization C A only Evaporative emission system California model only Replace vapor hose every 4 years PAIR air supply system Clutch cable play
23. i L a D I D 520VM 110 links 4 GS500K4 FK4 04 MODEL CHASSIS Front suspension Rear suspension Front suspension stroke Rear wheel travel Steering angle Turning radius Front brake Rear brake Front tire size Rear tire size ELECTRICAL Ignition type Ignition timing Spark Headlight Position light Turn signal light Brake light Taillight Speedometer light Tachometer light Neutral indicator light High beam indicator light Turn signal indicator light Oil pressure indicator light CAPACITIES Fuel tank including reserve reserve Engine oil oil change with filter change overhaul Front fork oil each leg Telescopic coil spring oil damped Link type coil spring oil damped 120 mm 4 7 in 115 mm 4 5 in 25 05 97 mm 3 82 in 35 2 7 8 9 ft Disc brake Disc brake 110 70 17M C 54H tubeless 130 70 17M C 62H tubeless Electronic ignition transistorized 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 DPR8EA 9 or DENSO X24EPR U9 12 V 39 6 11 Ah 10 HR Three phase A C generator 20A 12 V 60 55 W GS500 U 12V 5W GS500F FU 12V21W 12 V 32 3 cp x 2 pcs P 03 28 33 12 V 21 5 W x 2 pcs Others 12V 1 7W 12V 1 7W 12V 1 7W 12V 1 7W 12V 1 7W 12V 1 7W 19 L 5 0 4 2 US Imp gal 20 L 5 3 4 4 US Imp gal 4 3 L 1 1 0
24. il seal retainer O Anti friction metal Outer O Anti friction metal Inner B Oil lock piece INSPECTION DAMPER ROD RING Inspect the damper rod ring for wear or damage If damper rod ring is worn or damaged replace it with a new one INNER AND OUTER TUBES Inspect the inner and outer tube sliding surfaces for scratches or damage Replace the tube s if necessary 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 new one Front fork spring free length Service limit 336 mm 13 2 in INNER AND OUTER ANTI FRICTION METALS Inspect the teflon coated surface of the anti friction metals 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 metal groove Hold the inner tube vertically and install the anti friction metals by hand CAUTION Use special care to prevent damaging the teflon coated surface of the anti friction metals when install ing 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 GS500K4 FK4 04 MODEL 21 22 GS500K4 FK4 04 MODEL Insert the inner tube into the oute
25. ness Neutral switch Regulator Pass the regulator lead wire under pr the wiring harness Clamp the wiring harness at blue tape on the wiring harness Clamp Spark plug cap For GS500 U 1 1 Pass the combination meter lead wire above I the handlebar switch 1 1 1 1 1 1 Keep clearance between the regulator lead wires lead wire and helmet holder Clamp No slack Clam Rear brake Clamp Starter relay P light switch m4 ed Regulator NN AI I Re Pass the turn signal W TH T ay b gt light lead wire between 2 sapo u the frame and rear fender Side stand switch Ji ae S Pass the solenoid lead wire coupler must be located olenoid No slack over the starter relay Air cleaner box between the air cleaner box and solenoid coupler Side stand relay Turn signal relay Rear brake light switch Clamp Side stand switch 28 GS500K4 FKA 04 MODEL Ignition switch Left handlebar switch Right handlebar switch Right handlebar switch lead wire Left handlebar switch Wiring harness JERN Pass the horn lead wire behind the wiring harness guide Wiring harness guide VIEW A previous page Clamp Signal generator Battery lead wire Generator Frame AE Battery lead wire O Clamp lead wire Generator lead wire AN 1 LL a Cl l Pass the lead
26. r 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 new dust seal CD Anti friction metal Outer 2 Oil seal retainer 3 Oil seal Oil seal stopper ring 5 Dust seal CAUTION Make sure that the oil seal stopper ring is fit securely DAMPER ROD Install a new gasket 1 Apply THREAD LOCK to the damper rod bolt and tighten it to the specified torque 2 99000 32050 THREAD LOCK 1342 USA 99000 32110 THREAD LOCK 1322 Others V Damper rod bolt 28 N m 2 8 kgf m 20 0 Ib ft 09940 34520 handle 09940 34531 Attachment 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 410 or equivalent fork oil 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 new O ring and install it to the front fork cap bolt 99000 99044 10G SUZUKI FORK OIL 10 or equivalent fork oil e Temporarily tighten the cap bolt INSTALLATION Installation is in the reverse order of removal Pay attention to the following points When installing the front fork assembly align the upper sur
27. wires Clamp inside of all drain hoses For GS500 U Clamp Left turn signal Right turn signal Wiring harness VIEW B previous page Rear fender Turn signal Signal generator lead wire 4 i Pass the turn signal light lead wire between the and rear fender No slack Wiring harness Signal generator GS500K4 FK4 04 MODEL 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 Handlebar switch R Speedometer Clamp 4 RE IFI 1j Clamp Wiring harness Throttle cable Starater cable Horn Clutch cable Clamp Front turn signal light Clutch cable Clamp Ignition coil L lead wire L Handlebar switch L Ignition switch Clamp gt I 7 Starter cable Handlebar switch L lead wire E Handlebar switch L us e N Ignition switch SN Starter cable Z Clutch cable CS Front turn signal light L 30 GS500K4 FKA 04 MODEL OIL COOLER HOSE ROUTING For GS500F 7 im mi mim mio N 26 N m 2 6 19 0 Ib ft Oil cooler Oil cooler hose LH
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