🏷️ Basic Information

Make:

Suzuki

Model:

GS500

Sub Models:

GS500E, GS500F

Production Years:

1989-2009

Chassis Codes:

GM51, GM51A, GM51B

Engine Codes:

G500

👋 Introduction

Classification:

Entry-level to mid-range sport-standard motorcycle, known for its reliability and affordability

Competitors:

Kawasaki Ninja 500R, Honda CB500, Yamaha XJ600 Seca II (historically)

Durability:

Renowned for its robust and forgiving engine, making it a popular choice for new riders and commuters.

Simplicity:

Relatively simple mechanical design with easy access to components, facilitating maintenance.

Versatility:

Adaptable for commuting, light touring, and general sporty riding.

📋 Manual Details

Covered Years:

1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009

Covered Models:

GS500, GS500E, GS500F

Estimated Pages:

Hundreds (Specific count not provided, but indicated as extensive)

Type:

Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Complete overhaul, tuning, diagnostics, specific components (e.g., carburetor, ignition, cooling)

Transmission:

Clutch operation, gear shifting mechanism, lubrication, troubleshooting

Fuel System:

Carburetor adjustment (Mikuni BST34), fuel tank, fuel pump, fuel lines

Ignition System:

CDI, spark plugs, ignition timing, troubleshooting

Brakes:

Front and rear brake systems, hydraulic components, disc and pad replacement, bleeding procedure

Suspension:

Front telescopic forks (preload adjustment), rear monoshock absorber (preload adjustment), fork seal replacement, shock absorber overhaul

Electrical System:

Wiring diagrams, battery, charging system (alternator, regulator/rectifier), lighting, starting system, instrumentation

Chassis And Frame:

Frame inspection, steering head bearing maintenance, swingarm and rear suspension linkage

Bodywork:

Fairings, seat, fuel tank, fenders, minor body panel repairs and replacements

Wheels And Tires:

Tire replacement, wheel balancing, spoke tensioning, wheel bearing maintenance

Maintenance:

Routine servicing, oil changes, filter replacements, chain adjustment, lubrication points

Troubleshooting:

Diagnostic flowcharts, common problems and solutions for engine, electrical, and chassis issues

Repair:

Step-by-step instructions for component removal, installation, and rebuilding

Rebuilding:

Detailed procedures for engine and carburetor rebuilds

Refurbishing:

Guidance on restoring worn components and improving overall condition

Restoration:

Comprehensive information to guide a full vehicle restoration project

Depth:

Comprehensive, covering everything from basic maintenance to complete engine teardowns and rebuilds, suitable for both novice and experienced mechanics

📊 Manual Specifications

File Type:

PDF

Searchable:

Typically searchable if OCR'd properly

Quality:

High resolution (implied by 'Hundreds of pages' and detailed content)

Type:

Not Applicable (Digital PDF format)

Type:

Not Applicable (Digital PDF format)

⚙️ Engine Specifications

Type:

Air-cooled, four-stroke, parallel-twin

Displacement:

487 cc

Bore X Stroke:

74.0 mm x 56.6 mm

Compression Ratio:

9.0:1

Horsepower:

Approx. 48-52 HP @ 8,000-9,000 RPM (Varies slightly by year/spec)

Torque:

Approx. 41-43 Nm @ 6,000-7,000 RPM (Varies slightly by year/spec)

Carburetion:

Dual Mikuni BST34 carburetors

Fuel Capacity:

17 Liters (4.5 US gal)

System:

Wet sump

System:

Air-cooled

🔧 Transmission

Type:

6-speed constant mesh

Type:

N/A (Manual transmission only)

Clutch:

Wet multi-plate

Final Drive:

O-ring sealed chain

📐 Dimensions

Length:

Approx. 2,135 mm (84.1 in)

Width:

Approx. 760 mm (30.0 in)

Height:

Approx. 1,155 mm (45.5 in)

Wheelbase:

Approx. 1,415 mm (55.7 in)

Ground Clearance:

Approx. 140 mm (5.5 in)

Dry Weight:

Approx. 170 kg (375 lbs)

Wet Weight:

Approx. 185 kg (408 lbs) (with fluids)

Gross Vehicle Weight Rating:

Not specified, typical for motorcycle

🛡️ Safety Features

Crash Test Results:

Not applicable for motorcycles in the same manner as cars.

Brakes:

Dual disc front, single disc rear (ABS not standard on most models during this period, optional on later years/specific markets)

Lighting:

Halogen headlight, LED taillight (on later models)

Frame Design:

Steel diamond frame for rigidity

💡 Technology Features

System:

Not applicable (Basic motorcycle instrumentation: speedometer, tachometer, odometer, neutral indicator, turn signals)

Features:

N/A (No electronic driver assistance systems)

Features:

N/A (No connectivity features)

🔧 Maintenance

Oil Change:

Every 4,000-6,000 km (2,500-3,700 miles) or 6 months

Oil Filter Change:

At every oil change

Air Filter Inspection Cleaning:

Every 8,000-10,000 km (5,000-6,000 miles)

Spark Plug Replacement:

Every 10,000-12,000 km (6,000-7,500 miles)

Valve Clearance Check:

Every 16,000-24,000 km (10,000-15,000 miles)

Engine Oil Type:

SAE 10W-40, API SG or higher (JASO MA recommended)

Engine Oil Capacity:

Approx. 2.8 Liters (2.9 US qt) without filter change, 3.0 Liters (3.2 US qt) with filter change

Brake Fluid Type:

DOT 3 or DOT 4

Fork Oil Type:

Tends to be SAE 10W (refer to manual for exact specification)

Fork Oil Quantity:

Approx. 490 ml per fork leg (check manual for precise measurement)

Carburetor Performance:

Mikuni BST34 carburetors can be sensitive to gumming if fuel sits for extended periods, requiring cleaning and proper jetting adjustments.

Regulator Rectifier:

While generally reliable, the regulator/rectifier unit can be a potential failure point over time, affecting charging system performance.

Suspension Wear:

Fork seals can leak, and rear shock absorbers may lose damping effectiveness with high mileage.

Chain And Sprockets:

Regular lubrication and adjustment are critical to prevent premature wear on the drive chain and sprockets.

Electrical Connections:

Corrosion can affect electrical connections, especially in humid or coastal environments. Thorough inspection and cleaning are recommended.

📚 Vehicle History

Legacy:

Suzuki has a long history of producing reliable and performance-oriented motorcycles, often favored for their engineering and value.

Gs500 Lineage:

The GS500 platform was introduced in the early 1980s and evolved into the GS500E and later GS500F, with significant updates in the late 1990s and early 2000s including updated styling, dual disc front brakes, and improved suspension components.

Manufacturing Location:

Primarily Japan, with some assembly possibly in other locations depending on the market.

Model Longevity:

The GS500 enjoyed a remarkably long production run, indicating its enduring appeal and market success.

🏆 Awards & Recognition

Segment Popularity:

Consistently recognized as a great value and reliable motorcycle for riders entering the sport or seeking an economical commuter.

Long Term Reliability:

Highly rated for its long-term reliability and durability by owners and publications.

Emissions:

Meets emissions standards relevant to its production years and markets.