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Suzuki GS500E User Manual

Suzuki GS500E
440 pages
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99500-34094-03E

Table of Contents

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Suzuki GS500E Specifications

General IconGeneral
Displacement487 cc
Bore x Stroke74.0 mm x 56.6 mm
Compression Ratio9.0:1
IgnitionElectronic ignition (transistorized)
Transmission6-speed constant mesh
Final DriveChain
Front SuspensionTelescopic, coil spring, oil damped
Rear SuspensionSwingarm, coil spring, oil damped
Rear BrakesDrum
Front Tire110/70-17
Rear Tire130/70-17
Engine TypeAir-cooled, 4-stroke, DOHC, parallel twin
Fuel SystemCarburetor
Front BrakesDisc brake
Fuel Capacity17 liters
Seat Height790 mm
Max Torque40 Nm (29.5 lb-ft) @ 7, 500 rpm
Length2080 mm
Wheelbase1405 mm

Summary

Foreword

General Information

Fuel and Oil Recommendations

Provides guidelines for selecting appropriate fuel and engine oil types for the motorcycle.

Precautions and General Instructions

Provides essential safety precautions and general guidelines for servicing the motorcycle.

General Specifications

Details key technical specifications of the GS500E motorcycle, including dimensions and engine.

Periodic Maintenance and Tune-Up Procedures

Periodic Maintenance Schedule and Chart

Recommends intervals for service work and provides a chart for required maintenance tasks.

Engine Oil and Oil Filter Change

Details the procedure for changing engine oil and oil filter, including required quantities.

Tappet Clearance Adjustment

Explains how to inspect and adjust tappet clearances for proper engine operation.

Brake System Inspection

Details inspection procedures for brake fluid level, pads, and light switches.

Tire Inspection and Pressure

Details tire tread depth inspection and recommended cold inflation tire pressures.

Engine Service

Engine Compression Pressure and Oil Pressure Checks

Provides specifications and procedures for checking engine compression and oil pressure.

Engine Removal and Reinstallation

Details the procedure for removing and reinstalling the engine assembly.

Cylinder Head and Valve Service

Covers inspection and service procedures for the cylinder head, valves, guides, and seats.

Piston and Conrod Service

Details service procedures for pistons, rings, pins, conrods, crankshaft, and bearings.

Fuel and Lubrication System

Fuel Tank and Fuel Cock Service

Details the procedure for removing, inspecting, and cleaning the fuel tank and fuel cock.

Carburetor Adjustment and Balancing

Covers float height adjustment, needle valve inspection, and carburetor balancing.

Engine Oil Pressure and Filter Service

Details engine oil pressure specifications and service for the oil filter and sump filter.

Electrical System

Charging System Inspection and Testing

Provides procedures for inspecting charging output, AC generator, and regulator/rectifier.

Ignition System Inspection and Testing

Covers inspection of ignition coils, spark plugs, signal generator, and ignitor unit.

Starter System Inspection and Testing

Details inspection procedures for the starter motor, relay, and associated switches.

Side-Stand/Ignition Interlock System Inspection

Details inspection procedures for the diode, neutral switch, and side-stand switch.

Chassis Service

Front Wheel Service

Covers front wheel removal, disassembly, inspection, and reassembly.

Front Brake Caliper and Master Cylinder Service

Details removal, disassembly, inspection, and reassembly of front brake caliper and master cylinder.

Front Fork Service

Covers front fork removal, disassembly, inspection, oil level adjustment, and installation.

Steering System Service

Details steering system removal, disassembly, inspection, and reassembly.

Rear Wheel Service

Covers rear wheel removal, inspection, and reassembly procedures.

Rear Suspension Service

Details inspection and disassembly procedures for the rear suspension components.

Service Information

Troubleshooting Guide

Provides common problems and their causes and remedies for engine, electrical, chassis, and brakes.

Tightening Torque Charts

Comprehensive charts detailing tightening torque values for engine and chassis components.

Service Data Tables

Compiles critical service data for valves, pistons, crankshafts, and transmissions.

Emission Control Information

Evaporative Emission Control System (California)

Explains the evaporative emission control system components and operation for California models.

GS500EL ('90-Model) Specifications and Service Data

GS500EL ('90-Model) Specifications

Details dimensions, dry mass, engine, transmission, chassis, electrical, and capacities for the GS500EL.

GS500EL ('90-Model) Valve and Guide Service Data

Provides specific service data for valves and guides on the GS500EL model.

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