🏷️ Basic Information

Make:

Suzuki

Model:

GS500 / GS500E

Production Start Year:

1989

Production End Year:

2009

Engine Family:

GS500

👋 Introduction

Positioning:

Essential DIY and professional workshop resource for owners of the Suzuki GS500 series.

Comparison:

Provides factory-level detail equivalent to manuals found in official service centers, offering superior depth to generic online guides.

Features:

Hundreds of pages, detailed diagrams and photos, step-by-step instructions, troubleshooting guides, electrical schematics, critical specifications.

User Benefit:

Empowers owners to perform maintenance and repairs, saving significant costs compared to professional shop labor.

📋 Manual Details

Models Covered:

All GS500 and GS500E models

Years Covered:

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

Variants Covered:

All engines, trims, and transmission types

Estimated Pages:

Hundreds

Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Components:

Engine top end, fuel system, cooling system, lubrication system, crankshaft, transmission

Chassis Components:

Clutch, wheels, tires, final drive, brakes, suspension, steering, frame

Electrical System:

Complete electrical system, wiring diagrams, troubleshooting

General Information:

Includes general information, model identification, and basic specifications.

Appendix:

Often includes supplementary data, torque charts, and wiring diagrams.

Maintenance:

Regular maintenance, fluid changes, lubrication, inspections

Repair:

Disassembly, assembly, cleaning, reinstallation, component replacement

Troubleshooting:

Diagnostic procedures, problem identification, solutions

Engine Overhaul:

Detailed procedures for engine removal, disassembly, inspection, repair, and reassembly.

Suspension Service:

Instructions for fork seal replacement, rear shock maintenance, and linkage inspection.

Brake System Overhaul:

Procedures for brake caliper maintenance, bleeding the brake system, and replacing brake pads/rotors.

Depth:

Comprehensive: from basic maintenance to advanced diagnostics and rebuild procedures, as used by professional technicians.

Diagnostic Tools:

Covers use of common hand tools and specialized Suzuki tools where applicable.

Specifications Data:

Includes critical torque specifications, clearances, and measurements for all components.

📊 Manual Specifications

Digital Format:

PDF

Requirements:

Adobe PDF Reader & WinZip

Printable:

Full Printable

Zoom Functionality:

Zoom IN/OUT enabled

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Operating Systems:

Compatible with All Versions of Windows & Mac

⚙️ Engine Specifications

Type:

4-stroke, 2-cylinder, Air-cooled, DOHC, 4 valves per cylinder

Displacement:

487 cc (29.7 cu in)

Bore X Stroke:

74.0 mm x 56.6 mm

Compression Ratio:

9.0:1

Horsepower Approx:

47-52 HP (depending on year/market)

Carburetion:

Twin Mikuni carburetors (e.g., VM26SS or BST34)

Fuel Capacity:

Approximately 17 liters (4.5 US gal)

Ignition System:

CDI (Capacitor Discharge Ignition)

🔧 Transmission

Type:

5-speed constant mesh

Type:

N/A (Standard 5-speed manual)

Clutch Type:

Wet multi-plate

📐 Dimensions

Length Approx:

2145 mm (84.4 in)

Width Approx:

750 mm (29.5 in)

Height Approx:

1140 mm (44.9 in)

Dry Weight Approx:

173 kg (381 lbs)

Wet Weight Approx:

187 kg (412 lbs)

🛡️ Safety Features

Safety Focus:

Emphasis on mechanical integrity and predictable handling; safety features are rider-dependent.

Braking System:

Front: Hydraulic disc, Rear: Hydraulic disc (some early models may have drum rear, but disc is common for most of the covered period).

Suspension Type:

Front: Telescopic forks, Rear: Swingarm with adjustable preload (mono-shock).

Lighting:

Halogen headlight, taillight, turn signals.

💡 Technology Features

Infotainment System:

N/A (Classic motorcycle design, no integrated infotainment).

Assistance Features:

N/A (Standard motorcycle controls).

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 km (1,800-3,000 miles) or annually, refer to manual for specific interval.

Valve Clearance Check:

Typically every 10,000-15,000 km (6,000-9,000 miles), crucial for engine health.

Engine Oil Type:

SAE 10W-40 motorcycle specific, API SG or higher (check manual for exact specification).

Engine Oil Capacity:

Approximately 2.7 liters (2.8 US qt) with filter change.

Brake Fluid Type:

DOT 3 or DOT 4, check reservoir cap.

Fork Oil Type:

Typically SAE 10W or 15W, specific volume per leg required (refer to manual).

Common Wear Items:

Carburetor synchronization, fuel line degradation, rear shock absorber wear, clutch cable adjustment, chain and sprockets wear.

Electrical Gremlins:

Age-related issues like corroded connectors, aging battery, and rectifier/regulator failures can occur.

📚 Vehicle History

Heritage:

Suzuki has a long history in motorcycle manufacturing, known for reliable and accessible performance motorcycles.

Evolutionary Path:

The GS500 platform remained remarkably consistent throughout its production run, a testament to its effective design. Minor updates often focused on styling, minor engine tuning, and emissions compliance rather than fundamental mechanical changes.

Key Updates:

Later models might feature minor aesthetic changes, potentially improved suspension damping, and emissions-related tuning for compliance with evolving regulations.

Manufacturing Locations:

Primarily manufactured in Japan, with potential assembly in other regions depending on market.

🏆 Awards & Recognition

Market Recognition:

Widely recognized as a reliable, affordable, and easy-to-maintain beginner sport-standard motorcycle.

Owner Satisfaction:

Consistently praised for its dependability and low running costs by owners.