2006-2007 Suzuki GS500 Service & Repair Manual

GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2 ENGINE 3 FUELANDLUBRICATIONSYSTEM 4 ELECTRICALSYSTEM 5 CHASSIS 6 SERVICEINFORMATION 7 EMISSION CONTROL INFORMATION 8 FOREWORD The SUZUKI GS500E has been developed as a new generation motorcycle to the GS-models. It is packed with highly advanced design concepts including a New Twin Dome Combustion Chamber, a crankshaft couter-balancer, a fully transistorized ignition system and a full-floater rear suspension. Combined with precise control and easy handling the GS500E provides excellent performance and outstanding riding com fort. This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service SUZUKI motorcycles. Apprentice mechanics and do-it-yourself mechanics, will also find this manual an extremely useful repair guide. This manual contains the most up-to- date information at the time of publication. The rights are reserved to update or make corrections to this manual at any time. IMPORTANT All street-legal Suzuki motorcycles with engine dis- placement of 50 cc or greater are subject to Envi- ronmental Protection Agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includes specific information required to properly inspect and service the GS500E in accordance with all EPA regulations. It is strongly recommended that the chapter on Emis- sion Control, Periodic Servicing and Carburetion be thoroughly reviewed before any type of service work is performed. Further information concerning the EPA emission regulations and U.S. Suzuki’s emission control program can be found in the U.S. SUZUKI EMISSION CONTROL PROGRAM MANUAL/SERVICE BUL- LETIN.

GS500EL (’90-MODEL) 9 GS500EM (’91-MODEL) 10 GS500EN (’92-MODEL) 11 GS500EP (’93-MODEL) 12 GS500ER (’94-MODEL) 13 GS500ES (’95-MODEL) 14 GS500ET (’96-MODEL) 15 GS500EV (’97-MODEL) 16 GS500EW/X/Y (’98/’99/’00-MODELS) 17 GS500K1/K2 (’01/’02-MODELS) 18 GS500K3 (’03-MODEL) 19 GS500K4/FK4 (’04-MODEL) 20 GS500K5/UK5/FK5/FUK5 (’05-MODEL) 21 GS500/U/F/FUK6-K7 (’06-'07 MODELS) 22 SUPPLEMENTS GS500FK (’08 ODEL) 23 8 - M GS500FK9 (’09-MODEL) 24

VIEW OF GS500E RIGHT SIDE LEFT SIDE * Difference between photographs and actual motorcycle depends on markets.

1 GENERALINFORMATION CONTENTS

1-1 GENERAL INFORMATION SERIAL NUMBER LOCATIONS The frame number or V. I. N. (Vehicle Identification Number) CD is stamped on the right side of steering head pipe. The engine serial number ® is located on the right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts. FUEL AND OIL RECOMMENDATIONS FUEL (For U.S.A. model) 1. Use only unleaded or low-lead type gasoline of at least 85 - 95 pump octane {R ~ M )method or 89 octane or higher rated by the research method. 2. Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tert- iary Butyl Ether) is permitted. 4. Use of blended gasoline/alcohol fuel is permitted provid- ed that it contains not more than 10% ethanol. Gaso- line/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present. 5. If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol free unleaded gasoline. 6. Failure to follow these guideline could possibly void ap- plicable warranty coverage. Check with your fuel suppli- er to be sure that the fuel you intend to use meets the requirements listed above. FUEL (For Canadian model) Use only unleaded or low-lead type gasoline of at least 85 - 95 pump octane {R ~ M )method or 89 octane or higher rated by the research method. FUEL (For the other models) Gasoline used should be graded 85 - 95 octane (Research Method) or higher. An unleaded or low-lead gasoline type is recommended.

ENGINE OIL (For U.S.A. model) SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SE or SF under the API (American Petroleum Institute) classification system. The viscosity rating is SAE 10W/40. If an SAE 10W/40 motor oil is not available, select an alternate according to the following chart. ENGINE OIL (For the other models) Be sure that the engine oil you use comes under API (Ameri- can Petroleum Institute) classification of SE or SF and that its viscosity rating is SAE 1 OW 140. If an SAE 1 OW 140 motor oil is not available, select an alternate according to the following chart. FRONT FORK OIL Use fork oil # 10. BRAKE FLUID Specification and classification: DOT 4 WARNING: GENERAL INFORMATION 1·2 •• MULTIGRADE • • • lOW 30 °C TEMP. OF -22 -4 14 32 50 68 86 104 * Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufac- turer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. * Do not use any brake fluid taken from old or used or unsealed containers. * Never re-use brake fluid left over from the previous servicing and stored for a long period. BREAK-IN PROCEDURES During manufacture, only the best possible materials are used and all machined parts are finished to a very high standard, but it is still necessary to allow the moving parts to "BREAK-IN" before subject- ing the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows. • Keep to these break-in engine speed limits. Initial 800 km (500 miles) : Below 5 000 r/min Up to 1 600 km (1 000 miles) : Below 8 000 r/min Over 1 600 km (1 000 miles) : Below 10 000 r/min • Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. However, do not exceed red zone at any time. CYLINDER IDENTIFICATION The two cylinders of this engine are identified as left-hand and right-hand, as viewed by the rider on the seat.

1-3 GENERAL INFORMATION SPECIAL MATERIALS The materials listed below are needed for maintenance work on the GS500E, and should be kept on hand for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery cloth and the like. How to use them and where to use them are described in the text of this manual. MATERIAL For U.S.A. model SUZUKI SUPER GREASE "A" 99000-25030 SUZUKI SILICONE GREASE 99000-25100 SUZUKI MOLY PASTE 99000-25140 SUZUKI BOND NO. 1207B 99104-31140 For other models SUZUKI SUPER GREASE "A" 99000-25010 SUZUKI SILICONE GREASE 99000-25100 SUZUKI MOLY PASTE 99000-25140 SUZUKI BOND NO. 1207B 99000-31140 THREAD LOCK SUPER "1303" THREAD LOCK SUPER "1303" 99000-32030 99000-32030 PART PAGE • Driveshaft oil seal 3-43 • Crankshaft oil seal 3-53 • Oil filter 2-10 • Starter motor oil seal 5-11 • Wheel bearing 6-4 6-33 • Steering stem bearing 6-21 • Sprocket mounting drum 6-34 bearing • Swingarm spacer and dust 6-48 seal cover • Cushion lever bearing and 6-48 dust seal • Cushion lever rod bearing 6-48 and dust seal • Brake caliper axle 6-7 • Valve stem 3-25 • Con rod big end bearing 3-35 • Countershaft and driveshaft 3-43 • Crankshaft journal bearing 3-48 • Camshaft journal 3-56 • Starter motor armature end 5-11 • Counter-balancer journal 3-48 • Crankcase mating surface • Oil pressure switch • Cam end cap and cylinder head cover 3-48 3-53 3-59 • Cam sprocket bolt 3-28 • Cam chain guide bolt and screw 3-29 • 2nd drive gear 3-43 • Gearshift cam retainer screw 3-51

For U.S.A. model THREAD LOCK "1360" 99000-32130 THREAD LOCK "1342" 99000-32050 MATERIAL For other models THREAD LOCK "1360" 99000-32130 THREAD LOCK "1342" 99000-32050 THREAD LOCK SUPER "1303" THREAD LOCK SUPER "1305" 99000-32030 99000-32100 SUZUKI BRAKE FLUID DOT3& DOT4 99000-23110 FDRK DlL .,11 SUZUKI FORK OIL # 10 99000-99044-10G SUZUKI BRAKE FLUID DOT3& DOT4 99000-23110 SUZUKI FORK OIL # 10 99000-99044-10G GENERAL INFORMATION 1-4 PART • Disc plate mounting bolt PAGE 6-5 6-35 • Gearshift cam stopper bolt 3-51 • Oil pump mounting screw 3-52 • Countershaft bearing retainer 3-51 screw • Gearshift fork shaft stopper 3-46 screw • Generator stator mounting 5-7 screw • Generator lead wire guide 5-7 securing screw • Starter motor mounting bolt 3-49 • Oil separator plate mounting 3-47 screw • Starter motor housing screw • Front fork damper rod bolt 5-11 6-17 • Generator rotor mounting bolt 3-50 • Starter clutch allen bolt 3-41 • Brakes 2-14 6-17

1-5 GENERAL INFORMATION MATERIAL PART PAGE For U.S.A. model For other models • Carburetor set plate screw 4-11 ~D ~ , ... ~"" ·.:.. ... "x ........ ~ .... _._ . .... ~ ~ THREAD LOCK CEMENT THREAD LOCK CEMENT 99000-32040 99000·32040 PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when servicing, disassembling and reassembling motorcycles. o Do not run engine indoors with little or no ventilation o Be sure to replace packings, gaskets, circlips, O-rings and cotter pins with new ones. CAUTION: Never reuse a circlip.After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always insure that it is completely seated in its groove and securely fitted. o Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter, and from inside to outside diagonally, to the specified tightening torque. o Use special tools where specified. o Use genuine parts and recommended oils. o When 2 or more persons work together, pay attention to the safety of each other. o After the reassembly, check parts for tightness and operation o Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use gasoline as cleaning solvent. Warning, Caution and Note are included in this manual occasionally, describing the following contents. WARNING .................. The personal safety of the rider or bystanders may be involved. Disregarding this information could result in personal injury. CAUTION ................... These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine. NOTE ......................... This provides special information to make maintenance easier or important instructions clearer.

REPLACEMENT PARTS When you replace any parts, use only genuine SUZUKI replacement parts, or their equivalent. Genuine SUZUKI parts are high quality parts which are designd and built specifical- ly for SUZUKI vehicles. CAUTION: Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems and damage. ASBESTOS INFORMATION Note the following when handling a supply part with the above WARNING LABEL or any part in the parts list in this section which contains asbestos. • Operate if possible out of doors in a well ventilated place. • Preferably use hand tools or low speed tools equipped, if necessary, with an appropriate dust extractor facility. If high speed tools are used, they should always be so equipped. • If possible, dampen before cutting or drilling. • Dampen dust and place it in a properly closed receptacle and dispose of it safely. Any domestic asbestos product to which the above does not apply, but which is likely to release fibres during use should be replaced by new one when worn. 1. Breather cover gasket 2. Clutch cover gasket 3. Generator cover gasket 4. Starter gear cover gasket 5. Oil pan gasket 6. Cam chain tension adjuster gasket GENERAL INFORMATION 1·6 WARNING CONTAINS ASBESTOS Breathing .,bestos duet I, dangerous to health Follow safety Instructions

2006-2007 Suzuki GS500 Service & Repair Manual

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