Suzuki GS500 repair Manual, covers 1990-2009
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Sample pages from the Suzuki GS500 repair Manual, covers 1990-2009 manual
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Suzuki Models Covered & Key Technical Specifications
Models: Suzuki 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
Sub-models / Variants: 2-cylinder air-cooled DOHC, 6-speed constant mesh transmission, California models (E-33), Canadian models (E-28), General/International models
Build Years: 1989–2009
Technical Data:
- Engine displacement: 487 cm³
- Engine type: Four-stroke, air-cooled, DOHC, TDCC
- Number of cylinders: 2
- Compression ratio: 9.0:1
- Transmission: 6-speed constant mesh
- Valve clearance (cold): 0.03–0.08 mm (IN & EX)
- Fuel tank capacity: 17.0 L (including 3.5 L reserve)
- Idle speed: 1,200 ± 100 r/min
- Brake fluid: DOT 4
- Spark plug: NGK DPR8EA-9 or ND X24EPR-U9
Suzuki Manual Features & Content Preview
Technical Scope and Service Data for the 1989–2009 Suzuki GS500 Series
- Covers 1989–2009 Suzuki GS500E and GS500F variants, documenting standard, California, and international models including the GS500K9
- Official Suzuki Motor Corporation publication, first edition 1990 with ongoing model supplements through 2009
- Contains 474 pages of technical documentation including torque specifications, wiring diagrams, and engine maintenance sequences
- Downloads to your account within seconds of checkout
- Indexed PDF search covers every chapter and appendix
- Re-download the file any time, no expiration
- This 1990 first edition manual serves as the foundation for the entire 20-year production run of the air-cooled Suzuki GS500 series engine and chassis
Engine and Maintenance Overview
The 1989–2009 Suzuki GS500 service manual provides a structured breakdown of engine, fuel, electrical, and chassis systems across the long-running production lifecycle. Chapters detail the four-stroke DOHC architecture, covering disassembly, inspection, and reassembly steps for the twin-dome combustion chamber and crankshaft counter-balancer. Maintenance sections present interval charts, lubrication points, and technical specifications for daily and long-term upkeep of the bike.
Technical Preview and Specifications
Technical specifications are organized by system to assist with component identification. Cylinder head bolt torque values are documented at 35–40 Nm for the main 10mm nuts in the engine data section. The Suzuki GS500E fuel tank capacity is 17.0 liters, which includes a 3.5-liter reserve capacity. Valve clearance for the intake and exhaust is listed at 0.03–0.08 mm in the tappet specification table. Reference only — always consult a certified technician before performing service on this equipment.
An official 474-page Suzuki OEM workshop manual covering the 1989–2009 GS500 series, documenting engine, chassis, electrical, and fuel-system specifications for the various model-year configurations.
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