🏷️ Basic Information Identification Make: Suzuki Model: GS500 / GS500E Model Code: GS500, GS500E Codes Product Code: Suzuki GS500 GS500E 1989-1999 Service Repair Manual 👋 Introduction Market Position Target Audience: Suzuki GS500/GS500E owners, independent repair shops, DIY mechanics Value Proposition: Provides dealer-level diagnostic and repair information for cost-effective maintenance and repair Competitive Analysis Comparison To Other Manuals: Offers more comprehensive and detailed technical information than generic Haynes or Clymer manuals, mirroring official factory service manuals Key Features Content Type: Official dealer technician information, detailed illustrations, clear text, comprehensive diagrams Ease Of Use: Designed for individuals with basic mechanical knowledge, with clear and concise instructions 📋 Manual Details Coverage Areas Applicable Years: 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Page Count Estimated Page Count: Highly comprehensive (exact number not specified, typical for dealer-level manuals) Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: PDF Download Type: Free Download (Digital) Compatibility Operating Systems: Windows, macOS, Linux 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, troubleshooting, disassembly, assembly, tuning Fuel System: Carburetor tuning, fuel tank, fuel pump, fuel lines Ignition System: Ignition timing, spark plugs, ignition coils, CDI unit Clutch: Clutch operation, maintenance, disassembly, assembly, replacement Transmission: Gearbox inspection, maintenance, troubleshooting, disassembly, assembly Drivetrain: Chain and sprockets maintenance, rear hub Suspension: Front fork service (oil change, seal replacement), rear shock absorber inspection and replacement Brakes: Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, bleeding procedures Wheels And Tires: Tire inspection, pressure recommendations, wheel bearing service Electrical System: Wiring diagrams, battery maintenance, charging system (stator, rectifier/regulator), starter motor, lighting, instrumentation Cooling System: Air-cooled system, engine heat management Exhaust System: Exhaust pipe and muffler inspection, gasket replacement Frame And Bodywork: Frame inspection, body panel removal and installation, seat, fuel tank mounting Steering: Handlebar, steering stem bearings service and adjustment Procedures Included Routine Maintenance: Oil changes, filter replacement, chain adjustment, spark plug inspection/replacement, air filter cleaning/replacement Troubleshooting: Diagnostic procedures for common and uncommon problems across all systems Disassembly Assembly: Complete step-by-step guides for component removal and installation Rebuilds: Engine, carburetor, brake system, and fork rebuild procedures Adjustments: Carburetor synchronization, valve clearance adjustment, clutch and throttle cable adjustment Special Tools: Identification and usage of specialized tools required for specific repairs Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, component testing, electrical system tracing Rebuild Scope: Full engine and gearbox rebuilds, suspension overhauls, brake system overhauls Specification Detail: Comprehensive torque specifications, clearances, and tolerances for all major components Electrical Schematics: Detailed wiring diagrams with component identification and wire color codes Bulletins Recalls: Inclusion of Technical Service Bulletins (TSBs) and recall information 📊 Manual Specifications File Format PDF Quality: High-resolution, clear text and images, searchable content Print Quality Printable: Printable pages for offline use Binding Type Binding: Not applicable (Digital PDF) Paper Type Paper Type: Not applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, Air-cooled, DOHC, Parallel-twin Displacement: 487 cc (30.0 cu. in.) Bore X Stroke: 74.0 mm x 56.6 mm (2.91 in x 2.23 in) Compression Ratio: 9.0:1 Valve Arrangement: DOHC, 4 valves per cylinder Performance Horsepower Approx: Approx. 48-52 HP @ 9000 RPM (varies slightly by year/market) Torque Approx: Approx. 30-33 lb-ft @ 7000 RPM (varies slightly by year/market) Fuel System Carburetion: Twin Mikuni CV carburetors (e.g., VM26SS on earlier models, BST36 on later models) Fuel Capacity: 17.0 L (4.5 US gal) Lubrication System Oil Type Spec: API SE, SF, SG or SH; SAE 10W-40 or 20W-50 (refer to manual for exact specification) Oil Capacity W Filter: Approx. 2.6 L (2.7 US qt) Oil Filter Part Number Example: Suzuki: 16510-07300 (Verify for specific model year) 🔧 Transmission Standard Transmission Type: Constant mesh 6-speed, sequential manual Final Drive: Chain Drive Features Gear Ratios Example: 1st: 2.750, 2nd: 1.875, 3rd: 1.409, 4th: 1.160, 5th: 0.960, 6th: 0.833 (Refer to manual for exact ratios) Transmission Oil Type Spec: API GL-4 SAE 80W-90 gear oil (Refer to manual for exact specification) Transmission Oil Capacity: Approx. 1.7 L (1.8 US qt) 📐 Dimensions Exterior Overall Length: Approx. 2,130 mm (83.9 in) Overall Width: Approx. 760 mm (29.9 in) Overall Height: Approx. 1,105 mm (43.5 in) Wheelbase: Approx. 1,435 mm (56.5 in) Weights Dry Weight: Approx. 161 kg (355 lbs) Wet Weight: Approx. 175 kg (386 lbs) (Approximate, with full fluids) Max Load: Refer to manual for rider and cargo limits Wheels And Tires Front Tire Size: 110/70-17 M/C 54H Rear Tire Size: 130/80-17 M/C 65H Wheel Type: Cast Aluminum Alloy Wheelbase Bolt Pattern: Not applicable (Motorcycle, spoked wheels or solid hubs) 🛡️ Safety Features Ratings Crash Test Results: Not applicable (Motorcycle safety is primarily rider-dependent and system-based) Active Features Braking System: Hydraulic disc brakes front and rear Front Brake Spec: Single 310 mm disc with dual-piston caliper Rear Brake Spec: Single 250 mm disc with dual-piston caliper...