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Suzuki GS500 GS500E Service Repair Manual 89-99

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🏷️ Basic Information Identification Make: Suzuki Model: GS500 Model Variant: GS500E Codes Product Code: Suzuki GS500 GS500E Service Repair Manual 89-99 👋 Introduction Market Position Segment: Lightweight Naked Sportbike /...

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Taper: Motorcycle

Distributeur:

UGS: 267299

Mots clés: 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 GS Series GS500 GS500E Motorcycle Motorcycles Suzuki

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GS500

Model Variant:

GS500E

Codes

Product Code:

Suzuki GS500 GS500E Service Repair Manual 89-99

👋 Introduction

Market Position

Segment:

Lightweight Naked Sportbike / Standard Motorcycle

Competitive Analysis

Competitors:

Kawasaki Zephyr, Honda CB500, Yamaha XJ550/XJ600, Yamaha Seca II.

Key Features

Attributes:

Reliable air-cooled parallel-twin engine, user-friendly ergonomics, affordable maintenance, excellent beginner/intermediate motorcycle.

📋 Manual Details

Coverage Areas

Applicable Years:

1989-1999

Page Count

Estimated Pages:

Hundreds of pages

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

PDF

📖 Manual Coverage

Systems Covered

Engine:

Full engine overhaul, tuning, component diagnosis, piston, cylinder, crankshaft, camshaft, valve train, lubrication system, cooling system.

Fuel System:

Carburetor disassembly, cleaning, adjustment, jetting, fuel pump, fuel lines, fuel tank maintenance.

Transmission:

Clutch operation, gearbox disassembly, assembly, gear selection mechanisms, shift drum, shift forks, maintenance.

Electrical System:

Ignition system, charging system (stator, rectifier/regulator), starter motor, battery, lighting, wiring diagrams, fuses, relays, switches, instrument cluster.

Brakes:

Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, brake fluid bleeding, brake line inspection, drum brake adjustment (if applicable).

Suspension:

Front fork service (oil change, seal replacement, spring inspection), rear shock absorber inspection, linkage maintenance.

Chassis And Bodywork:

Frame inspection, swingarm maintenance, wheel bearing replacement, steering head bearing service, fairing removal/installation, seat, tank, and body panel components.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, lubrication points, spark plug replacement, air filter service, tire pressure checks.

Troubleshooting:

Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, electrical system diagnostics.

Repair:

Detailed step-by-step instructions for component disassembly, repair, and reassembly across all major vehicle systems.

Rebuild Refurbish Restore:

Comprehensive guides for full engine rebuilds, gearbox overhauls, suspension overhauls, and complete vehicle restoration.

Technical Depth

Depth:

Comprehensive: Covers basic maintenance to complete engine and gearbox rebuilds, including detailed technical specifications and diagnostic procedures.

📊 Manual Specifications

File Format

Digital Format:

PDF

Print Quality

Quality:

High-resolution, ensuring clear diagrams and text.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Type:

Air-cooled, four-stroke, parallel-twin

Displacement:

487 cc (specific to GS500E)

Bore X Stroke:

74.0 mm x 56.6 mm

Compression Ratio:

9.0:1

Performance

Horsepower:

Approx. 48-50 hp @ 9,200 rpm (model dependent)

Torque:

Approx. 40 Nm (29.5 lb-ft) @ 7,500 rpm (model dependent)

Fuel System

Carburetor:

Twin Mikuni B26-26 carburetors

Fuel Capacity:

17 Liters (4.5 US gal)

Engine Oil

Oil Type:

API SG or higher, JASO MA certified motorcycle oil

Oil Capacity:

Approx. 2.8 Liters (2.9 US qt) with filter change

🔧 Transmission

Standard

Type:

6-speed constant mesh

Optional

Options:

N/A (standard on all GS500E models)

Features

Clutch:

Wet multi-plate

Transmission Oil

Oil Type:

API SG or higher, JASO MA certified motorcycle oil (same as engine oil)

Oil Capacity:

Included in engine oil capacity

📐 Dimensions

Exterior

Length:

Approx. 2,145 mm (84.4 in)

Width:

Approx. 770 mm (30.3 in)

Height:

Approx. 1,070 mm (42.1 in)

Weights

Dry Weight:

Approx. 174 kg (383.6 lbs)

Wet Weight:

Approx. 189 kg (416.7 lbs)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles are not typically subjected to automotive crash test ratings.)

Active Features

Braking:

Front: Hydraulic disc, Rear: Hydraulic disc (early models may have drum rear)

Passive Features

Lighting:

Halogen headlight, LED taillight/brake light (depending on specific year).

💡 Technology Features

Infotainment

Features:

N/A (Basic motorcycle instrumentation)

Driver Assistance

Features:

N/A (No electronic rider aids typically found on this model)

Connectivity

Features:

N/A

🔧 Maintenance

Service Intervals

Oil Change:

Every 4,000 km (2,500 miles) or 6 months, whichever comes first.

Air Filter Cleaning:

Every 8,000 km (5,000 miles).

Spark Plug Replacement:

Every 16,000 km (10,000 miles).

Valve Clearance Check:

Every 24,000 km (15,000 miles).

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4 (refer to manual for specific caliper type)

Fork Oil:

SAE 10W (specific weight may vary slightly by year/preference)

Known Issues

Common Problems:

Carburetor synchronization drift, stator failure (rectifier/regulator burnout), cam chain noise, starter clutch wear, occasional charging system issues.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation, Japan

Model Evolution

First Generation:

Introduced in 1977 as GS500.

Gs500E Era:

The GS500E designation became prominent for models featuring updated styling and components, particularly from the late 1980s onwards.

Production

Production Years:

1977-2007 (across all variants)

Production Locations

Manufacturing:

Primarily Japan, with some later production in other global facilities.

🏆 Awards & Recognition

Recognitions

Awards And Accolades:

Consistently praised for its reliability, affordability, and ease of use, making it a popular choice for new riders and commuters. Often cited as a benchmark for value in its class.