Suzuki GS500/F Service Manual
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Suzuki GS500/F Service Manual

Gs500/f
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Summary of Contents for Suzuki GS500/F

  • Page 2: Table Of Contents

    OIL COOLER HOSE ROUTING (For GS500F) ........30 CARBURETOR AND AIR CLEANER HOSE ROUTING ......31 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING........32 FRONT BRAKE HOSE ROUTING (For GS500F) ........33 FRONT TURN SIGNAL LIGHT INSTALLATION (For GS500F)......34 © COPYRIGHT SUZUKI MOTOR CORPORATION 2004...

  • Page 3: Country/Area Codes

    GS500K4/FK4 (’04-MODEL) COUNTRY AND AREA CODES The following codes stand for the applicable country (-ies) and area (-s). CODE COUNTRY or AREA P-02 P-03 USA (Except for California) P-09 Colombia P-19 P-24 Australia P-28 Canada P-33 California (USA) P-54 Spain...

  • Page 4: Specifications

    GS500K4/FK4 (’04-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 080 mm (81.9 in) Overall width ............800 mm (31.5 in) Overall height ............1 060 mm (41.7 in) ....GS500/U * 1 150 mm (45.3 in) ....GS500F/FU Wheelbase ............
  • Page 5 GS500K4/FK4 (’04-MODEL) CHASSIS Front suspension ..........Telescopic, coil spring, oil damped Rear suspension ..........Link type, coil spring, oil damped Front suspension stroke........120 mm (4.7 in) Rear wheel travel ..........115 mm (4.5 in) ° Caster ..............25 05’ Trail ..............

  • Page 6: Service Data

    GS500K4/FK4 (’04-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.5) — (1.3) Valve lift — (0.33) — (0.31) Tappet clearance (when cold) 0.03 – 0.08 IN. & EX. — (0.001 – 0.003) Valve guide to valve stem 0.025 –...
  • Page 7 GS500K4/FK4 (’04-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.090 – 36.130 35.80 (1.4208 – 1.4224) (1.409) 36.090 – 36.130 35.80 (1.4208 – 1.4224) (1.409) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.0013 –...

  • Page 8: Oil Pump

    GS500K4/FK4 (’04-MODEL) ITEM STANDARD LIMIT Piston ring groove width 1.21 – 1.23 — (0.047 – 0.048) 1.21 – 1.23 — (0.047 – 0.048) 2.51 – 2.53 — (0.099 – 0.100) Piston ring thickness 1.17 – 1.19 — (0.046 – 0.047) 1.17 –...
  • Page 9 GS500K4/FK4 (’04-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 — (0.4 – 0.6) Clutch release screw 1/4 – 1/2 turn back — Drive plate thickness 2.92 – 3.08 2.62 (0.115 – 0.121) (0.103) Drive plate claw width 15.8 –...
  • Page 10 GS500K4/FK4 (’04-MODEL) CARBURETOR SPECIFICATION ITEM GS500 P-02, 19, 24, 54 GS500U P-19 GS500F P-02, 19, 24, 54 GS500FU P-19 Carburetor type MIKUNI ← BSR34 ← Bore size 34 mm I.D. No. * 01DN * 01DP ← Idle r/min 1 200 ±100 r/min ←...
  • Page 11 GS500K4/FK4 (’04-MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing * 5° B.T.D.C. at 1 200 r/min P-03, 28, 33 12° B.T.D.C. at 1 200 r/min Others Firing order L·R Spark plug DENSO: X24EPR-U9 Type NGK: DPR8EA-9 0.8 – 0.9 (0.031 –...

  • Page 12: Brake + Wheel

    GS500K4/FK4 (’04-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height — (2.2) Brake disc thickness 4.5 ± 0.2 Front (0.177 ± 0.008) (0.16) 6.0 ± 0.2 Rear (0.236 ± 0.008) (0.22) Brake disc runout 0.30 —...

  • Page 13: Suspension

    (13.5) (13.2) Front fork oil level * 110 — (4.3) Front fork oil type SUZUKI FORK OIL #10 or equivalent fork oil — Front fork oil capacity * 380 ml — (each leg) (12.8/13.4 US/lmp oz) Front fork inner tube O.D.

  • Page 14: Tightening Torque

    GS500K4/FK4 (’04-MODEL) TIGHTENING TORQUE ENGINE ITEM N·m kgf-m lb-ft Cylinder head cover bolt 10.0 Cylinder head nut 27.5 Cylinder head bolt Cylinder stud bolt 11.0 Camshaft journal holder bolt Cam sprocket bolt 13.0 Cam chain tensioner mounting bolt Conrod bearing cap nut 23.0 Generator mounting rotor bolt 12.0...

  • Page 15: Chassis

    GS500K4/FK4 (’04-MODEL) CHASSIS ITEM N·m kgf-m lb-ft Steering stem head nut 32.5 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 21.5 Front fork cap bolt * 25 * 2.5 * 18.0 Front fork damper rod bolt * 28 * 2.8 * 20.0 Front axle nut...

  • Page 16: Periodic Maintenance Chart

    GS500K4/FK4 (’04-MODEL) PERIODIC MAINTENANCE CHART Interval: This interval should be judged by odometer reading or months, whichever comes first. Interval 1 000 6 000 12 000 18 000 24 000 miles 4 000 7 500 11 000 14 500 Item months Battery (Specific gravity of electrolyte) —...

  • Page 17: Lower Crankcase

    GS500K4/FK4 (’04-MODEL) LOWER CRANKCASE Dowel pin position Apply SUZUKI BOND to the mating surface of the lower and upper crankcase at shaded area. Dowel pin Dowel pin position position Dowel pin position ! 99104-31140: SUZUKI BOND “1207B” (USA) " 99000-31110: SUZUKI BOND “1215” (Others)

  • Page 18: Cowling (For Gs500F)

    GS500K4/FK4 (’04-MODEL) COWLING (For GS500F) 1 Screen 2 Front cowling cover (Center) 3 Front cowling 4 Front cowling cover (LH) 5 Front cowling cover (RH) 6 Cowling brace...

  • Page 19: Front Fork

    GS500K4/FK4 (’04-MODEL) FRONT FORK 1 O-ring 2 Spacer 3 Spring retainer 4 Front fork spring 5 Damper rod ring 6 Damper rod 7 Rebound spring 8 Inner tube 9 Anti-friction metal (Inner) 0 Dust seal A Oil seal stopper ring B Oil seal C Oil seal retainer D Anti-friction metal (Outer)

  • Page 20: Disassembly

    GS500K4/FK4 (’04-MODEL) • Loosen the front fork lower clamp bolt 3 and remove the front fork. NOTE: Hold the front fork by the hand to prevent sliding out of the steer- ing stem. Do not operate the brake lever while the caliper is removed.

  • Page 21: Inspection

    GS500K4/FK4 (’04-MODEL) • Remove the dust seal 6 and oil seal stopper ring 7. • Separate the inner tube out of the outer tube. • Remove the following parts. A Oil seal B Oil seal retainer C Anti-friction metal (Outer) D Anti-friction metal (Inner) E Oil lock piece INSPECTION...

  • Page 22: Reassembly

    Use special care to prevent damaging the teflon coated surface of the anti-friction metals when install- ing them. OIL SEAL • Apply fork oil lightly to the lip of a new oil seal and install it. ( 99000-99044-10G: SUZUKI FORK OIL #10 or equivalent fork oil...
  • Page 23 & 09940-34520: “T” handle 09940-34531: Attachment “A” FORK OIL • Pour specified fork oil into the inner tube. ' Front fork oil capacity (each leg): 380 ml (12.8/13.4 US/Imp oz) ( 99000-99044-10G: SUZUKI FORK OIL #10 or equivalent fork oil...

  • Page 24: Installation

    • Apply fork oil lightly to a new O-ring and install it to the front fork cap bolt. ( 99000-99044-10G: SUZUKI FORK OIL #10 or equivalent fork oil • Temporarily tighten the cap bolt. INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points.

  • Page 25: Wiring Diagram

    GS500K4/FK4 (’04-MODEL) WIRING DIAGRAM GS500K4/UK4 (P-02, 09, 19, 54) GS500FK4/FUK4 (P-02, 19, 54)

  • Page 26: Gs500K4 (P-24, 28)

    GS500K4/FK4 (’04-MODEL) GS500K4 (P-24, 28)

  • Page 27: Gs500Fk4 (P-03, 24, 28, 33)

    GS500K4/FK4 (’04-MODEL) GS500FK4 (P-03, 24, 28, 33)

  • Page 28: Wiring Harness And Hose Routing

    GS500K4/FK4 (’04-MODEL) WIRING HARNESS AND HOSE ROUTING WIRING HARNESS ROUTING Clamp Ignition coil lead wire Clutch cable Pass the lead wire Throttle cable underneath the frame. Clamp Ignition coil (LH) Do not allow the Neutral wiring harness to switch contact with the coupler fuel tank bracket bolt.
  • Page 29 GS500K4/FK4 (’04-MODEL) For GS500/U Clamp Clamp Ignition switch Left turn signal Left handlebar switch Right turn signal Clamp Right handlebar switch Wiring harness Right handlebar switch lead wire Left handlebar switch Brake hose Wiring harness Wiring harness guide Pass the horn lead wire behind the wiring harness guide.

  • Page 30: Wiring Harness Routing (For Gs500F)

    GS500K4/FK4 (’04-MODEL) WIRING HARNESS ROUTING (For GS500F) Lead wire guide Handlebar switch (R) Clamp Handlebar switch (R) Speedometer Throttle cable Ignition coil (R) Wiring harness Clamp To the front turn signal light (R) Wiring harness Wiring harness Clamp Handlebar switch (R) Speedometer Clamp Wiring harness...

  • Page 31: Oil Cooler Hose Routing (For Gs500F)

    GS500K4/FK4 (’04-MODEL) OIL COOLER HOSE ROUTING (For GS500F) 26 N·m (2.6 kgf-m, 19.0 lb-ft) 1 Oil cooler 2 Oil cooler hose (LH) 3 Oil cooler hose (RH)

  • Page 32: Carburetor And Air Cleaner Hose Routing

    GS500K4/FK4 (’04-MODEL) CARBURETOR AND AIR CLEANER HOSE ROUTING Air cleaner To the fuel valve Throttle cable Air vent hose Breather hose Air cleaner Carburetor clamp position (Intake manifold side) Fuel valve vacuum hose Throttle cable Air control hose 15˚ Carburetor clamp position (Air cleaner side) Air cleaner drain hose Breather hose...

  • Page 33: Pair (Air Supply) System Hose Routing

    GS500K4/FK4 (’04-MODEL) PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING Fuel valve vacuum hose No. 1 3-way joint PAIR valve vacuum hose Fuel valve vacuum hose No.2 PAIR valve Connect the thick side of the vacuum hose Marking PAIR air to the 3-way joint. (Yellow) cleaner hose Keep clearance...

  • Page 34: Front Brake Hose Routing (For Gs500F)

    GS500K4/FK4 (’04-MODEL) FRONT BRAKE HOSE ROUTING (For GS500F) 10˚ 14˚ Front brake hose Throttle cable Throttle cable Front brake hose Clamp Clamp 28˚ 28˚ Stopper Front brake caliper After positioning the brake hose union to the stopper, tighten the union bolt. 23 N·m (2.3 kgf-m, 16.5 lb-ft)

  • Page 35: Front Turn Signal Light Installation (For Gs500F)

    GS500K4/FK4 (’04-MODEL) FRONT TURN SIGNAL LIGHT INSTALLATION (For GS500F) 14 N·m (1.4 kgf-m, 10.0 lb-ft) 1 Forward 2 Cowling 3 Front turn signal light...
  • Page 36 Prepared by January, 2004 Part No. 99501-34150-03E Printed in Japan...

This manual is also suitable for:

2004 gs5002004 gs500f2004 gs500k42004 gs500fk4

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