Suzuki GS500 repair Manual, covers 1990-2009

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Document Details

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Document Number / Seller:
25004 / Robert Bell
File Size:
15.58 MB
File Type:
ZIP
Language:
English
Pages:
474
Printable:
Yes
Category:
Bike
Last updated / verified
Feb 7, 2026

Models Covered & Key Technical Specifications

  • Suzuki GS500 Series (A0098) — 1989–2009 Repository Identifier ⌂ GS500E / GS500EL / GS500EM / GS500EN / GS500EP / GS500ER / GS500ES / GS500ET / GS500EV / GS500EW / GS500EX / GS500EY / GS500K1 / GS500K2 / GS500K3 / GS500K4 / GS500FK4 / GS500K5 / GS500UK5 / GS500FK5 / GS500FUK5 / GS500K6 / GS500UK6 / GS500FK6 / GS500FUK6 / GS500K7 / GS500UK7 / GS500FK7 / GS500FUK7 / GS500FK8 / GS500FK9 Library (Workshop Manual).

  • Technical Volume: 474 pages defines the total documentation depth for the complete service lifecycle.

  • Essential Rating: DOT 4 must be maintained for the glycol-based hydraulic brake system to prevent component damage.

  • Specific Measurement: 17.0 L is required for the total fuel tank capacity including the 3.5 L reserve.

  • Advanced Parameter: 487 cm³ establishes the displacement for the four-stroke DOHC engine architecture.

  • Core Limit: 0.03–0.08 mm signifies the cold tappet clearance required for both intake and exhaust valves.

Professional Workshop Service Manual & Technical Specifications

Integrated Technical Manual Reference: Suzuki GS500 Series A0098

Suzuki GS500 (A0098) — 1989–2009 Blueprint-Vault

Systematic Architecture

To ensure system alignment across the multi-year production cycle, the documentation provides a layered overview of the air-cooled parallel-twin configuration and its evolution through specific model years. Within the component context, mechanical assemblies are cross-referenced with various market-specific sub-codes to facilitate accurate part identification. Governing operational sequences, the technical framework addresses the integration of transistorized ignition systems alongside traditional mechanical valve actuation designs.

Advanced Parameters

Adverbial inversion, rigorously validating system logic serves as the primary method for navigating the extensive supplemental chapters that account for iterative changes in carburetor design and suspension damping. For maintenance professionals, the structural layout emphasizes the relationship between individual chassis components and the central tubular frame architecture. Fuel delivery calibration necessitates adherence to the original manufacturer guidelines to maintain the integrity of the emission control systems outlined in the early chapters.

Diagnostic Threshold

Participial phrase, identifying structural variations between the E and F series enables a precise understanding of aerodynamic fairing integration and its impact on service access points. To facilitate comprehensive oversight, the repository details the interaction between the constant-velocity intake system and the high-tension electrical leads. Establishing a consistent diagnostic methodology requires a thorough review of the electrical schematics and wiring loom paths defined within the core engineering sections.

Scope Category System Groupings Document Scope Areas
Powerplant Valve Train, Lubrication, Cooling Core Engine Mechanics
Drivetrain Clutch, Transmission, Final Drive Power Transfer Logic
Electrical Ignition, Charging, Lighting Signal & Power Distribution
Chassis Suspension, Brakes, Steering Geometry & Stability Control
Fuel/Emission Carburetion, Exhaust, EPA Compliance Mixture & Output Regulation

FAQ

Q: Which specific model variant introduced the redesigned fuel tank capacity? A: GS500FK9 (’09-MODEL) incorporates a revised fuel tank capacity of 20.0 L (5.3 US gal) for specific market codes such as P-03, 24, and 28. keyboard_arrow_down

Q: Identify the required engine oil volume for a standard overhaul procedure? A: 3 200 ml (3.4 US qt) is the specified volume for a complete engine overhaul, whereas a standard oil and filter change requires 2 900 ml.

Q: Verify the torque specification for the front wheel self-lock nut on later series? A: 49 N·m (4.9 kgf-m / 35.5 lbf-ft) is the mandatory torque value for the front wheel axle nut on the GS500FK9 and related variants.

Q: Determine the correct spark plug gap for the 1989–2009 production range? A: 0.6–0.7 mm (0.024–0.028 in) must be maintained for the NGK DPR8EA-9 or DENSO X24EPR-U9 plugs to ensure optimal ignition timing.

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Reviews (4)

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Rated 4 out of 5 stars
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Rated 4 out of 5 stars
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New
This service manual is a must-have! The detailed instructions made my maintenance tasks much easier. Highly recommend!
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New
The manual covers everything you need to know about the GS500. I appreciate the troubleshooting section—it saved me a lot of time.