Suzuki GS500E GS500 GS500F 1989-2009 Service Repair Workshop Manual 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008

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🏷️ Basic Information Identification Make: Suzuki Model: GS500E, GS500, GS500F Codes Engine Type Code: GS500E/F 👋 Introduction Market Position Segment: Entry-level to mid-range sport-standard motorcycle. Competitive Analysis Competitors: Honda CB500,...

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Taper: Motorcycle

Distributeur:

UGS: 482434

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

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GS500E, GS500, GS500F

Codes

Engine Type Code:

GS500E/F

👋 Introduction

Market Position

Segment:

Entry-level to mid-range sport-standard motorcycle.

Competitive Analysis

Competitors:

Honda CB500, Kawasaki Ninja 500R, Yamaha FZR600R (during its production lifespan).

Key Features

Durability:

Known for its robust and reliable air-cooled engine, making it a popular choice for commuting and general riding.

Simplicity:

Relatively simple mechanical design, making it approachable for DIY maintenance and repairs.

Versatility:

Adaptable for various riding styles, from city commuting to sport touring, with aftermarket customization options.

📋 Manual Details

Coverage Areas

Years Covered:

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

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download (potentially zipped)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, tuning, carburetion, ignition, lubrication, cooling systems.

Transmission:

Gearbox, clutch, drive chain maintenance and repair.

Electrical:

Wiring diagrams, battery, charging system, lighting, ignition system components.

Chassis And Suspension:

Front fork, rear shock absorber, steering head bearings, frame inspection and repair.

Brakes:

Hydraulic brake system, caliper service, master cylinder, brake fluid replacement.

Bodywork And Fairings:

Panel removal and installation, cosmetic repairs.

Fuel Tank And Petcock:

Service and repair of the fuel tank, petcock, and fuel lines.

Exhaust System:

Inspection, maintenance, and repair of the exhaust components.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, spark plug service, brake checks, chain lubrication.

Troubleshooting:

Diagnostic procedures for common issues, fault finding charts.

Repair:

Step-by-step instructions for component repair and replacement.

Restoration:

Guidance for rebuilding and restoring the motorcycle to factory specifications.

Diagnostics:

Detailed diagnostic trees and procedures for various systems.

Engine Diagnostics:

Detailed engine diagnostic procedures for troubleshooting performance issues.

Technical Depth

Depth:

Comprehensive (covers all aspects from basic maintenance to complete engine rebuilds and electrical system troubleshooting).

Illustrations:

Illustrated with clear, step-by-step instructions, including zoomable illustrations and exploded views.

Part Breakdowns:

Detailed component breakdowns and part number information for all aspects.

📊 Manual Specifications

File Format

Compatibility:

Windows, Linux, Mac (requires PDF reader; may require WinZip or WinRAR for extraction).

File Size Potential:

Up to 5 GB (indicative of comprehensive content).

Print Quality

Printable:

Yes, the manual is printable without restrictions.

Binding Type

Type:

N/A (Digital Download - not a physical book)

Paper Type

Type:

N/A (Digital Download - not applicable)

⚙️ Engine Specifications

Primary Engine

Type:

Air-cooled, four-stroke, DOHC, parallel-twin

Displacement:

487 cc (approximately)

Bore X Stroke:

74.0 mm x 56.6 mm (typical)

Compression Ratio:

9.0:1 (typical)

Performance

Horsepower:

Approx. 47-50 hp @ 9000 rpm (depending on year and market)

Torque:

Approx. 40-42 Nm @ 7500 rpm (depending on year and market)

Fuel System

Carburetion:

Twin Mikuni CV carburetors (e.g., VM29SS or similar models).

Fuel Type:

Unleaded gasoline (minimum 91 octane recommended).

🔧 Transmission

Standard

Type:

6-speed constant mesh

Final Drive:

O-ring sealed chain drive

Features

Clutch:

Wet multi-plate

📐 Dimensions

Exterior

Length:

Approx. 2140 mm (depending on fairing type)

Width:

Approx. 760 mm (depending on fairing type)

Height:

Approx. 1100 mm (depending on seat height and handlebars)

Weights

Dry Weight:

Approx. 173 kg

Wet Weight:

Approx. 187 kg (with all fluids)

Fuel Capacity:

17 Liters (including reserve)

🛡️ Safety Features

Ratings

Crash Test Data:

Motorcycle safety ratings are not typically standardized in the same way as automobiles. Focus is on component integrity and rider aids.

Active Features

Braking System:

Dual front disc brakes, single rear disc brake. ABS was not standard on most GS500 models during this period.

Passive Features

Lighting:

Halogen headlight, LED taillight and turn signals (depending on specific year/market updates).

💡 Technology Features

Infotainment

System:

Basic analog instrumentation (speedometer, tachometer, fuel gauge, indicator lights). No advanced infotainment systems.

Driver Assistance

Features:

Limited; primarily focused on core motorcycle function. No electronic rider aids like traction control or ABS (on most models).

🔧 Maintenance

Service Intervals

Oil Change:

Every 6,000 km or 6 months, whichever comes first (refer to manual for specific oil type and viscosity).

Valve Clearance Check:

Every 12,000 km or 12 months.

Spark Plug Replacement:

Every 12,000 km or 12 months.

Air Filter Cleaning:

Every 6,000 km or 6 months, replacement as needed.

Fluid Specifications

Engine Oil:

SAE 10W-40 API SG or higher (or as specified in the manual).

Engine Oil Capacity:

Approximately 3.2 Liters with filter change (refer to manual for exact capacity).

Brake Fluid:

DOT 4 or DOT 5.1 (refer to manual for specific recommendation and replacement intervals).

Coolant:

N/A (Air-cooled engine)

Known Issues

Carburetor Sync:

Can require periodic syncing for smooth running, especially after extensive use or modifications.

Cam Chain Tensioner:

Some early models may benefit from an aftermarket manual cam chain tensioner to prevent noise.

Electrical Connections:

Corrosion on electrical connectors can lead to intermittent issues; regular inspection is advised.

📚 Vehicle History

Brand Heritage

Origin:

Suzuki Motor Corporation, Japan.

Model Evolution

Generations:

The GS500 platform has been relatively consistent, with minor updates to styling, suspension, and braking over its long production run.

Production

Manufacturing Locations:

Primarily Japan, with potential assembly in other regions.

Production Run:

First introduced in 1988/1989 and produced through 2009, marking a remarkably long and successful model lifecycle.

🏆 Awards & Recognition

Recognitions

Reputation:

Widely recognized as a reliable and affordable beginner motorcycle, often praised for its longevity and low running costs.

Ratings

Owner Satisfaction:

Generally high owner satisfaction due to its dependability and ease of maintenance.