Suzuki GS500E Manuals

Suzuki GS500E Manuals

Manuals and User Guides for Suzuki GS500E. We have 1 Suzuki GS500E manual available for free PDF download: Service Manual

Suzuki GS500E Service Manual

Suzuki GS500E Service Manual (441 pages)

Motorcycle Suzuki

Brand: Suzuki | Category: Motorcycle | Size: 41.98 MB

Table of Contents

Table of Contents
2
Group Index
2
View of GS500E
3
General Information
4
- Contents
  4
- Serial Number Locations
  5
- Fuel and Oil Recommendations
  5
- Break-In Procedures
  6
- Special Materials
  7
- Precautions and General Instructions
  9
- Replacement Parts
  10
- Asbestos Information
  10
- Specifications
  11
- Periodic Maintenance and Tune-Up Procedures
  14
- Periodic Maintenance Schedule
  15
- Lubrication Points
  16
- Battery Maintenance
  17
- Cylinder Head Maintenance
  18
- Exhaust Pipe and Muffler Maintenance
  18
- Air Cleaner Maintenance
  19
- Tappet Clearance Maintenance
  19
- Tappet Clearance Adjustment
  20
- Shim Selection Chart
  22
- Spark Plugs Maintenance
  23
- Recommended Spark Plug
  23
- Fuel Line
  24
- Engine Oil and Oil Filter Maintenance
  24
- Necessary Amount of Engine Oil
  24
- Carburetors Maintenance
  25
- Throttle Cable Play
  25
- Clutch Maintenance
  25
- Drive Chain Maintenance
  26
- Drive Chain Checking
  27
- Drive Chain Adjusting
  27
- Drive Chain Cleaning and Lubrication
  27
- Brakes Maintenance
  28
- Brake Fluid Level
  28
- Brake Pads Maintenance
  29
- Brake Pedal Height
  29
- Brake Light Switches
  29
- Air Bleeding from the Brake Fluid Circuit
  30
- Tires Maintenance
  31
- Tire Tread Condition
  31
- Tire Pressure
  31
- Steering Maintenance
  32
- Front Forks Maintenance
  32
- Rear Suspension Maintenance
  32
- Chassis Bolts and Nuts
  33
Engine
35
- Compression Test Procedure
  36
- Compression Pressure Check
  36
- Oil Pressure Check
  37
- Low Oil Pressure
  37
- High Oil Pressure
  37
- Oil Pressure Test Procedure
  37
- Engine Components Removable with Engine in Place
  38
- Engine Removal
  39
- Engine Reinstallation
  44
- Engine Disassembly
  45
- Engine Components Inspection and Service
  54
- Cylinder Head Service
  54
- Cylinder Head Distortion
  55
- Valve Stem Runout
  55
- Valve Head Radial Runout
  55
- Valve Face Wear
  56
- Valve Guide-Valve Stem Clearance
  56
- Valve Stem Wear
  56
- Valve Guide Service
  56
- Valve Seat Width
  57
- Valve Seat Service
  58
- Valve Springs
  59
- Camshafts
  61
- Cam Wear
  61
- Camshaft Journal Wear
  62
- Camshaft Runout
  63
- Cam Sprocket
  63
- Cam Chain Tensioner
  63
- Cylinder Bore
  64
- Cam Chain Length
  64
- Cylinder Distortion
  64
- Cam Chain Guide
  64
- Piston Diameter
  65
- Piston-Cylinder Clearance
  65
- Piston Ring-Groove Clearance
  65
- Piston Ring End Gap
  66
- Oversize Piston Ring
  66
- Oversize Oil Ring / Side Rail
  66
- Conrod Big End Side Clearance
  67
- Piston Pin Diameter
  67
- Conrods - Conrod Small End I.D.
  67
- Piston Pin Bore
  67
- Conrod-Crank Pin Bearing Selection
  68
- Bearing Selection Table
  69
- Conrod I.D. Specification
  69
- Crank Pin O.D. Specification
  69
- Bearing Assembly
  70
- Bearing Thickness Specification
  70
- Crankshaft and Counter-Balancer Sharft
  71
- Crankcase-Crankshaft and Counter-Balancer Bearing Selection
  71
- Crankshaft Runout
  73
- Counter-Balancer Shaft Disassembly
  73
- Crankshaft Thrust Bearing
  73
- Counter-Balancer Shaft Reassembly
  74
- Clutch Drive and Drive Plates
  75
- Clutch Spring Free Length
  75
- Clutch Release Bearing
  75
- Oil Pump
  76
- Starter Clutch Disassembly
  76
- Starter Clutch Reassembly
  76
- Transmission Gears Disassembly
  77
- Transmission Gears Reassembly
  78
- Location of Small Parts
  79
- Gearshift Fork-Groove Clearance
  80
- Engine Reassembly
  81
- Oil Orifice Location
  82
Fuel and Lubrication System
96
- Fuel Tank and Fuel Cock Diagram
  97
- Fuel Tank and Fuel Cock Inspection and Cleaning
  97
- Carburetor Construction
  98
- Fuel and Lubrication System Specifications
  99
- Carburetor I.D. No. Location
  100
- Diaphragm and Piston Operation
  101
- Slow System
  102
- Main System
  103
- Starter System
  104
- Float System
  104
- Fuel System
  105
- Carburetor Reassembly and Remounting
  106
- Carburetor Inspection and Adjustment
  106
- Needle Valve Inspection
  106
- Float Height Adjustment
  106
- Balance or Carburetors
  107
- Calibrating each Gauge
  107
- Balancing Carburetors
  108
- Lubrication System
  109
- Oil Sump Filter
  109
- Engine Lubrication System Chart
  110
- Engine Lubrication System View
  111
Electrical System
112
- Charging System Description
  113
- Function of Regulator
  113
- AC Generator Continuity Check
  115
- AC Generator No-Load Performance
  115
- Charging Output Check
  115
- Regulator/Rectifier
  116
- Ignition System Description
  117
- Ignition System Inspection
  118
- Ignition Coil (Checking with Electro Tester)
  118
- Ignition Coik (Checking with Pocket Tester)
  118
- Signal Generator (Checking with Pocket Tester)
  118
- Spark Plug
  119
- Ignitor Unit (Checking with Digital Ignitor Checker)
  120
- Starter System Description
  122
- Starter Removal and Disassembly
  122
- Starter Motor Inspection
  123
- Carbon Brush
  123
- Commutator
  123
- Armature Coil
  124
- Starter Motor Reassembly
  124
- O-Ring
  124
- Housing End
  124
- Side-Stand/Ignition Interlock System Description
  125
- Starter Relay Inspection
  125
- Interlock System Inspection
  127
- Diode
  127
- Neutral Switch
  127
- Side-Stand/Ignition Interlock Relay
  127
- Combination Meter Removal and Disassembly
  128
- Combination Meter Inspection
  129
- Tail/Brake Light Exploded View
  130
- Headlight Exploded View
  130
- Lamps
  130
- Switches
  131
- Turn Signal Light Exploded View
  131
- Oil Pressure Switch
  131
- Starter Relay
  132
- Side-Stand Relay
  132
- Turn Signal Relay
  132
- Battery Servicing
  133
- Filling Electrolyte
  133
- Battery Initial Charging
  133
- Battery Specifications
  133
- Recharging Operation Based on S.G. Reading
  134
- Battery Servicing Life
  135
Chassis
136
- Front Wheel Exploded View
  137
- Front Wheel Removal
  137
- Speedometer Gear Box Dust Seal Inspection and Disassembly
  138
- Wheel Inspection
  139
- Axle Shaft Inspection
  139
- Wheel Bearing Inspection
  139
- Front Wheel Reassembly and Remounting
  140
- Wheel Bearing
  140
- Brake Disc
  141
- Speedometer Gearbox
  141
- Brake Caliper
  141
- Axle Shaft
  142
- Front Brake Pad Replacement
  143
- Front Brake Exploded View
  143
- Caliper Removal and Disassembly
  144
- Caliper and Disc Inspection
  145
- Piston Inspection
  145
- Rubber Parts Inspection
  145
- Disc Inspection
  145
- Caliper Reassembly and Remounting
  146
- Caliper Bolts
  146
- Master Cylinder Removal and Disassembly
  146
- Master Cylinder Reassembly and Remounting
  147
- Master Cylinder Inspection
  147
- Front Fork Exploded View
  149
- Front Fork Removal
  149
- Front Fork Disassembly
  150
- Front Fork Inspection
  152
- Front Fork Reassembly and Remounting
  152
- Inner and Outer Tube Inspection
  152
- Fork Spring Inspection
  152
- Fork Oil
  153
- Outer Tube Metal, Oil Seal and Dust Seal
  153
- Damper Rod Bolt
  153
- Inner Tube
  154
- Clamp Bolts and Nuts
  154
- Steering Exploded View
  155
- Steering Removal
  155
- Steering Disassembly
  156
- Steering Inspection
  156
- Stem Nut
  157
- Outer Races
  157
- Steering Reassembly and Remounting
  157
- Steering Tension Adjustment
  158
- Handlebar Holder
  158
- Ignition Switch
  159
- Rear Brake Exploded View
  160
- Brake Pad Replacement
  160
- Caliper Removal and Disassembly (Rear)
  161
- Caliper Reassembly and Remounting (Rear)
  162
- Caliper Bolts (Rear)
  162
- Master Cylinder Removal and Disassembly (Rear)
  163
- Master Cylinder Inspection (Rear)
  164
- Cylinder, Piston and Cup Set Inspection
  164
- Master Cylinder Reassembly and Remounting (Rear)
  165
- Rear Wheel Exploded View
  166
- Rear Wheel Removal
  166
- Axle Shaft Inspection
  168
- Rear Wheel Inspection
  168
- Wheel and Sprocket Drum Bearings Inspection
  168
- Rear Wheel Inspection and Disassembly
  168
- Rear Wheel Reassembly and Remounting
  169
- Damper Inspection
  169
- Rear Wheel Bearing
  169
- Sprocket Drum Bearing and Sprocket
  170
- Brake Disc Check
  171
- Tire and Wheel
  172
- Tire Removal
  172
- Valve Inspection
  174
- Wheel Check
  174
- Tire Inspection
  174
- Valve Installation
  175
- Tire Mounting
  175
- Rear Suspension
  177
- Swingarm Exploded View
  177
- Shock Absorber and Cushion Lever Exploded View
  178
- Shock Absorber and Cushion Lever Removal
  179
- Shock Absorber and Cushion Lever Inspection
  180
- Swingarm Pivot Shaft Check
  181
- Shock Absorber and Cushion Lever Disassembly
  181
- Cushion Lever Rod
  182
- Chassis: Reassembly Information
  183
- Chassis Reassembly and Remounting
  184
- Final Inspection and Adjustment
  186
- Shock Absorber Spring Pre-Load
  186
Service Information
187
- Troubleshooting - Engine
  188
- Troubleshooting - Carburetor
  190
- Troubleshooting - Electrical
  191
- Troubleshooting - Battery
  192
- Troubleshooting - Chassis
  193
- Troubleshooting - Brakes
  194
- Wiring Diagram for USA and Canada Models
  195
- Wiring Diagram for Other Models
  196
- Wire Harness, Cable and Hose Routing
  197
- Wire Routing
  197
- Engine Lead Wires
  199
- High Tension Cord Routing
  200
- Cable Routing
  201
- Speedometer Cable Routing
  202
- Front Brake Hose Routing
  203
- Rear Brake Hose Routing
  204
- Battery Breather Hose Routing
  205
- Fuel Hose, Vacuum Hose and Air Vent Hose Routing
  206
- Fuel Hose Routing
  207
- Fuel Hose, Air Cleaner Water Drain Hose and Fuel Tank Water Drain Hose Routing
  208
- Seat Lock Cable Routing
  209
- Canister Hose Routing (for Califorinia Model)
  210
- Special Tools
  211
- Tightening Torque - Engine
  214
- Tightening Torque - Chassis
  215
- Tightening Torque - Other Bolts and Nuts
  216
- Service Data - Valve + Guide
  217
- Service Data - Camshaft + Cylinder Head
  217
- Service Data - Cylinder + Piston + Piston Ring
  218
- Service Data - Clutch
  219
- Service Data - Conrdod + Crankshaft + Balancer
  219
- Service Data - Oil Pum
  219
- Service Data - Transmission + Drive Chain
  220
- Service Data - Carburetor
  220
- Service Data - Electrical
  222
- Service Data - Wattage
  222
- Service Data - Brake + Wheel
  223
- Service Data - Suspension
  224
- Service Data - Tire Pressure
  224
- Service Data - Fuel + Oil
  224
Emission Control Information
225
GS500EL ('90-Model)
229
GS500EM ('91-Model)
245
GS500EN ('92-Model)
256
GS500EP ('93-Model)
268
GS500ER ('94-Model)
279
GS500ES ('95-Model)
290
GS500ET ('96-Model)
302
GS500EV ('97-Model)
313
GS500EW/X/Y ('98/'99/'00-Models)
327
GS500K1/K2 ('01/'02-Models)
339
GS500K3 ('03-Model)
350
GS500K4/FK4 ('04-Model)
379
GS500K5/UK5/FK5/FUK5 ('05-Model)
413
GS500K6/UK6/FK6/FUK6 ('06-Model)
424

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