Suzuki GS500E User Manual

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 ......................................................................................... 20- 5
TIGHTENING TORQUE ............................................................................. 20-13
ENGINE ............................................................................................... 20-13
CHASSIS ............................................................................................. 20-14
PERIODIC MAINTENANCE CHART ......................................................... 20-15
LOWER CRANKCASE .............................................................................. 20-16
COWLING (For GS500F) .......................................................................... 20-17
FRONT FORK ............................................................................................ 20-18
REMOVAL ........................................................................................... 20-18
DISASSEMBLY ................................................................................... 20-19
INSPECTION ....................................................................................... 20-20
REASSEMBLY .................................................................................... 20-21
INSTALLATION ................................................................................... 20-23
WIRING DIAGRAM .................................................................................... 20-24
GS500K4/UK4 (P-02, 09, 19, 54) ........................................................ 20-24
GS500FK4/FUK4 (P-02, 19, 54) .......................................................... 20-24
GS500K4 (P-24, 28) ............................................................................ 20-25
GS500FK4 (P-03, 24, 28, 33) .............................................................. 20-26
WIRING HARNESS AND HOSE ROUTING .............................................. 20-27
WIRING HARNESS ROUTING ........................................................... 20-27
WIRING HARNESS ROUTING (For GS500F) .................................... 20-29
OIL COOLER HOSE ROUTING (For GS500F) .................................. 20-30
CARBURETOR AND AIR CLEANER HOSE ROUTING .................... 20-31
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ............................... 20-32
FRONT BRAKE HOSE ROUTING (For GS500F) .............................. 20-33
FRONT TURN SIGNAL LIGHT INSTALLATION (For GS500F) ............... 20-34
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.

Suzuki GS500E Specifications

General

Displacement	487 cc
Bore x Stroke	74.0 mm x 56.6 mm
Compression Ratio	9.0:1
Ignition	Electronic ignition (transistorized)
Transmission	6-speed constant mesh
Final Drive	Chain
Front Suspension	Telescopic, coil spring, oil damped
Rear Suspension	Swingarm, coil spring, oil damped
Rear Brakes	Drum
Front Tire	110/70-17
Rear Tire	130/70-17
Engine Type	Air-cooled, 4-stroke, DOHC, parallel twin
Fuel System	Carburetor
Front Brakes	Disc brake
Fuel Capacity	17 liters
Seat Height	790 mm
Max Torque	40 Nm (29.5 lb-ft) @ 7, 500 rpm
Length	2080 mm
Wheelbase	1405 mm