Suzuki GS500E - GS500 K4;FK4 (04-Model) Service Data - Camshaft + Cylinder Head; GS500 K4;FK4 (04-Model) Service Data - Cylinder + Piston + Piston Ring

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 – 0.066
(0.0013 – 0.0026)
0.150
(0.0060)
Camshaft journal holder I.D.
IN. & EX.
22.012 – 22.025
(0.8666 – 0.8671)
—
Camshaft journal O.D.
IN. & EX.
21.959 – 21.980
(0.8645 – 0.8654)
—
Camshaft runout
IN. & EX. —
0.10
(0.004)
Cam chain pin (at arrow “3”) 18th pin —
Cylinder head distortion
—
0.10
(0.004)
ITEM STANDARD LIMIT
Compression pressure 1 000 – 1 400 kPa
(10 – 14 kgf/cm
2
, 142 – 199 psi)
800 kPa
(8 kgf/cm
2
, 114 psi)
Compression pressure difference
—
200 kPa
(2 kgf/cm
2
, 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
1st N Approx. 7.0 (0.28)
5.6
(0.22)
2nd N Approx. 11.0 (0.43)
8.8
(0.35)
Piston ring end gap
1st
0.10 – 0.25
(0.004 – 0.010)
0.70
(0.028)
2nd
0.10 – 0.25
(0.004 – 0.010)
0.70
(0.028)
Piston ring to groove clearance
1st —
0.180
(0.0071)
2nd —
0.150
(0.0059)