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Suzuki GS500E GS500 GS500F 1989-2009 Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: GS500E, GS500, GS500F Production Years: 1989-2009 👋 Introduction Market Position Market Segment: Affordable and reliable middleweight naked motorcycle, popular for commuting, beginner riders,...
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Taper: Motorcycle
Distributeur:
Suzuki
UGS: 298772
Mots clés: 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Featured GS Series GS500 GS500E GS500F Motorcycle Motorcycles Suzuki
Suzuki GS500E GS500 GS500F 1989-2009 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
GS500E, GS500, GS500F
Production Years:
1989-2009
👋 Introduction
Market Position
Market Segment:
Affordable and reliable middleweight naked motorcycle, popular for commuting, beginner riders, and custom builds.
Competitive Analysis
Key Competitors:
Kawasaki Ninja 500R, Honda CB500, Yamaha FZR600 (older models), entry-level 4-cylinder bikes of similar displacement.
Key Features
Vehicle Attributes:
Simple, robust air-cooled parallel-twin engine, straightforward chassis, excellent fuel efficiency, low maintenance costs, and a vast aftermarket support.
Manual Value
Value Proposition:
Provides comprehensive technical guidance essential for maintaining, repairing, and optimizing the Suzuki GS500 series, significantly reducing reliance on expensive dealership services.
📋 Manual Details
Coverage
Manual Type:
Service and Repair Manual
Language:
English
File Format:
PDF
Availability:
Downloadable
Compatibility:
Windows & Mac (all versions)
📖 Manual Coverage
Systems
Systems Covered:
Engine, Cooling and Lubrication System, Driveline/Axle, Transmission/Transaxle, Fuel System and Throttle, Electrical Systems, Suspension, Steering, Brake System, Frame, Bodywork
Procedures
Procedures Included:
Troubleshooting, Periodic Maintenance, Tune-up, Repair, Inspection, Adjustment
Depth
Technical Depth:
Comprehensive; includes step-by-step instructions and detailed illustrations for a wide range of service and repair tasks, suitable for both novice and experienced technicians.
Specific Procedures
Engine Overhaul:
Detailed procedures for top-end and bottom-end engine rebuilds, piston replacement, valve seat work, and crankshaft inspection.
Carburetor Rebuild:
Step-by-step guide for disassembling, cleaning, rebuilding, and synchronizing the CV carburetors, including jetting information.
Suspension Fork Service:
Instructions for disassembling, cleaning, replacing seals and bushings, and refilling fork oil.
Electrical Troubleshooting:
Wiring diagrams, component testing procedures for ignition, charging systems, and lighting circuits.
Brake System Maintenance:
Procedures for brake fluid changes, caliper rebuilds, pad replacement, and rotor inspection.
Technical Data
Torque Specifications:
Comprehensive list of torque values for all critical fasteners (engine, chassis, suspension, brakes).
Clearances:
Precise specifications for valve clearances, bearing clearances, and general engine component tolerances.
Part Numbers:
While this is a service manual, it often cross-references or implies the use of specific Suzuki OEM part numbers, crucial for ordering correct components.
📊 Manual Specifications
Digital
File Format:
Portable Document Format (PDF)
Searchability:
Likely text-searchable given PDF format, facilitating quick access to specific information.
Print Quality:
High resolution, allowing for clear printing of text and illustrations.
Usage Rights:
Downloadable and saveable to PC/MAC, allowing for offline access and printing.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, DOHC, 2-valve per cylinder, Parallel-twin
Displacement:
487 cc (396 cc for early models)
Performance
Bore X Stroke:
70.0 mm x 64.0 mm (approx.)
Compression Ratio:
9.0:1 (approx.)
Horsepower:
Approximately 48-52 hp @ 9,200 rpm (varies slightly by year and emissions controls)
Torque:
Approximately 28-30 lb-ft @ 7,400 rpm (varies slightly by year)
Fuel System
Carburetion:
Dual Mikuni CV carbs (e.g., VM26SS or BST34)
Fuel Type:
Unleaded gasoline, 87 octane or higher recommended
Lubrication
Oil Type:
SAE 10W-40 API SG or higher (check manual for exact spec)
Oil Capacity:
Approx. 2.5 liters (including filter change)
🔧 Transmission
Drivetrain
Transmission Type:
6-speed constant mesh
Final Drive:
O-ring sealed chain
Clutch Type:
Wet, multi-plate
Fluid Specs
Transmission Oil Type:
Refer to manual for specific transmission oil; often shared with engine oil or a dedicated gear oil.
📐 Dimensions
General
Dry Weight:
Approx. 170-180 kg (varies by model and fairing)
Fuel Capacity:
17 Liters (approx. 4.5 gallons)
Wheels Tires
Front Tire Size:
110/70-17
Rear Tire Size:
130/70-17
Wheelbase:
Approx. 1430 mm (56.3 in)
🛡️ Safety Features
Braking
Front Brake:
Single hydraulic disc (290mm) with 2-piston caliper; later models may have dual discs.
Rear Brake:
Single hydraulic disc (250mm) with 1-piston caliper
Brake Fluid:
DOT 3 or DOT 4 (check manual for specifics)
Lighting
Headlight:
Halogen, typically H4 type bulb
💡 Technology Features
Infotainment
System:
Basic analog instrumentation: speedometer, tachometer, odometer, trip meter, engine temperature warning light, neutral indicator, oil pressure light, high beam indicator.
Driver Assistance
Features:
No electronic driver assistance features (ABS, traction control, etc.) on most models, reflecting its era and design philosophy.
Lighting
Lighting Type:
Standard halogen headlight, taillight, and turn signals.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 km or 6-12 months, whichever comes first (refer to manual for precise intervals).
Spark Plug Replacement:
Typically every 10,000 - 15,000 km (check manual for specific plug type and gap).
Chain Adjustment Lubrication:
Check and adjust slack every 1,000 - 2,000 km; clean and lubricate regularly.
Valve Clearance Check:
Interval varies, often around 20,000 - 30,000 km; requires shims for adjustment (screw-and-locknut on some earlier versions).
Fluid Specifications
Coolant Type:
If applicable (some GS500 variants may be air-cooled only, others have oil coolers). If liquid-cooled, use a high-quality ethylene glycol-based coolant.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Fork Oil Viscosity:
Typically SAE 10W fork oil, capacity specified in manual.
Known Issues
Common Problems:
Carburetor synchronization issues, worn swingarm bushings, cam chain noise (especially on high mileage), clutch wear, and potential stator failures. Rusty fuel tanks are also a common issue on older models.
Preventive Measures:
Regular maintenance, proper fuel storage, and addressing minor issues promptly can prevent most common problems.
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation, Japan
Model Evolution
Introduction Date:
GS500 model line introduced in the early 1980s, with the GS500E variant gaining popularity in the late 1980s.
Key Changes Over Years:
Introduction of the GS500F (faired version), minor engine updates for emissions, suspension improvements (e.g., adjustable preload on later models), carburetor upgrades, and cosmetic changes.
Production
Manufacturing Locations:
Primarily Japan, with some production potentially in other Suzuki facilities.
🏆 Awards & Recognition
Recognitions
Market Reputation:
Widely recognized for its reliability, low cost of ownership, and ease of maintenance. Often praised as an excellent beginner's bike or a solid commuter.
Ratings
Owner Satisfaction:
Generally high owner satisfaction due to its dependability and performance relative to its price point.
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