Suzuki T500-II / GT500A Service Manual

Suzuki T500-II and GT500A service manual covering diagnostics and maintenance procedures. Includes technical specifications and part information. PN T500-GT500A

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Document Details

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Document Number / Seller:
30674 / Mary Martinez
File Size:
40.59 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Motorbike
Last updated / verified
Jan 24, 2026

Models Covered & Key Technical Specifications

Suzuki T500-II / GT500A (T500-GT500A) - 1969 / N/A Technical Reference | Series Manual. Section Measured End Play: 0.065-0.075 mm establishes the minimum crankshaft end play. Fundamental Power Framework: For optimal operation, 47 hp @ 7,000 rpm defines the maximum engine output. Baseline Ambient Limits: The ambient operating temperature range is 10-30°C for best performance. Integral Dimensional Limits: The overall length is 2,206 mm for standard road handling. Operational Torque Data: 375 kg-cm signifies the front axle nut tightening torque. Critical Measurement Bounds: The front brake disc thickness requires 6 mm for safe operation.

Professional Workshop Service Manual & Technical Specifications

Practical Service Operator's Manual: Suzuki T500-II Motorcycle Workshop Manual - Factory Diagnostics & Maintenance Knowledge-Base

Performance-Values: Suzuki T500-II / GT500A // Product-Line: Motorcycle / Engine Logic // Performance-Values: 179 kg (395 lb) weight.

Service-Nexus Rating Calibration-Data
Engine Specifications 47 hp @ 7,000 rpm 8-9kg/cm² (114-128 lb/in²) @ 1,200 rpm
Transmission 5-speeds, constant-mesh 4.79 : 1 overall reduction ratio
Chassis 1,125 mm (44.3 in) Telescopic fork with hydraulic damper
Electrical 12V 7 AH Flywheel magneto
Capacities 1.8 lit (3.2 US/1 Imp pt) Reserve 3.7/3.1 lit (4.5/3.7 US/1 Imp gal)

Torque Statement: ...documents torque specifications for the front axle nut to ensure thread engagement security.

Repair data is categorized into the following major sections:

  • Engine (8-1 to 8-25)
  • Transmission (8-22)
  • Chassis (9-1 to 9-7)
  • Electrical Equipment (10-1 to 10-6)

Thoroughly requiring comprehensive and accurate information for servicing your motorcycle, this manual provides detailed procedures for disassembly, inspection, repair, and reassembly. Coverage includes engine, transmission, chassis, and electrical systems. The document includes coverage of specific diagnostic procedures and troubleshooting guides to help identify and resolve potential issues. Maintenance schedules and specifications are clearly outlined. This manual documents torque specifications for critical components to ensure proper assembly and reliable operation. Technical data and diagrams are provided for clarity and ease of use.

FAQ

Check the **standard** component identification for the clutch release lever adjustment. keyboard_arrow_down

4 mm (0.16 in) is the specified play for the clutch release lever, adjusted via the cable adjuster and lock nut.

What does the **necessary** adjustment procedures detail for the ignition timing? keyboard_arrow_down

24° B.T.D.C. is the specified ignition timing, adjusted by rotating the stator and aligning the timing marks on the stator and crankcase.

Reference the **recommended** pressure specifications for the tires. keyboard_arrow_down

1.6 kg/sq cm (23 lb/sq in) for the front and 1.9 kg/sq cm (27 lb/sq in) for the rear is recommended for solo riding.

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Reviews (3)

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Rated 4 out of 5 stars
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This manual is incredibly detailed and easy to follow. The troubleshooting tips helped me fix a persistent issue quickly! Great support from the team during the download process too!
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The step-by-step repair instructions are a lifesaver! I had a smooth download experience, and the response from customer support was impressive. Highly recommend!