Suzuki GS500E - Engine Service

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3

ENGINE

CONTENTS

Table of Contents

Table of Contents2
Group Index2
View of GS500E3
General Information4
- Contents4
- Serial Number Locations5
- Fuel and Oil Recommendations5
- Break-In Procedures6
- Special Materials7
- Precautions and General Instructions9
- Replacement Parts10
- Asbestos Information10
- Specifications11
- Periodic Maintenance and Tune-Up Procedures14
- Periodic Maintenance Schedule15
- Lubrication Points16
- Battery Maintenance17
- Cylinder Head Maintenance18
- Exhaust Pipe and Muffler Maintenance18
- Air Cleaner Maintenance19
- Tappet Clearance Maintenance19
- Tappet Clearance Adjustment20
- Shim Selection Chart22
- Spark Plugs Maintenance23
- Recommended Spark Plug23
- Fuel Line24
- Engine Oil and Oil Filter Maintenance24
- Necessary Amount of Engine Oil24
- Carburetors Maintenance25
- Throttle Cable Play25
- Clutch Maintenance25
- Drive Chain Maintenance26
- Drive Chain Checking27
- Drive Chain Adjusting27
- Drive Chain Cleaning and Lubrication27
- Brakes Maintenance28
- Brake Fluid Level28
- Brake Pads Maintenance29
- Brake Pedal Height29
- Brake Light Switches29
- Air Bleeding from the Brake Fluid Circuit30
- Tires Maintenance31
- Tire Tread Condition31
- Tire Pressure31
- Steering Maintenance32
- Front Forks Maintenance32
- Rear Suspension Maintenance32
- Chassis Bolts and Nuts33
Engine35
- Compression Test Procedure36
- Compression Pressure Check36
- Oil Pressure Check37
- Low Oil Pressure37
- High Oil Pressure37
- Oil Pressure Test Procedure37
- Engine Components Removable with Engine in Place38
- Engine Removal39
- Engine Reinstallation44
- Engine Disassembly45
- Engine Components Inspection and Service54
- Cylinder Head Service54
- Cylinder Head Distortion55
- Valve Stem Runout55
- Valve Head Radial Runout55
- Valve Face Wear56
- Valve Guide-Valve Stem Clearance56
- Valve Stem Wear56
- Valve Guide Service56
- Valve Seat Width57
- Valve Seat Service58
- Valve Springs59
- Camshafts61
- Cam Wear61
- Camshaft Journal Wear62
- Camshaft Runout63
- Cam Sprocket63
- Cam Chain Tensioner63
- Cylinder Bore64
- Cam Chain Length64
- Cylinder Distortion64
- Cam Chain Guide64
- Piston Diameter65
- Piston-Cylinder Clearance65
- Piston Ring-Groove Clearance65
- Piston Ring End Gap66
- Oversize Piston Ring66
- Oversize Oil Ring / Side Rail66
- Conrod Big End Side Clearance67
- Piston Pin Diameter67
- Conrods - Conrod Small End I.D.67
- Piston Pin Bore67
- Conrod-Crank Pin Bearing Selection68
- Bearing Selection Table69
- Conrod I.D. Specification69
- Crank Pin O.D. Specification69
- Bearing Assembly70
- Bearing Thickness Specification70
- Crankshaft and Counter-Balancer Sharft71
- Crankcase-Crankshaft and Counter-Balancer Bearing Selection71
- Crankshaft Runout73
- Counter-Balancer Shaft Disassembly73
- Crankshaft Thrust Bearing73
- Counter-Balancer Shaft Reassembly74
- Clutch Drive and Drive Plates75
- Clutch Spring Free Length75
- Clutch Release Bearing75
- Oil Pump76
- Starter Clutch Disassembly76
- Starter Clutch Reassembly76
- Transmission Gears Disassembly77
- Transmission Gears Reassembly78
- Location of Small Parts79
- Gearshift Fork-Groove Clearance80
- Engine Reassembly81
- Oil Orifice Location82
Fuel and Lubrication System96
- Fuel Tank and Fuel Cock Diagram97
- Fuel Tank and Fuel Cock Inspection and Cleaning97
- Carburetor Construction98
- Fuel and Lubrication System Specifications99
- Carburetor I.D. No. Location100
- Diaphragm and Piston Operation101
- Slow System102
- Main System103
- Starter System104
- Float System104
- Fuel System105
- Carburetor Reassembly and Remounting106
- Carburetor Inspection and Adjustment106
- Needle Valve Inspection106
- Float Height Adjustment106
- Balance or Carburetors107
- Calibrating each Gauge107
- Balancing Carburetors108
- Lubrication System109
- Oil Sump Filter109
- Engine Lubrication System Chart110
- Engine Lubrication System View111
Electrical System112
- Charging System Description113
- Function of Regulator113
- AC Generator Continuity Check115
- AC Generator No-Load Performance115
- Charging Output Check115
- Regulator/Rectifier116
- Ignition System Description117
- Ignition System Inspection118
- Ignition Coil (Checking with Electro Tester)118
- Ignition Coik (Checking with Pocket Tester)118
- Signal Generator (Checking with Pocket Tester)118
- Spark Plug119
- Ignitor Unit (Checking with Digital Ignitor Checker)120
- Starter System Description122
- Starter Removal and Disassembly122
- Starter Motor Inspection123
- Carbon Brush123
- Commutator123
- Armature Coil124
- Starter Motor Reassembly124
- O-Ring124
- Housing End124
- Side-Stand/Ignition Interlock System Description125
- Starter Relay Inspection125
- Interlock System Inspection127
- Diode127
- Neutral Switch127
- Side-Stand/Ignition Interlock Relay127
- Combination Meter Removal and Disassembly128
- Combination Meter Inspection129
- Tail/Brake Light Exploded View130
- Headlight Exploded View130
- Lamps130
- Switches131
- Turn Signal Light Exploded View131
- Oil Pressure Switch131
- Starter Relay132
- Side-Stand Relay132
- Turn Signal Relay132
- Battery Servicing133
- Filling Electrolyte133
- Battery Initial Charging133
- Battery Specifications133
- Recharging Operation Based on S.G. Reading134
- Battery Servicing Life135
Chassis136
- Front Wheel Exploded View137
- Front Wheel Removal137
- Speedometer Gear Box Dust Seal Inspection and Disassembly138
- Wheel Inspection139
- Axle Shaft Inspection139
- Wheel Bearing Inspection139
- Front Wheel Reassembly and Remounting140
- Wheel Bearing140
- Brake Disc141
- Speedometer Gearbox141
- Brake Caliper141
- Axle Shaft142
- Front Brake Pad Replacement143
- Front Brake Exploded View143
- Caliper Removal and Disassembly144
- Caliper and Disc Inspection145
- Piston Inspection145
- Rubber Parts Inspection145
- Disc Inspection145
- Caliper Reassembly and Remounting146
- Caliper Bolts146
- Master Cylinder Removal and Disassembly146
- Master Cylinder Reassembly and Remounting147
- Master Cylinder Inspection147
- Front Fork Exploded View149
- Front Fork Removal149
- Front Fork Disassembly150
- Front Fork Inspection152
- Front Fork Reassembly and Remounting152
- Inner and Outer Tube Inspection152
- Fork Spring Inspection152
- Fork Oil153
- Outer Tube Metal, Oil Seal and Dust Seal153
- Damper Rod Bolt153
- Inner Tube154
- Clamp Bolts and Nuts154
- Steering Exploded View155
- Steering Removal155
- Steering Disassembly156
- Steering Inspection156
- Stem Nut157
- Outer Races157
- Steering Reassembly and Remounting157
- Steering Tension Adjustment158
- Handlebar Holder158
- Ignition Switch159
- Rear Brake Exploded View160
- Brake Pad Replacement160
- Caliper Removal and Disassembly (Rear)161
- Caliper Reassembly and Remounting (Rear)162
- Caliper Bolts (Rear)162
- Master Cylinder Removal and Disassembly (Rear)163
- Master Cylinder Inspection (Rear)164
- Cylinder, Piston and Cup Set Inspection164
- Master Cylinder Reassembly and Remounting (Rear)165
- Rear Wheel Exploded View166
- Rear Wheel Removal166
- Axle Shaft Inspection168
- Rear Wheel Inspection168
- Wheel and Sprocket Drum Bearings Inspection168
- Rear Wheel Inspection and Disassembly168
- Rear Wheel Reassembly and Remounting169
- Damper Inspection169
- Rear Wheel Bearing169
- Sprocket Drum Bearing and Sprocket170
- Brake Disc Check171
- Tire and Wheel172
- Tire Removal172
- Valve Inspection174
- Wheel Check174
- Tire Inspection174
- Valve Installation175
- Tire Mounting175
- Rear Suspension177
- Swingarm Exploded View177
- Shock Absorber and Cushion Lever Exploded View178
- Shock Absorber and Cushion Lever Removal179
- Shock Absorber and Cushion Lever Inspection180
- Swingarm Pivot Shaft Check181
- Shock Absorber and Cushion Lever Disassembly181
- Cushion Lever Rod182
- Chassis: Reassembly Information183
- Chassis Reassembly and Remounting184
- Final Inspection and Adjustment186
- Shock Absorber Spring Pre-Load186
Service Information187
- Troubleshooting - Engine188
- Troubleshooting - Carburetor190
- Troubleshooting - Electrical191
- Troubleshooting - Battery192
- Troubleshooting - Chassis193
- Troubleshooting - Brakes194
- Wiring Diagram for USA and Canada Models195
- Wiring Diagram for Other Models196
- Wire Harness, Cable and Hose Routing197
- Wire Routing197
- Engine Lead Wires199
- High Tension Cord Routing200
- Cable Routing201
- Speedometer Cable Routing202
- Front Brake Hose Routing203
- Rear Brake Hose Routing204
- Battery Breather Hose Routing205
- Fuel Hose, Vacuum Hose and Air Vent Hose Routing206
- Fuel Hose Routing207
- Fuel Hose, Air Cleaner Water Drain Hose and Fuel Tank Water Drain Hose Routing208
- Seat Lock Cable Routing209
- Canister Hose Routing (for Califorinia Model)210
- Special Tools211
- Tightening Torque - Engine214
- Tightening Torque - Chassis215
- Tightening Torque - Other Bolts and Nuts216
- Service Data - Valve + Guide217
- Service Data - Camshaft + Cylinder Head217
- Service Data - Cylinder + Piston + Piston Ring218
- Service Data - Clutch219
- Service Data - Conrdod + Crankshaft + Balancer219
- Service Data - Oil Pum219
- Service Data - Transmission + Drive Chain220
- Service Data - Carburetor220
- Service Data - Electrical222
- Service Data - Wattage222
- Service Data - Brake + Wheel223
- Service Data - Suspension224
- Service Data - Tire Pressure224
- Service Data - Fuel + Oil224
Emission Control Information225
- Emission Control Carburetor Components226
- Evaporative Emisson Control System (for California Model) Diagram227
- Canister Hose Routing (for California Model) Diagram228
GS500EL ('90-Model)229
- GS500EL ('90-Model) Specifications230
- GS500EL ('90-Model) Service Data - Valve + Guide232
- GS500EL ('90-Model) Service Data - Camshaft + Cylinder Head232
- GS500EL ('90-Model) Service Data - Cylinder + Piston + Piston Ring233
- GS500EL ('90-Model) Service Data - Clutch234
- GS500EL ('90-Model) Service Data - Conrod + Crankshaft + Balancer234
- GS500EL ('90-Model) Service Data - Oil Pump234
- GS500EL ('90-Model) Service Data - Transmission + Drive Chain235
- GS500EL ('90-Model) Service Data - Carburetor235
- GS500EL ('90-Model) Service Data - Electrical237
- GS500EL ('90-Model) Service Data - Wattage237
- GS500EL ('90-Model) Service Data - Brake + Wheel238
- GS500EL ('90-Model) Service Data - Fuel + Oil239
- GS500EL ('90-Model) Service Data - Tire Pressure239
- GS500EL ('90-Model) Service Data - Suspension239
- GS500EL Wiring Diagram - for USA and Canada Models240
- GS500EL Wiring Diagram - for Other Models241
- GS500EL Wire Routing242
- GS500EL Cable Routing244
GS500EM ('91-Model)245
- GS500EM ('91-Model) Specifications246
- GS500EM ('91-Model) Service Data - Valve + Guide247
- GS500EM ('91-Model) Service Data - Camshaft + Cylinder Head247
- GS500EM ('91-Model) Service Data - Cylinder + Piston + Piston Ring248
- GS500EM ('91-Model) Service Data - Conrod + Crankshaft + Balancer249
- GS500EM ('91-Model) Service Data - Oil Pump249
- GS500EM ('91-Model) Service Data - Clutch249
- GS500EM ('91-Model) Service Data - Transmission + Drive Chain250
- GS500EM ('91-Model) Service Data - Carburetor250
- GS500EM ('91-Model) Service Data - Electrical252
- GS500EM ('91-Model) Service Data - Wattage252
- GS500EM ('91-Model) Service Data - Brake + Wheel253
- GS500EM ('91-Model) Service Data - Fuel + Oil254
- GS500EM ('91-Model) Service Data - Tire Pressure254
- GS500EM ('91-Model) Service Data - Suspension254
- GS500EM ('91-Model) Wire Routing255
GS500EN ('92-Model)256
- GS500EN ('92-Model) Specifications257
- GS500EN ('92-Model) Service Data - Valve + Guide258
- GS500EN ('92-Model) Service Data - Camshaft + Cylinder Head258
- GS500EN ('92-Model) Service Data - Cylinder + Piston + Piston Ring259
- GS500EN ('92-Model) Service Data - Clutch260
- GS500EN ('92-Model) Service Data - Oil Pump260
- GS500EN ('92-Model) Service Data - Conrod + Crankshaft + Balancer260
- GS500EN ('92-Model) Service Data - Transmission + Drive Chain261
- GS500EN ('92-Model) Service Data - Carburetor261
- GS500EN ('92-Model) Service Data - Electrical263
- GS500EN ('92-Model) Service Data - Wattage263
- GS500EN ('92-Model) Service Data - Brake + Wheel264
- GS500EN ('92-Model) Service Data - Suspension264
- GS500EN ('92-Model) Service Data - Fuel + Oil265
- GS500EN ('92-Model) Service Data - Tire Pressure265
- GS500EN ('92-Model) Service Data - Wiring Diagram (for Australian Model)266
- GS500EN ('92-Model) Service Data - Speedometer Cable Routing267
GS500EP ('93-Model)268
- GS500EP ('93-Model) Specifications269
- GS500EP ('93-Model) Service Data - Valve + Guide270
- GS500EP ('93-Model) Service Data - Camshaft + Cylinder Head270
- GS500EP ('93-Model) Service Data - Cylinder + Piston + Piston Ring271
- GS500EP ('93-Model) Service Data - Clutch272
- GS500EP ('93-Model) Service Data - Oil Pump272
- GS500EP ('93-Model) Service Data - Conrod + Crankshaft + Balancer272
- GS500EP ('93-Model) Service Data - Transmission + Drive Chain273
- GS500EP ('93-Model) Service Data - Carburetor273
- GS500EP ('93-Model) Service Data - Electrical276
- GS500EP ('93-Model) Service Data - Wattage276
- GS500EP ('93-Model) Service Data - Brake + Wheel277
- GS500EP ('93-Model) Service Data - Suspension277
- GS500EP ('93-Model) Service Data - Fuel + Oil278
- GS500EP ('93-Model) Service Data - Tire Pressure278
GS500ER ('94-Model)279
- GS500ER ('94-Model) Specifications280
- GS500ER ('94-Model) Service Data - Valve + Guide281
- GS500ER ('94-Model) Service Data - Camshaft + Cylinder Head281
- GS500ER ('94-Model) Service Data - Cylinder + Piston + Piston Ring282
- GS500ER ('94-Model) Service Data - Conrod + Crankshaft + Balancer283
- GS500ER ('94-Model) Service Data - Oil Pump283
- GS500ER ('94-Model) Service Data - Clutch283
- GS500ER ('94-Model) Service Data - Transmission + Drive Chain284
- GS500ER ('94-Model) Service Data - Carburetor284
- GS500ER ('94-Model) Service Data - Electrical287
- GS500ER ('94-Model) Service Data - Wattage287
- GS500ER ('94-Model) Service Data - Brake + Wheel288
- GS500ER ('94-Model) Service Data - Suspension288
- GS500ER ('94-Model) Service Data - Tire Pressure289
- GS500ER ('94-Model) Service Data - Fuel + Oil289
GS500ES ('95-Model)290
- GS500ES ('95-Model) Specifications291
- GS500ES ('95-Model) Service Data - Valve + Guide292
- GS500ES ('95-Model) Service Data - Camshaft + Cylinder Head292
- GS500ES ('95-Model) Service Data - Cylinder + Piston + Piston Ring293
- GS500ES ('95-Model) Service Data - Conrod + Crankshaft + Balancer294
- GS500ES ('95-Model) Service Data - Oil Pump294
- GS500ES ('95-Model) Service Data - Clutch294
- GS500ES ('95-Model) Service Data - Transmission + Drive Chain295
- GS500ES ('95-Model) Service Data - Carburetor295
- GS500ES ('95-Model) Service Data - Wattage298
- GS500ES ('95-Model) Service Data - Electrical298
- GS500ES ('95-Model) Service Data - Brake + Wheel299
- GS500ES ('95-Model) Service Data - Suspension299
- GS500ES ('95-Model) Service Data - Tire Pressure300
- GS500ES ('95-Model) Service Data - Fuel + Oil300
- GS500ES ('95-Model) Carburetor301
- GS500ES ('95-Model) - Pilot Screw Removal and Installation301
GS500ET ('96-Model)302
- GS500ET ('96-Model) Specifications303
- GS500ET ('96-Model) Service Data - Valve + Guide304
- GS500ET ('96-Model) Service Data - Camshaft + Cylinder Head304
- GS500ET ('96-Model) Service Data - Cylinder + Piston + Piston Ring305
- GS500ET ('96-Model) Service Data - Conrod + Crankshaft + Balancer306
- GS500ET ('96-Model) Service Data - Oil Pump306
- GS500ET ('96-Model) Service Data - Clutch306
- GS500ET ('96-Model) Service Data - Transmission + Drive Chain307
- GS500ET ('96-Model) Service Data - Carburetor307
- GS500ET ('96-Model) Service Data - Wattage308
- GS500ET ('96-Model) Service Data - Electrical308
- GS500ET ('96-Model) Service Data - Brake + Wheel309
- GS500ET ('96-Model) Service Data - Suspension309
- GS500ET ('96-Model) Service Data - Tire Pressure310
- GS500ET ('96-Model) Service Data - Fuel + Oil310
- GS500ET ('96-Model) Front Brake311
- GS500ET ('96-Model) Brake Pad Inspection311
- GS500ET ('96-Model) Caliper Interchangeability312
- GS500ET ('96-Model) Caliper Removal and Disassembly312
- GS500ET ('96-Model) Brake Pad Replacement312
GS500EV ('97-Model)313
- GS500EV ('97-Model) Specifications314
- GS500EV ('97-Model) Service Data - Valve + Guide315
- GS500EV ('97-Model) Service Data - Camshaft + Cylinder Head316
- GS500EV ('97-Model) Service Data - Cylinder + Piston + Piston Ring316
- GS500EV ('97-Model) Service Data - Conrod + Crankshaft + Balancer317
- GS500EV ('97-Model) Service Data - Oil Pump317
- GS500EV ('97-Model) Service Data - Clutch318
- GS500EV ('97-Model) Service Data - Transmission + Drive Chain318
- GS500EV ('97-Model) Service Data - Carburetor319
- GS500EV ('97-Model) Service Data - Electrical320
- GS500EV ('97-Model) Service Data - Wattage321
- GS500EV ('97-Model) Service Data - Brake + Wheel321
- GS500EV ('97-Model) Service Data - Suspension322
- GS500EV ('97-Model) Service Data - Tire Pressure322
- GS500EV ('97-Model) Service Data - Fuel + Oil323
- GS500EV ('97-Model) Wiring Diagram for USA and Canada Models324
- GS500EV ('97-Model) Wiring Diagram for Australia Model325
- GS500EV ('97-Model) Wiring Diagram for Other Models326
GS500EW/X/Y ('98/'99/'00-Models)327
- GS500EW/X/Y ('98/'99/'00-Models) Specifications328
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Valve + Guide329
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Camshaft + Cylinder Head330
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Cylinder + Piston + Piston Ring330
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Conrod + Crankshaft + Balancer331
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Oil Pump331
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Clutch332
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Transmission + Drive Chain332
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Carburetor333
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Electrical335
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Wattage335
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Brake + Wheel336
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Suspension337
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Tire Pressure337
- GS500EW/X/Y ('98/'99/'00-Models) Service Data - Fuel + Oil338
GS500K1/K2 ('01/'02-Models)339
- GS500K1/K2 ('01/'02-Models) Specifications340
- GS500K1/K2 ('01/'02-Models) Service Data - Valve + Guide341
- GS500K1/K2 ('01/'02-Models) Service Data - Camshaft + Cylinder Head342
- GS500K1/K2 ('01/'02-Models) Service Data - Cylinder + Piston + Piston Ring342
- GS500K1/K2 ('01/'02-Models) Service Data - Conrod + Crankshaft + Balancer343
- GS500K1/K2 ('01/'02-Models) Service Data - Oil Pump343
- GS500K1/K2 ('01/'02-Models) Service Data - Clutch344
- GS500K1/K2 ('01/'02-Models) Service Data - Transmission + Drive Chain344
- GS500K1/K2 ('01/'02-Models) Service Data - Carburetor345
- GS500K1/K2 ('01/'02-Models) Service Data - Electrical346
- GS500K1/K2 ('01/'02-Models) Service Data - Wattage346
- GS500K1/K2 ('01/'02-Models) Service Data - Brake + Wheel347
- GS500K1/K2 ('01/'02-Models) Service Data - Suspension348
- GS500K1/K2 ('01/'02-Models) Service Data - Tire Pressure348
- GS500K1/K2 ('01/'02-Models) Service Data - Fuel + Oil349
GS500K3 ('03-Model)350
- GS500K3 ('03-Model) Specifications351
- Dimensions and Dry Mass351
- Drive Train351
- GS500K3 ('03-Model) Service Data - Valve + Guide353
- GS500K3 ('03-Model) Service Data - Cylinder + Piston + Piston Ring354
- GS500K3 ('03-Model) Service Data - Camshaft + Cylinder Head354
- GS500K3 ('03-Model) Service Data - Conrod + Crankshaft + Balancer355
- GS500K3 ('03-Model) Service Data - Oil Pump355
- GS500K3 ('03-Model) Service Data - Clutch356
- GS500K3 ('03-Model) Service Data - Transmission + Drive Chain356
- GS500K3 ('03-Model) Service Data - Carburetor357
- GS500K3 ('03-Model) Service Data - Electrical358
- GS500K3 ('03-Model) Service Data - Wattage358
- GS500K3 ('03-Model) Service Data - Brake + Wheel359
- GS500K3 ('03-Model) Service Data - Suspension360
- GS500K3 ('03-Model) Service Data - Tire Pressure360
- GS500K3 ('03-Model) Service Data - Fuel + Oil361
- GS500K3 ('03-Model) Front Brake Master Cylinder Removal and Disassembly362
- GS500K3 ('03-Model) Front Brake Master Cylinder Inspection363
- GS500K3 ('03-Model) Front Brake Master Cylinder Reassembly and Remounting364
- GS500K3 ('03-Model) Ignition System Description366
- GS500K3 ('03-Model) Ignition System Troubleshooting367
- GS500K3 ('03-Model) Ignition Coil Primary Peak Voltage368
- GS500K3 ('03-Model) Signal Generator369
- GS500K3 ('03-Model) Signal Generator Peak Voltage370
- GS500K3 ('03-Model) Signal Generator Resistance370
- GS500K3 ('03-Model) Regulator/Rectifier371
- GS500K3 ('03-Model) Combination Meter Inspection372
- GS500K3 ('03-Model) Turn Signal Light: Bulb Replacement373
- Wiring Diagram for GS500HK3/GS500HUK3 P-19374
- Wiring Diagram for GS500HK3/GS500UK3 P-02, 19, 54375
- Wiring Diagram for GS500 P-24, 28376
- GS500K3 ('03-Model) Wire Routing377
GS500K4/FK4 ('04-Model)379
- GS500K4/FK4 ('04-Model): Country and Area Codes380
- GS500K4/FK4 ('04-Model) Specifications381
- GS500K4/FK4 ('04-Model) Service Data - Valve + Guide383
- GS500K4/FK4 ('04-Model) Service Data - Camshaft + Cylinder Head384
- GS500K4/FK4 ('04-Model) Service Data - Cylinder + Piston + Piston Ring384
- GS500K4/FK4 ('04-Model) Service Data - Conrod + Crankshaft + Balancer385
- GS500K4/FK4 ('04-Model) Service Data - Oil Pump385
- GS500K4/FK4 ('04-Model) Service Data - Clutch386
- GS500K4/FK4 ('04-Model) Service Data - Transmission + Drive Chain386
- GS500K4/FK4 ('04-Model) Service Data - Carburetor387
- GS500K4/FK4 ('04-Model) Service Data - Electrical388
- GS500K4/FK4 ('04-Model) Service Data - Wattage388
- GS500K4/FK4 ('04-Model) Service Data - Brake + Wheel389
- GS500K4/FK4 ('04-Model) Service Data - Fuel + Oil390
- GS500K4/FK4 ('04-Model) Service Data - Suspension390
- GS500K4/FK4 ('04-Model) Service Data - Tire Pressure390
- Specifications390
  - GS500K4/FK4 ('04-Model) Tightening Torque - Engine391
  - GS500K4/FK4 ('04-Model) Tightening Torque - Chassis392
  - GS500K4/FK4 ('04-Model) Periodic Maintenance Chart393
  - GS500K4/FK4 ('04-Model) Lower Crankcase394
- Cowling (for GS500F)395
  - GS500K4/FK4 ('04-Model) Front Fork Diagram396
  - GS500K4/FK4 ('04-Model) Front Fork Removal396
  - GS500K4/FK4 ('04-Model) Front Fork Disassembly397
  - GS500K4/FK4 ('04-Model) Damper Rod Ring Inspection398
  - GS500K4/FK4 ('04-Model) Inner and Outer Tubes Inspection398
  - GS500K4/FK4 ('04-Model) Fork Spring Inspection399
  - GS500K4/FK4 ('04-Model) Fron Fork Reassembly399
  - GS500K4/FK4 ('04-Model) Damper Rod400
  - GS500K4/FK4 ('04-Model) Fork Oil400
  - GS500K4/FK4 ('04-Model) Front Fork Installation401
  - Wiring Diagram - GS500K4/UK4 (P-02, 09, 19, 54), GS500FK4/FUK4 (P-02, 19, 54)402
- Gs500K4 (P-24, 28)403
- Wiring Diagram - GS500K4 (P-24, 28)403
- Gs500Fk4 (P-03, 24, 28, 33)404
  - Wiring Diagram - GS500FK4 (P-03, 24, 28, 33)404
  - GS500K4/FK4 ('04-Model) Wiring Harness Routing405
- Wiring Harness and Hose Routing405
- Wiring Harness Routing (for GS500F)407
- Oil Cooler Hose Routing (for GS500F)408
  - GS500K4/FK4 ('04-Model) Carburetor and Air Cleaner Hose Routing409
  - GS500K4/FK4 ('04-Model) Pair (Air Supply) System Hose Routing410
- Front Brake Hose Routing (for GS500F)411
- Front Turn Signal Light Installation (for GS500F)412
GS500K5/UK5/FK5/FUK5 ('05-Model)413
- GS500K5/UK5/FK5/FUK5 ('05-Model) Specifications414
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Valve + Guide416
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Camshaft + Cylinder Head417
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Cylinder + Piston + Piston Ring417
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Conrod + Crankshaft + Balancer418
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Oil Pump418
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Clutch419
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Transmission + Drive Chain419
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Carburetor420
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Electrical421
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Wattage421
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Brake + Wheel422
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Suspension423
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Tire Pressure423
- GS500K5/UK5/FK5/FUK5 ('05-Model) Service Data - Fuel + Oil423
GS500K6/UK6/FK6/FUK6 ('06-Model)424
- GS500K6/UK6/FK6/FUK6 ('06-Model) Specifications425
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Valve + Guide427
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Camshaft + Cylinder Head428
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Cylinder + Piston + Piston Ring428
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Conrod + Crankshaft + Balancer429
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Oil Pump429
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Clutch430
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Transmission + Drive Chain430
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Carburetor431
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Electrical432
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Wattage432
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Brake + Wheel433
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Fuel + Oil434
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Suspension434
- GS500K6/UK6/FK6/FUK6 ('06-Model) Service Data - Tire Pressure434
- GS500K6/UK6/FK6/FUK6 ('06-Model) Starter Button435
- Wiring Diagram GS500K6/FK6 (for P-02, 09, 19, 54)436
- Wiring Diagram GS500K6 (for P-24, 28)437
- GS500FK6 (for P-03, 24, 28, 33)438
- Wiring Diagram GS500FK6 (for P-03, 24, 28, 33)438

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