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Suzuki GS500 GS500E 1989-2009 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: GS500 / GS500E Product Name: Suzuki GS500 GS500E 1989-2009 Factory Service Repair Manual Download PDF Generation Generation Identifier: 1989-2009 Models Codes Chassis Codes:...
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类型: Motorcycle
厂商:
Suzuki
斯库: 482887
标签: 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 GS Series GS500 GS500E Motorcycle Motorcycles Suzuki
Suzuki GS500 GS500E 1989-2009 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
GS500 / GS500E
Product Name:
Suzuki GS500 GS500E 1989-2009 Factory Service Repair Manual Download PDF
Generation
Generation Identifier:
1989-2009 Models
Codes
Chassis Codes:
Likely includes variations such as GM511 (GS500F, faired version if applicable within the range).
👋 Introduction
Market Position
Positioning:
Essential technical resource for owners and independent mechanics seeking to maintain and repair the Suzuki GS500/GS500E series.
Competitive Analysis
Type Of Manual:
Official Factory Service Repair Manual (not 3rd party), ensuring accuracy and completeness.
Key Features
Authenticity:
Actual genuine repair service factory manual, providing authoritative information.
User Friendliness:
Easy to use, with numbered instructions, bold figure numbers, and detailed illustrations. No advanced computer skills required.
Cost Savings:
Enables DIY servicing, potentially saving $50-$60 per hour in labor costs.
Information Access:
Searchable functionality within the PDF for quick information retrieval.
Update Advantage:
Printable pages eliminate wear and tear issues of physical manuals.
Diagnostic Tools:
Includes advanced troubleshooting guides and detailed wiring diagrams for electrical systems.
Utility
Owner Empowerment:
Empowers owners to make informed maintenance decisions and communicate effectively with mechanics.
📋 Manual Details
Coverage Areas
Applicable Years:
1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Model Variants Covered:
GS500, GS500E, and potentially GS500F (faired variant) for the specified years.
Page Count
Estimated Page Count:
Hundreds of pages (exact number not specified but implies comprehensive coverage).
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
General Information, Fuel System, Cooling System, Engine Top End, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission.
Drivetrain:
Clutch, Crankshaft/Transmission, Final Drive.
Chassis:
Wheels/Tires, Brakes, Suspension, Steering, Frame.
Electrical:
Electrical System (including wiring diagrams and troubleshooting).
Procedures Included
Maintenance:
Routine maintenance, fluid checks and changes, filter replacements, basic adjustments.
Diagnostics:
Fault symptom diagnosis, troubleshooting guides, electrical system diagnostics, common problem fixes.
Repair:
Step-by-step repair procedures for all major systems, component disassembly and reassembly, engine rebuilding, transmission overhaul.
Tuning:
Tuning procedures, carburetor adjustments, performance optimization.
Technical Data:
Specifications, torque values, clearances, electrical resistance, fluid capacities, wiring diagrams.
Technical Depth
Depth:
Comprehensive, covering fundamental maintenance to complete engine and chassis overhauls. Aimed at factory-trained technician level knowledge.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
Windows and Mac OS compatible.
Print Quality
Printability:
Fully printable without restriction; individual pages or entire manual.
Resolution:
High resolution.
Binding Type
Binding:
Digital (Downloadable, can be burned to CD-ROM).
Paper Type
Paper Type:
N/A (Digital format).
Software Requirements
Reader Software:
Adobe PDF Reader.
⚙️ Engine Specifications
Primary Engine
Type:
4-stroke, Air-cooled, DOHC, Parallel-twin.
Displacement:
487 cc (common for GS500 variants within this range).
Bore X Stroke:
74.0 mm x 56.6 mm (typical for GS500).
Compression Ratio:
9.0:1 (typical for GS500).
Valve Clearance Intake Cold:
0.08 - 0.13 mm (refer to manual for precise specification).
Valve Clearance Exhaust Cold:
0.13 - 0.18 mm (refer to manual for precise specification).
Performance
Horsepower:
Approx. 48-52 HP @ 9000 RPM (depending on market and specific model year variations).
Torque:
Approx. 40-42 Nm @ 7500 RPM (depending on market and specific model year variations).
Fuel System
Carburetion:
Twin Mikuni CV carburetors (e.g., VM26SS).
Fuel Type:
Unleaded gasoline (minimum 87 octane recommended).
Fuel Tank Capacity:
17 Liters (approx. 4.5 Gallons).
Fuel Pump:
Gravity feed from tank to carburetors.
🔧 Transmission
Standard
Type:
Constant mesh, 6-speed sequential.
Clutch Type:
Wet multi-plate.
Features
Gear Ratios:
Detailed gear ratios provided in the manual for each speed.
Transmission Oil Capacity:
Approx. 1.8 Liters (refer to manual for exact specification and type).
Final Drive:
O-ring sealed chain drive.
📐 Dimensions
Exterior
Length:
Approx. 2,130 mm (213 cm).
Width:
Approx. 760 mm (76 cm).
Height:
Approx. 1,100 mm (110 cm).
Weights
Dry Weight:
Approx. 172 kg (379 lbs).
Wet Weight:
Approx. 185 kg (408 lbs).
Wheelbase
Wheelbase:
Approx. 1,410 mm (55.5 inches).
🛡️ Safety Features
Ratings
Safety Equipment:
Standard motorcycle safety features: Headlight, taillight, brake light, turn signals, mirrors.
Active Features
Brakes Front:
Hydraulic disc, dual piston caliper.
Brakes Rear:
Drum brake (earlier models) or Hydraulic disc, single piston caliper (later models).
Passive Features
Lighting:
Halogen headlight, incandescent taillight/brake light and turn signals.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Designed as a functional motorcycle, not featuring modern infotainment systems).
Driver Assistance
Electronic Aids:
N/A (No electronic rider aids like ABS or traction control were standard on most GS500 models within this range).
Connectivity
Connectivity Features:
N/A.
🔧 Maintenance
Service Intervals
Oil Change:
Every 6,000 km (approx. 3,700 miles) or 6 months. Refer to manual for exact interval and conditions.
Air Filter Cleaning:
Inspect every 6,000 km, clean or replace as needed. Refer to manual.
Spark Plug Replacement:
Typically every 12,000 km (approx. 7,500 miles). Refer to manual for specific plug type and gap.
Valve Clearance Check:
Every 24,000 km (approx. 15,000 miles). Refer to manual for precise interval.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SE, SF or SG quality motorcycle oil. Refer to manual for specific viscosity grade and API classification.
Engine Oil Capacity:
Approx. 2.4 Liters (without filter change), 2.6 Liters (with filter change). Refer to manual for exact capacity.
Brake Fluid Type:
DOT 3 or DOT 4. Always use fresh, high-quality brake fluid.
Coolant Type:
N/A (Air-cooled engine).
Known Issues
Carburetor Sync:
Carburetors may require periodic synchronization for optimal performance and smooth idling.
Cam Chain Tensioner:
Some models may experience noise from the automatic cam chain tensioner; inspection and replacement might be necessary over time.
Fuel Petcock:
Diaphragm in the vacuum-operated fuel petcock can degrade over time, leading to fuel delivery issues.
Regulator Rectifier:
While generally reliable, like many motorcycles of this era, the regulator/rectifier can be a point of failure. The manual will guide diagnosis.
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation, a renowned Japanese manufacturer with a strong legacy in motorcycles and automobiles.
Model Evolution
Gs500 Lineage:
The GS500 platform has been a staple in Suzuki's lineup, known for its reliability, affordability, and user-friendliness as an entry-level to mid-range sportbike.
Production
Production Span:
Originally introduced in the mid-1980s, the GS500 series saw continuous production and evolution through 2009 and beyond in some markets, demonstrating its enduring appeal.
🏆 Awards & Recognition
Recognitions
Market Perception:
Consistently praised for its value proposition, reliability, and ease of maintenance, making it a popular choice for new riders and commuters.
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