Suzuki GS500E - GS500 K4;FK4 (04-Model) Lower Crankcase

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20-16 GS500K4/FK4 (’04-MODEL)

LOWER CRANKCASE

! 99104-31140: SUZUKI BOND “1207B” (USA)

" 99000-31110: SUZUKI BOND “1215” (Others)

Apply SUZUKI BOND to the mating surface of the lower

and upper crankcase at shaded area.

Dowel pin position

Dowel pin

position

Dowel pin position

Dowel pin

position

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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