Suzuki GS500, GS500E Repair Service Manual 1989-2009
Complete service repair manual with Electrical Wiring Diagrams for Suzuki GS500, GS500E, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Suzuki GS500, GS500E workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Suzuki GS500E (GS500EK, GS500EL, GS500EM, GS500EN, GS500EKP, GS500ER, GS500ES, GS500ET, GS500EV) Manuel D’Entertien '89-'97 (FR).pdf
Suzuki GS500E Service Manual '89-'99 (EN).pdf
Suzuki GS500E Twin (GS500E. 487cc. 1989 to 1997) Service Manual '89-'97 (EN).pdf
Suzuki GS500 Owner's Manual ('09).pdf
SUZUKI GS500E (GS500EK, GS500EL, GS500EM, GS500EN, GS500EKP, GS500ER, GS500ES, GS500ET, GS500EV, GS500EW, GS500EX) SERVICE MANUAL '89-'09 (EN).pdf
PRODUCT DETAILS:
Total Pages: 1,382 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
“GS500E '89-'99 (EN).pdf”
MAKE: Suzuki
MODEL: GS500E (GS500EK, GS500EL, GS500EM, GS500EN, GS500EKP, GS500ER, GS500ES, GS500ET, GS500EV, GS500EW, GS500EX)
YEAR: 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999
PAGE: 361
“GS500E Twin '89-'97 (EN).pdf”
MAKE: Suzuki
YEAR: 1989 1990 1991 1992 1993 1994 1995 1996 1997
MODEL: GS500E Twin (GS500E. 487cc. 1989 to 1997)
LANGUAGE: English
PAGE: 221
“GS500E '89-'97 (FR).pdf”
MAKE: Suzuki
YEAR: 1989 1990 1991 1992 1993 1994 1995 1996 1997
MODEL: GS500E (GS500EK, GS500EL, GS500EM, GS500EN, GS500EKP, GS500ER, GS500ES, GS500ET, GS500EV)
LANGUAGE: French
PAGE: 229
Suzuki GS500E Manuel D’Entertien
“GS500 '89-'09 (EN).pdf”
MAKE: Suzuki
MODEL: GS500 (GS500EK, GS500EL, GS500EM, GS500EN, GS500EKP, GS500ER, GS500ES, GS500ET, GS500EV, GS500EW, GS500EX, GS500EY, GS500K1, GS500K2, GS500K3, GS500K4, GS500FK4, GS500K5, GS500FK5, GS500FUK5, GS500UK5, GS500K6, GS500UK6, GS500FK6, GS500FUK6, GS500K7. GS500UK7, GS500FK7, GS500FUK7, GS500FK8, GS500FK9)
YEAR: 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
PAGE: 468
“GS500 Owner's Manual ('09).pdf”
102 pages
TABLE OF CONTENTS
SUZUKI GS500E (GS500EK, GS500EL, GS500EM, GS500EN, GS500EKP, GS500ER, GS500ES, GS500ET, GS500EV, GS500EW, GS500EX) SERVICE MANUAL '89-'09 (EN)...2
FOREWORD...2
01 GENERAL INFORMATION...6
SERIAL NUMBER LOCATIONS ...7
FUEL AND OIL RECOMMENDATIONS ...7
BREAK-IN PROCEDURES ...8
CYLINDER IDENTIFICATION ...8
SPECIAL MATERIALS ...9
PRECAUTIONS AND GENERAL INSTRUCTIONS ...11
SPECIFICATIONS ...13
COUNTRY OR AREA ...15
02 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES...16
PERIODIC MAINTENANCE SCHEDULE...17
PERIODIC MAINTENANCE CHART...17
LUBRICATION POINTS...18
MAINTENANCE AND TUNE-UP PROCEDURES...19
BATTERY...19
CYLINDER HEAD NUTS AND EXHAUST PIPE BOLTS...20
AIR CLEANER...21
TAPPET CLEARANCE...21
SPARK PLUGS...25
FUEL LINE...26
ENGINE OIL AND OIL FILTER...26
CARBURETORS...27
CLUTCH...27
DRIVE CHAIN...28
BRAKES...30
TIRES...33
STEERING...34
FRONT FORKS...34
REAR SUSPENSION...34
CHASSIS BOLTS AND NUTS...35
03 ENGINE...38
COMPRESSION PRESSURE CHECK ...39
COMPRESSION TEST PROCEDURE...39
OIL PRESSURE CHECK ...40
OIL PRESSURE TEST PROCEDURE...40
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...41
ENGINE REMOVAL AND REINSTALLATION ...42
ENGINE REMOVAL...42
ENGINE REINSTALLATION...47
ENGINE DISASSEMBLY ...48
ENGINE COMPONENTS INSPECTION AND SERVICE ...57
CYLINDER HEAD...57
VALVES...58
CAMSHAFTS...64
CAM CHAIN TENSIONER...66
CYLINDER...67
PISTONS...68
PISTON RINGS...69
PISTON PINS...70
CONRODS...70
CRANKSHAFT AND COUNTER-BALANCER SHAFT...74
COUNTER-BALANCER SHAFT...76
CLUTCH...78
STARTER CLUTCH...79
OIL PUMP...79
TRANSMISSION GEARS...80
ENGINE REASSEMBLY ...84
04 FUEL AND LUBRICATION SYSTEM...100
FUEL TANK AND FUEL COCK...101
FUEL TANK REMOVAL...101
FUEL COCK REMOVAL...101
INSPECTION AND CLEANING...101
CARBURETOR...102
CONSTRUCTION...102
SPECIFICATIONS...103
I.D. NO. LOCATION...104
DIAPHRAGM AND PISTON OPERATION...105
SLOW SYSTEM...106
MAIN SYSTEM...107
STARTER SYSTEM...108
FLOAT SYSTEM...108
FUEL SYSTEM...109
REMOVAL...110
DISASSEMBLY...110
INSPECTION AND ADJUSTMENT...110
NEEDLE VALVE INSPECTION...110
FLOAT HEIGHT ADJUSTMENT...110
REASSEMBLY AND REMOUNTING...110
BALANCE OF CARBURETORS...111
LUBRICATION SYSTEM ...113
OIL PRESSURE...113
OIL FILTER...113
OIL SUMP FILTER...113
ENGINE LUBRICATION SYSTEM CHART...114
05 ELECTRICAL SYSTEM...116
CHARGING SYSTEM...117
DESCRIPTION...117
INSPECTION...119
IGNITION SYSTEM...121
DESCRIPTION...121
INSPECTION...122
STARTER SYSTEM ...126
DESCRIPTION...126
REMOVAL AND DISASSEMBLY...126
INSPECTION...127
REASSEMBLY...128
STARTER RELAY INSPECTION...129
SIDE-STAND/IGNITION INTERLOCK SYSTEM ...129
DESCRIPTION...129
INSPECTION...131
COMBINATION METER ...132
REMOVAL AND DISASSEMBLY...132
INSPECTION...133
LAMPS ...134
HEADLIGHT...134
TAIL/BRAKE LIGHT...134
TURN SIGNAL LIGHT...135
SWITCHES ...135
RELAY...136
STARTER RELAY...136
SIDE-STAND RELAY...136
TURN SIGNAL RELAY...136
BATTERY ...137
SPECIFICATIONS...137
INITIAL CHARGING...137
SERVICING...137
RECHARGING OPERATION BASED ON S.G. READING...138
SERVICE LIFE...139
06 CHASSIS...140
FRONT WHEEL ...141
REMOVAL...141
INSPECTION AND DISASSEMBLY...142
REASSEMBLY AND REMOUNTING...144
FRONT BRAKE ...147
BRAKE PAD REPLACEMENT...147
CALIPER REMOVAL AND DISASSEMBLY...148
CALIPER AND DISC INSPECTION...149
CALIPER REASSEMBLY AND REMOUNTING...150
MASTER CYLINDER REMOVAL AND DISASSEMBLY...150
MASTER CYLINDER INSPECTION...151
MASTER CYLINDER REASSEMBLY AND REMOUNTING...151
FRONT FORK ...153
REMOVAL...153
DISASSEMBLY...154
INSPECTION...156
REASSEMBLY AND REMOUNTING...156
STEERING...159
REMOVAL...159
DISASSEMBLY...160
INSPECTION...160
REASSEMBLY AND REMOUNTING...161
STEERING TENSION ADJUSTMENT...162
IGNITION SWITCH...163
REAR BRAKE...164
BRAKE PAD REPLACEMENT...164
CALIPER REMOVAL AND DISASSEMBLY...165
CALIPER AND DISC INSPECTION...166
CALIPER REASSEMBLY AND REMOUNTING...166
MASTER CYLINDER REMOVAL AND DISASSEMBLY...167
MASTER CYLINDER INSPECTION...168
MASTER CYLINDER REASSEMBLY AND REMOUNTING...169
REAR WHEEL...170
REMOVAL...170
INSPECTION AND DISASSEMBLY...172
REASSEMBLY AND REMOUNTING...173
TIRE AND WHEEL ...176
TIRE REMOVAL...176
INSPECTION...178
TIRE MOUNTING...179
REAR SUSPENSION ...181
SWINGARM...181
SHOCK ABSORBER AND CUSHION LEVER...182
REMOVAL...183
INSPECTION...184
DISASSEMBLY...185
REASSEMBLY INFORMATION...187
REASSEMBLY AND REMOUNTING...188
FINAL INSPECTION AND ADJUSTMENT...190
SHOCK ABSORBER SPRING PRE-LOAD...190
07 SERVICE INFORMATION...192
TROUBLESHOOTING ...193
WIRING DIAGRAM...200
WIRE HARNESS, CABLE AND HOSE ROUTING...202
SPECIAL TOOLS ...216
TIGHTENING TORQUE ...219
SERVICE DATA ...222
08 EMISSION CONTROL INFORMATION...230
EMISSION CONTROL CARBURETOR COMPONENTS ...231
EVAPORATIVE EMISSION CONTROL SYSTEM...232
CANISTER HOSE ROUTING...233
09 GS500EL (’90-MODEL) ...234
SPECIFICATIONS...235
SERVICE DATA...237
WIRING DIAGRAM...245
WIRE ROUTING...247
CABLE ROUTING...249
10 GS500EM (’91-MODEL) ...250
SPECIFICATIONS ...251
SERVICE DATA...252
WIRE HARNESS, CABLE AND HOSE ROUTING...260
11 GS500EN (’92-MODEL) ...262
SPECIFICATIONS...263
SERVICE DATA ...264
WIRING DIAGRAM...272
SPEEDOMETER CABLE ROUTING ...273
12 GS500EP (’93-MODEL) ...274
SPECIFICATIONS ...275
SERVICE DATA...276
13 GS500ER (’94-MODEL) ...286
SPECIFICATIONS ...287
SERVICE DATA ...288
14 GS500ES (’95-MODEL) ...298
SPECIFICATIONS ...299
SERVICE DATA...300
CARBURETOR...309
15 GS500ET (’96-MODEL)...310
SPECIFICATIONS ...311
SERVICE DATA ...312
FRONT BRAKE...319
16 GS500EV (’97-MODEL) ...322
SPECIFICATIONS ...323
SERVICE DATA ...324
WIRING DIAGRAM...333
17 GS500EW/X/Y (’98/’99/’00-MODELS) ...336
SPECIFICATIONS...337
SERVICE DATA...338
18 GS500K1/K2 (’01/’02-MODELS) ...348
SPECIFICATIONS...349
SERVICE DATA...350
19 GS500K3 (’03-MODEL) ...360
SPECIFICATIONS ...361
SERVICE DATA ...363
FRONT BRAKE MASTER CYLINDER ...372
IGNITION SYSTEM ...376
REGULATOR/RECTIFIER ...381
COMBINATION METER ...382
TURN SIGNAL LIGHT ...383
WIRING DIAGRAM ...384
WIRE ROUTING ...387
20 GS500K4/FK4 (’04-MODEL) ...390
SPECIFICATIONS ...392
SERVICE DATA ...394
TIGHTENING TORQUE ...402
ENGINE ...402
CHASSIS ...403
PERIODIC MAINTENANCE CHART ...404
LOWER CRANKCASE ...405
TP (THROTTLE POSITION) SENSOR INSPECTION...406
COWLING (FOR GS500F)...407
FRONT FORK ...408
REMOVAL ...408
DISASSEMBLY ...409
INSPECTION ...410
REASSEMBLY ...411
INSTALLATION ...413
WIRING DIAGRAM ...414
GS500K4/UK4 (P-02, 09, 19, 54) GS500FK4/FUK4 (P-02, 19, 54) ...414
GS500FK4/FUK4 (P-02, 19, 54)...414
GS500K4 (P-24, 28) ...415
GS500FK4 (P-03, 24, 28, 33) ...416
WIRING HARNESS AND HOSE ROUTING ...417
WIRING HARNESS ROUTING ...417
WIRING HARNESS ROUTING (For GS500F)...419
OIL COOLER HOSE ROUTING (For GS500F)...420
CARBURETOR AND AIR CLEANER HOSE ROUTING ...421
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING...422
FRONT BRAKE HOSE ROUTING (For GS500F)...423
21 GS500K5/UK5/FK5/FUK5 (’05-MODEL) ...426
SPECIFICATIONS ...427
SERVICE DATA ...429
CAMSHAFT INSTALLATION & INTERCHANGEABILITY...437
22 GS500/U/F/FUK6-K7 ( '06 -'07 MODELS)...438
SPECIFICATIONS...439
SERVICE DATA...441
STARTER BUTTON...449
WIRING DIAGRAM...450
GS500K6/FK6-K7 (FOR P-02, 09, 19, 54)...450
GS500K6-K7 (FOR P-24, 28)...451
GS500FK6-K7 (FOR P-03, 24, 28, 33)...452
23 GS500FK8 ( '08-MODEL) ...454
SPECIFICATIONS ...455
SERVICE DATA ...456
TIGHTENING TORQUE ...464
24 GS500FK9 ( '09-MODEL)...466
SPECIFICATIONS...467
FRONT WHEEL...468
REAR WHEEL...469
Suzuki GS500 Owner's Manual ('09)...470
Suzuki GS500E (GS500EK, GS500EL, GS500EM, GS500EN, GS500EKP, GS500ER, GS500ES, GS500ET, GS500EV) Manuel D’Entertien '89-'97 (FR)...572
cover...572
part1...575
part2...586
part3...608
part4...671
part5...687
part6...712
part7...764
Suzuki GS500E Service Manual '89-'99 (EN)...801
GS500E SERVICE MANUAL...0
GROUP INDEX...801
GENERAL INFORMATION...803
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES...813
ENGINE...834
FUEL AND LUBRICATION SYSTEM...895
ELECTRICAL SYSTEM...911
CHASSIS...935
SERVICING INFORMATION...986
GS500EL ('90-MODEL)...1024
GS500EM ('91-MODEL)...1040
GS500EN ('92-MODEL)...1051
GS500EP ('93-MODEL)...1065
GS500ER ('94-MODEL)...1077
GS500ES ('95-MODEL)...1088
GS500ET ('96-MODEL)...1100
GS500EV ('97-MODEL)...1113
GS500EW ('98-MODEL)...1127
GS500EX ('99-MODEL)...1148
Suzuki GS500E Twin (GS500E. 487cc. 1989 to 1997) Service Manual '89-'97 (EN)...1162
COVER...1162
TABLE OF CONTENTS...1164
INTRODUCTION...1166
CH 1 ROUTINE MAINT & SERVICING...1175
CH 2 ENGINE, CLUTCH & TRANSMISSION...1197
CH 3 FUEL & EXHAUST SYSTEMS...1255
CH 4 IGNITION SYSTEM...1271
CH 5 FRAME, SUSPENSION & FINAL DRIVE...1277
CH 6 BRAKES, WHEELS & TYRES...1295
CH 7 BODYWORK...1315
CH 8 ELECTRICAL SYSTEM...1319
REFERENCE...1349
TOOLS...1350
MAINT TECHNIQUES...1352
CHEMICALS & LUBRICANTS...1353
TEST CHECKS...1354
STORAGE...1358
FAULT FINDING...1360
TECHNICAL TERMS...1372
CONVERSION FACTORS...1376
INDEX...1377
Suzuki GS500, GS500E Repair Service Manual 1989-2009
