Suzuki GS550 / GS550E / GS550L Service Manual, 1976–1980 (P/N 99500-35003-01E)

Suzuki’s GS550 Service Manual, P/N 99500-35003-01E, combines the main manual with integrated GS550 and four-cylinder GS500 supplement sections. This is the seventh edition, dated October 1990; the first edition was published in January 1977.

PDF Search, Bookmarks and Wiring Detail

Navigation and small print: PDF text search is not available. Embedded bookmarks link to the main chapters and supplement sections. Small wiring labels require zooming, and some diagrams are easier to read after rotating the page.

One printable PDF contains 716 pages, including five opening pages, the integrated supplements, the publication page and four otherwise blank pages.

Engine Overhaul, Carburetor Service and Electrical Diagnosis

The following highlights are a selection of the manual’s contents. Other topics include air-cleaner service and control-switch continuity checks.

• Engine repair: Step-by-step engine removal and crankcase disassembly, cylinder-head repair, cam-chain timing, and tensioner service.

• Transmission and clutch: Transmission gear inspection, wet multiplate clutch overhaul, shift-fork checks, and shift-drum removal and reassembly.

• Carburetor service: Mikuni VM22SS and BS32SS overhaul and synchronization, including float-height and fuel-level inspection.

• Steering and suspension: Steering stem maintenance, front fork rebuilds, rear shock absorber inspection, and swingarm bearing replacement.

• Brake repair: Hydraulic caliper and master-cylinder overhaul, brake bleeding, and rear drum brake service.

• Electrical diagnosis: Contact-breaker and transistorized ignition coverage, charging-system tests, starter motor repair, and market-specific wiring diagrams.

This manual was written primarily for workshop mechanics and is also intended as a guide for owners experienced in servicing Suzuki motorcycles.

GS550 and Four-Cylinder GS500 Coverage

The supplements document model-specific changes and refer back to earlier sections for procedures that remain applicable.

The GS500 coverage concerns the four-cylinder models in the 1981 supplement. Market sections distinguish general specifications (E-01), U.S. specifications (E-03), and Canadian specifications (E-28), with additional country-specific data where equipment differs.

Cylinder-Head Work and Camshaft Revisions

Engine coverage extends to valve-guide replacement and reaming, valve-seat refinishing, camshaft journal-clearance inspection, and piston and cylinder wear assessment. The tappet-shim chart lists sizes and part numbers, while the engine chapter identifies components that can be serviced with the engine installed.

A camshaft, sprocket, and bolt revision chart distinguishes the earlier 6 mm fasteners from the later 7 mm arrangement, which does not interchange with either earlier version. This distinction matters when matching replacement camshafts and sprockets.

Valve-timing diagrams and transmission assembly views support the mechanical sections. Compression and oil pump pressure tests accompany the engine inspection material.

VM22SS and BS32SS Fuel Systems

The carburetor sections distinguish the mechanically operated VM22SS from the vacuum-piston BS32SS. BS32SS fuel-circuit section views explain the slow, main, starter, and float systems.

U.S. emission-control sections explain close-tolerance jets and factory-set mixture adjustments, including sealed idle circuits on the BS32SS.

Wheel, Brake and Suspension Differences

Chassis coverage distinguishes spoked and cast wheels, single- and twin-disc front brakes, and rear disc or drum brakes. The GS550D’s spoked-wheel, twin-front-disc configuration is identified separately, and exploded views show the GS550E wheel assemblies.

U.S. and Canadian GS550LZ sections include air-assisted forks. Their reassembly cautions address damage to the Teflon-coated bushings during installation; drive-chain service notes explain how unsuitable cleaning and lubrication products can harm the chain’s O-rings.

Electrical Tests and Workshop References

Charging-system coverage distinguishes separate regulator and rectifier components from the integrated regulator/rectifier unit. Coil-resistance data and signal-generator/ignitor circuit diagrams address the transistorized ignition variants.

Fuel-gauge troubleshooting charts distinguish meter, sending-unit, and wiring faults. Market-specific wiring diagrams are supplemented by wire, cable, and brake-hose routing drawings.

The special-tool listings identify tappet depressor 09916-64510 and carburetor balancer set 09913-13121, so the required workshop equipment can be checked before a repair is planned. Component-specific torque tables, fluid capacities, lubrication requirements, and wear limits accompany the relevant service sections.

Work on these vintage engines, steering assemblies, and brakes requires adherence to the applicable factory tolerances and safety precautions.

Valve-Clearance and Clutch-Wear Preview

The GS550L E-03 service data specify cold intake and exhaust tappet clearance at 0.03–0.08 mm.

For the base GS550 clutch, new drive plates are specified at 2.9–3.1 mm thick, with 2.6 mm as the service limit.