Suzuki GS500 GS500E GS500F Workshop Repair Service Manual 1989-2009 PDF - MSZKGS500OPES.zip

A full factory-level service and repair guide for the Suzuki GS500 and GS500E, complete with Electrical Wiring Diagrams and every technical detail needed to service, troubleshoot, fix, and rebuild the bike just like a trained technician.

The workshop service and repair manual for the Suzuki GS500, GS500E covers:

* 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