2001-2002 Suzuki GS500 GS500K1 GS500E2 Parts Manual

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🏷️ Basic Information Identification Make: Suzuki Model: GS500 Model Variant: GS500K1, GS500E2 Codes Year Code K1: 2001 Year Code E2: 2002 👋 Introduction Market Position Segment: Entry-level to mid-range sportbike/standard...

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Taper: Motorcycle

Distributeur:

UGS: 275237

Mots clés: 2001 2002 GS Series GS500 GS500E2 GS500K1 Motorcycle Motorcycles Suzuki

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GS500

Model Variant:

GS500K1, GS500E2

Codes

Year Code K1:

Year Code E2:

👋 Introduction

Market Position

Segment:

Entry-level to mid-range sportbike/standard motorcycle

Target Audience:

New riders, budget-conscious enthusiasts, commuters, track day participants

Competitive Analysis

Key Competitors:

Kawasaki Ninja 500R, Honda CB500F (older models), Yamaha FZR600 (older models)

Key Features

Engine Configuration:

Parallel-twin, air-cooled

Durability Reputation:

Known for robust and reliable engine design

Simplicity Of Maintenance:

Relatively straightforward mechanics for basic servicing

Manual Value Proposition

Purpose:

Essential for owners and technicians to identify, order, and understand the assembly of genuine Suzuki parts

📋 Manual Details

Coverage Areas

Comprehensive Coverage:

Engine Systems:

Fuel System:

Ignition System:

Transmission:

Clutch System:

Chassis And Frame:

Suspension Front:

Suspension Rear:

Brake System Front:

Brake System Rear:

Steering System:

Electrical System:

Lighting System:

Instrumentation:

Bodywork And Fittings:

Special Tools:

Troubleshooting Guide:

Schematics Diagrams:

Page Count

Estimated Pages:

Approx. 300-400 pages

Manual Type

Type:

Parts Manual

Language

Language:

English

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Internals:

Cylinder head, pistons, crankshaft, camshafts, valves, timing chain

Fuel Delivery:

Carburetors (Mikuni BST36), fuel lines, fuel pump, fuel filter

Ignition Components:

Spark plugs, ignition coils, CDI unit, wiring

Exhaust System:

Exhaust pipes, muffler, heat shields

Cooling System:

Air-cooled (no coolant, but related airflow components)

Transmission Internals:

Gears, shift drum, shift forks, output shafts

Clutch Mechanism:

Clutch plates, springs, pressure plate, clutch cable

Frame Structure:

Main frame, subframe, engine mounts

Front Fork Assembly:

Fork tubes, springs, dampers, seals, triple clamps

Rear Shock ABSorber:

Shock unit, linkages (if applicable), bushings

Front Brake Assembly:

Brake caliper, brake pads, brake disc, master cylinder, brake lines

Rear Brake Assembly:

Brake caliper, brake pads, brake disc, master cylinder, brake lines

Wheel Hubs And Bearings:

Front and rear wheel components, bearings, seals

Steering Headstock:

Steering stem, bearings, seals

Electrical Harness:

Wiring diagrams, connectors, fuses, relays

Battery And Charging:

Battery, stator, regulator/rectifier

Lighting Components:

Headlight, taillight, turn signals, brake light switch

Instrument Cluster:

Speedometer, tachometer, indicators

Fuel Tank And Petcock:

Fuel tank components, petcock assembly

Seat And Body Panels:

Seat, side covers, tail cowl, fenders

Controls And Levers:

Handlebars, levers, throttle, cables

Fasteners And Hardware:

Bolts, nuts, washers, clips, specific fasteners

Procedures Included

Disassembly And Assembly:

Detailed exploded views for component removal and reinstallation

Part Identification:

Identification of all individual parts with corresponding part numbers

Component Interchangeability:

Indication of compatible parts across different model years/variants

Quantities And References:

Specifies quantities of parts needed and cross-references

Technical Depth

Depth:

Component-level breakdown for parts sourcing and replacement

Diagrams:

Rich with exploded view diagrams and part number callouts

Detail Level:

Specific to identifying and ordering replacement parts

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Likely text-searchable if professionally scanned

Print Quality

Print Readability:

Designed for clear reproduction if printed

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, DOHC, parallel-twin

Displacement:

487 cc

Bore X Stroke:

74.0 mm x 56.0 mm

Compression Ratio:

9.2:1

Cooling System:

Air-cooled

Performance

Horsepower Estimated:

Around 48-52 hp @ 8,800 rpm (varies slightly by year/market)

Torque Estimated:

Around 40 Nm @ 7,000 rpm (varies slightly by year/market)

Fuel System

Carburetor Type:

Twin Mikuni BST36 carburetors

Fuel Type:

Unleaded gasoline (91+ octane recommended)

Fuel Tank Capacity:

17 Liters (4.5 US gal)

🔧 Transmission

Standard

Transmission Type:

Constant-mesh, 6-speed sequential

Clutch Type:

Wet, multi-plate

Features

Final Drive:

Sealed O-ring chain

📐 Dimensions

Exterior

Overall Length:

Approx. 2145 mm (84.4 in)

Overall Width:

Approx. 745 mm (29.3 in)

Overall Height:

Approx. 1190 mm (46.9 in)

Wheelbase:

Approx. 1425 mm (56.1 in)

Weights

Dry Weight:

Approx. 174 kg (384 lbs)

Wet Weight:

Approx. 193 kg (425 lbs)

Gvwr:

N/A (Motorcycle)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycles typically do not have NHTSA/Euro NCAP ratings)

Active Features

Braking System:

Hydraulic disc brakes front and rear

Tire Selection:

Standard sport-touring or sport-biased tires

Passive Features

Frame Design:

Steel diamond frame providing rigidity

Lighting:

Adequate headlight, taillight, and brake lights for visibility

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation)

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Options:

Instrumentation

Instrument Panel:

Analog speedometer, tachometer, odometer, trip meter, neutral indicator, high-beam indicator, turn signal indicators

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Air Filter Cleaning:

Every 8,000 km (5,000 miles)

Spark Plug Replacement:

Every 12,000 km (7,500 miles)

Valve Clearance Check:

Every 12,000 km (7,500 miles)

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SE, SF or SG

Engine Oil Capacity:

2.8 Liters (2.9 US qt) with filter change

Brake Fluid Type:

DOT 3 or DOT 4

Chain Lube Type:

Motorcycle-specific chain lubricant

Known Issues

Carburetor Sync:

Carburetors may require periodic syncing for optimal performance

Clutch Cable Wear:

Clutch cable can stretch or wear over time, requiring adjustment or replacement

Charging System Issues:

Stator or regulator/rectifier can fail, leading to charging problems (though less common than some other bikes)

Fuel Filter Clogging:

Fuel filter can become clogged with debris, affecting fuel delivery

Maintenance Importance

Manual Utility:

This parts manual is crucial for accurately identifying the correct replacement parts for all maintenance and repair tasks.

📚 Vehicle History

Brand Heritage

Suzuki Motorcycles:

Suzuki has a long history of producing reliable and performance-oriented motorcycles across various segments.

Model Evolution

Gs500 Lineage:

The GS500 platform has been a staple for Suzuki for many years, evolving from earlier models with minor updates. The 2001-2002 models represent a refined version of this established platform.

Production

Production Period:

The GS500 was produced from the late 1980s through various iterations until around 2009 in most markets. The K1/E2 are specific model designations within this long production run.

Manufacturing Location:

Primarily Japan, with potential assembly in other global locations.

🏆 Awards & Recognition

Recognitions

Awards History:

While specific awards for the 2001-2002 GS500 are not prominently advertised, the model consistently received praise for its value, reliability, and ease of use in motorcycle publications of its era.

Ratings

Reliability Rating:

Generally considered very reliable with proper maintenance.

Certifications

Emissions Certification:

Compliant with prevailing emissions standards for its model years.