Suzuki GS500ET SERVICE MANUAL

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG1 CYLINDER HEAD COVER

Ref No

Part No

Description

Suzuki Worldwide Motorcycle-ATV Page: 1 of 67

1 2 3 4 5 7 8 9 10 11 12

11171-01D02 11173-15502 09106-07010 09106-07009 09280-15006 11176-33201 11186-15501 11177-15510-H17 01550-06253 09404-06413 11400-01861

Cover, Cylinder Head Gasket, Head Cover Bolt (l:19) Bolt (l:5.5) O Ring Cover, Breather Separator, Oil Breather Gasket, Breather Cover Bolt Clamp Gasket Set

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG2 CYLINDER HEAD

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 2 of 67

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 16 17 18 19 20 21 22 23 24

11100-01D01 11115-45740 09381-10003 09103-06071 09206-08001 01550-06123 09168-06023 11141-01D10 11143-06B00 01550-06303 04211-11189 09159-10069 09159-10026 09168-10031 09482-00334 09482-00335-111 26431-45002 26441-49000 26451-45000 09289-05002 09128-05101 13110-01D00 09280-40003 02112-36203 09402-54208

Head Assy, Cylinder

• . Guide, Valve

• . Ring, Valve Guide

• . Bolt (6x39)

• . Pin

• . Bolt, Oil Gallery

• . Gasket Gasket, Cylinder Head O Ring, Cylinder Head Bolt Pin Nut Nut Gasket Spark Plug (ngk,dpr8ea-9) Spark Plug (nd,x24epr-u9) Gear, Tacho. Driven (nt:10) Sleeve Seal Band Oil Seal Screw Pipe, Intake O Ring Screw Clamp

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG3 CYLINDER

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 3 of 67

Description

1 2 3 4 5

11210-01D01 09108-10112 09108-10111 04211-11189 11241-01D00

Cylinder Stud Bolt (l:168) Stud Bolt (l:178) Pin Gasket, Cylinder

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG4 CRANKCASE

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 4 of 67

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

11300-44881 09206-13004 09206-11005 07130-08703 09103-08182 09103-08134 09103-08230 01550-08653 01550-08453 09103-06033 09103-06067 01550-06903 01550-06703 01550-06653 01550-06507 01550-06453 09168-08008 09493-22010 09493-32002 09493-24008 09280-03003 09103-10137 09103-10212 09103-10127 09103-10278 09159-10078 11611-01D10 11610-45410 11521-44100 02112-06123

Crankcase Set

• . Pin

• . Bolt (8x70)

• . Bolt (8x125)

• . Bolt (8x110)

• . Bolt (8x100)

• . Bolt (8x65)

• . Bolt (8x45)

• . Bolt (6x125)

• . Bolt (6x105)

• . Bolt (6x90)

• . Bolt (6x70)

• . Bolt (6x65)

• . Bolt (6x50)

• . Bolt (6x45)

• . Gasket

• . Jet, Oil Gallery Mission

• . Jet, Oil Galy. Bal. Shaft

• . Jet, Oil Gallery Cylinder

• . O Ring Bolt (10x255) Bolt (10x240) Bolt (10x170) Bolt (10x160) Nut Spacer (l:16.8) Spacer (l:65) Plate, Oil Separator Screw

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG5 CRANKCASE COVER

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 5 of 67

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

11341-01D00 11482-44110 04211-13189 01547-06557 01547-06357 01547-06257 11970-44110 09280-26006 09247-14026 09168-14002 11381-01D00 01547-05167 68233-01D00 11351-01D00 11483-44110 04211-13189 01547-06357 68233-01D00 11361-01D00 04211-09129 01547-06657 01547-06507 01547-06407 11382-44111 01547-05087 11387-01D00 02122-05127 37820-33D00

Cover, Clutch Gasket, Clutch Cover Pin Bolt Bolt Bolt Gauge, Oil Level O Ring Plug, Oil Check Gasket Cover, Contact Breaker Bolt Emblem Cover, Generator Gasket, Generator Cover Pin Bolt Emblem Cover, Engine Sprocket Pin Bolt Bolt Bolt Cover, Starter Motor Bolt Cap, Clutch Release Screw Switch, Oil Pressure

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG6 OIL FILTER - OIL PUMP

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 6 of 67

Description

1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

11511-44100 11489-44110 01550-06303 09247-14001 09168-14002 16440-05C01 16510-45040 16518-45000 09440-32004 16512-45D00 01421-06208 08313-20063 16520-01D01 01570-06123 16400-44100 09280-13004 02112-06253 16331-01D10 08221-10185 09261-04009 08331-31106

Pan, Oil Gasket, Oil Pan Bolt Plug, Oil Drain Gasket Regulator, Oil Filter, Engine Oil O Ring Spring Cap, Engine Oil Filter Stud Bolt Nut Strainer, Engine Oil Screw Pump Assy, Engine Oil O Ring Screw Gear, Driven (nt:27) Washer Pin Circlip

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG7 CRANKSHAFT

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 7 of 67

Description

1 2 3 3 3 3 3 3 4 5 6 6 6 6 6 6 7 8 9 10 11 12 13 14 15 16 17 17

12160-44100 09159-08033 12164-01D01-0A0 12164-01D01-0B0 12164-01D01-0C0 12164-01D01-0D0 12164-44100-025 12164-44100-050 12220-01D02 09202-03016 12229-01D01-0A0 12229-01D01-0B0 12229-01D01-0C0 12229-01D01-0D0 12229-44100-025 12229-44100-050 12228-44106 21111-44100 09140-24007 09164-25001 08341-31059 09283-22015 12111-01D01-0F0 12140-01D20 12151-45501 09381-18002 12100-01D00-050 12100-01D00-100

Rod Assy, Connecting

• . Nut Bearing, Crank Pin (green) Bearing, Crank Pin (black) Bearing, Crank Pin (brown) Bearing, Crank Pin (yellow) Bearing, Crank Pin (us:0.25) Bearing, Crank Pin (us:0.5) Crankshaft

• . Pin Bearing, Crankshaft (green) Bearing, Crankshaft (black) Bearing, Crankshaft (brown) Bearing, Crankshaft (yellow) Bearing, Crankshaft (us:0.25) Bearing, Crankshaft (us:0.5) Bearing, Thrust Gear, Primary Drive (nt:28) Nut Washer Key Oil Seal, Rh Piston Ring Set, Piston Pin, Piston Circlip Piston Set (os:0.5) Piston Set (os:1.0)

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG8 CRANKSHAFT BALANCER

Ref No

Part No

Description

Suzuki Worldwide Motorcycle-ATV Page: 8 of 67

1 2 3 4 5 6 7 8 9 9 9 9

12650-01D01 12666-44000 09160-24026 09440-15007 09201-08001 09180-24009 09160-12039 01500-12203 12229-01D01-0A0 12229-01D01-0B0 12229-01D01-0C0 12229-01D01-0D0

Balancer, Crankshaft Gear, Driven (nt:46) Washer Spring Pin Spacer Washer Bolt Bearing (green) Bearing (black) Bearing (brown) Bearing (yellow)

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG9 STARTER CLUTCH

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 9 of 67

Description

1 2 3 3 3 4 5 6 7 8

12611-01D00 09206-13003 12600-44831 12600-44832 12600-44833 09261-15001 09440-04015 12633-31000 07130-08163 12649-45000

Gear, Starter Idle (nt:55/19) Pin Clutch Set, Starter Clutch Set, Starter Clutch Set, Starter

• . Roller

• . Spring

• . Piece, Push Bolt Shim

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG10 CAM SHAFT - VALVE

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 10 of 67

Description

1 2 3 3 3 3 4 5 6 7 8 9 10 10 10 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 24 25 26

12711-01D00 12710-01810 08211-22301 09160-22074 09160-22075 09160-22076 12740-45042 12748-44000 09111-06027 12747-44000 12721-01D00 12720-01810 08211-22301 09160-22074 09160-22075 09160-22076 12750-45041 12748-44000 09111-06027 12747-44000 12891-15500 12891-15500 12911-01D00 12912-01D00 12920-44110 12931-45000 12932-45010 12933-45001 09289-07002 12892-45000-215 12892-45000-220 12892-45000-225 12892-45000-230 12892-45000-235 12892-45000-240 12892-45000-245 12892-45000-250 12892-45000-255 12892-45000-260 12892-45000-265 12892-45000-270 12892-45000-275 12892-45000-280 12892-45000-285 12892-45000-290 12892-45000-295 12892-45000-300 12892-45000-305 12892-45000-310 12800-45811 99000-69521

Cam Shaft, Intake Cam Shaft Set, Intake

• . Washer (t:1.0)

• . Washer (t:1.1)

• . Washer (t:1.2)

• . Washer (t:1.3) Sprocket (nt:30) Pin Bolt Washer Cam Shaft, Exhaust Cam Shaft Set, Exhaust

• . Washer (t:1.0)

• . Washer (t:1.1)

• . Washer (t:1.2)

• . Washer (t:1.3) Sprocket (nt:30) Pin Bolt Washer Tappet, Intake Tappet, Exhaust Valve, Intake Valve, Exhaust Spring Set, Valve Retainer, Spring Cotter, Valve Seat, Spring Oil Seal Shim, Tappet (t:2.15) Shim, Tappet (t:2.20) Shim, Tappet (t:2.25) Shim, Tappet (t:2.30) Shim, Tappet (t:2.35) Shim, Tappet (t:2.40) Shim, Tappet (t:2.45) Shim, Tappet (t:2.50) Shim, Tappet (t:2.55) Shim, Tappet (t:2.60) Shim, Tappet (t:2.65) Shim, Tappet (t:2.70) Shim, Tappet (t:2.75) Shim, Tappet (t:2.80) Shim, Tappet (t:2.85) Shim, Tappet (t:2.90) Shim, Tappet (t:2.95) Shim, Tappet (t:3.00) Shim, Tappet (t:3.05) Shim, Tappet (t:3.10) Shim Set Inc.no.24-1~24-20(3pcs.each)

• . Case

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG11 CAM CHAIN

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 11 of 67

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14

12760-45040 12771-45052 12782-49200 02112-05103 12791-45040 01550-06123 09168-06023 12810-01D00 12814-44101 12830-01D11 12838-38200-H17 12839-38200 12837-24A10 07130-06253

Chain, Cam Shaft Drive (120l) Guide, Cam Chain No.1 Guide, Cam Chain No.2 Screw Guide, Cam Chain No.3 Bolt Washer Tensioner, Cam Chain Cushion Adjuster Assy, Tensioner

• . Gasket Plug Gasket, Adjuster Bolt

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG12 CARBURETOR

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 12 of 67

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53

13201-01D20 13202-02D60 13604-44080 13551-01D00 13382-42A00 13394-40D20 13417-42A00 13502-01D00 13501-01D00 13507-17C01 13387-47010 13550-01D00 13573-44B00 13508-17C00 13671-05A40 13550-01D10 13556-44B00 13247-13A00 09492-40014 02112-05123 13509-17C00 13258-44B00 13250-44B00 13374-46710 09494-00748 09491-24013 13383-01D10 13370-44B00 13374-44080 13267-14D10 13375-14D10 13427-38300 13411-01D00 13418-17C00 13418-17C10 13417-09110 13574-01D00 13574-28A00 02112-75163 13557-47070 13617-44080 13279-47070 13268-47070 13291-29900 13295-29900 13268-96110 13271-44B00 13267-44B00 13628-01D00 02112-05123 13684-01D10 13628-01D10 13683-17C30

Carburetor Assy, Lh Carburetor Assy, Rh

• . Screw

• . Valve, Throttle (120)

• . Ring

• . E Ring

• . Spring

• . Cover, Diaphragm

• . Valve, Piston

• . Diaphragm

• . Ring

• . Shaft Assy

• . Spring

• . Cap

• . Clip

• . Shaft Assy

• . Seal

• . Screw, Drain

• . Jet, Pilot (40)

• . Screw

• . O Ring

• . Gasket, Float Chamber

• . Float Assy

• . O Ring

• . Jet, Needle (o-2)

• . Jet, Main (122.5)

• . Needle, Jet (5dh9-3)

• . Valve Assy, Needle

• . O Ring

• . Adjuster

• . Spring

• . Washer

• . Plunger Assy

• . Cap

• . Holder, Guide

• . Spring

• . Ring

• . Screw

• . Washer

• . E Ring

• . Screw, Pilot (2 1/4)

• . Spring

• . Washer

• . O Ring Spring Spring Screw Plate Screw Hose (5x9x350) Plate Hose Assy

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG12 CARBURETOR

Ref No

54 55 56 57 58

Part No

13673-44B00 13685-44B00 13413-01D00 13439-17C00 09401-08410

Suzuki Worldwide Motorcycle-ATV Page: 13 of 67

Description

Seal Nipple Lever Holder Clip

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG13 AIR CLEANER

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 14 of 67

Description

1 2 3 4 5 6 7 8 9 10 11 12

13700-01D01 13780-01D00 02142-05087 13881-01D00 09402-68208 09352-11153-600 09401-14301 13870-21458 09401-13409 09404-06404 02112-76163 09404-06433

Cleaner Assy, Air

• . Filter Assy

• . Screw

• . Tube, Outlet

• . Clamp

• . Tube, Breather

• . Clip

• . Tube, Drain

• . Clip

• . Clamp Screw Clamp

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG14 MUFFLER

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 15 of 67

Description

1 2 3 4 5 6 7 8

14181-01D00 07120-08403 14301-01DA0 09103-08256 09160-08002 09180-08152 09320-12048 08316-10083

Gasket, Exhaust Pipe Bolt Muffler Assy Bolt (8x40) Washer (8.5x29x1.6) Spacer (8.6x12x20.1) Cushion Nut

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG15 CLUTCH

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 16 of 67

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

21200-44102 08211-25381 21411-44101 09140-20002 09167-20009 09160-20015 21441-37400 21451-28C30 21462-14301 09440-20019 09100-06145 21414-01D00 23121-44100 09263-15003 09160-15045 16321-01D10 09261-06002 08331-31383 23110-44111 23111-24A01 09285-06011 23117-44102 01500-06123 23200-01D00 09134-06010 08310-00067 03141-06163 09443-08001

Gear, Primary Driven (nt:76) Washer Hub, Sleeve Nut Washer Washer (20x44x3) Plate, Drive Plate, Driven Disk, Pressure Spring Bolt Spacer Piece, Push Bearing (15x28x2) Washer (15x28x1) Gear, Oil Pump Drive (nt:39) Pin Circlip Rod, Push Rh Rod, Push Lh Oil Seal (6x34x7-10) Holder, Oil Seal Bolt Screw Assy, Release

• . Screw

• . Nut Screw Spring

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG16 TRANSMISSION

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 17 of 67

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

24121-01D00 24221-44001 24231-01D00 24251-01D00 09300-25023 24260-01D00 08211-25341 09380-25010 09262-25105 09390-62012 09263-20026 04221-07129 24741-44102 02122-06163 24131-01D00 24310-44000 08211-20341 24321-44004 09301-25001 09380-25010 24331-44002 09167-25012 09167-25013 09380-25010 24341-44002 09167-25012 09169-25001 09380-25010 24351-44001 24361-44002 09390-62012 09283-32015 09263-20028 09262-25105 09282-32002 27511-01D01 27531-01D10 08331-31256 27600-01C10-110

Countershaft (nt:13) Gear, 2nd Drive (nt:18) Gear, 3/4 Drive (nt:21/24) Gear, 5th Drive (nt:26) Bush Gear, 6th Drive (nt:27) Washer Circlip Bearing, Rh C Ring Bearing, Lh Pin Holder, Bearing Screw Driveshaft Gear, 1st Driven (nt:32) Washer Gear, 2nd Driven (nt:32) Bush Circlip Gear, 3rd Driven (nt:29) Washer Lock Washer Circlip Gear, 4th Driven (nt:27) Washer Lock Washer Circlip Gear, 5th Driven (nt:25) Gear, 6th Driven (nt:23) C Ring Oil Seal (32x62x7) Bearing, Rh Bearing, Lh Oil Seal Sprocket, Engine (nt:16) Spacer (l:32.7) Circlip Chain, Drive (did520vs2x110le)

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG17 GEAR SHIFTING

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 18 of 67

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

25211-44001 25221-44001 25231-44000 25411-18900 02142-06083 08211-06141 25311-01D00 09261-04001 09209-04013 09181-26001 25322-44000 02112-06163 25341-33300 09111-06054 01500-06163 09263-40001 25350-44000 09443-09007 25351-30010 25354-30000 09440-06020 09168-14002 25510-44100 09448-13008 08332-11076 09444-26012 09180-12068 25671-01000 09285-12002 25600-01D02 25652-20C00 01500-06207 37720-47D00 09280-26003 02112-75203 09209-05011 09440-04010

Fork, Gear Shifting No.1 Fork, Gear Shifting No.2 Fork, Gear Shifting No.3 Shaft, Gear Shifting Fork Screw Washer Cam, Gear Shifting Pin Pin Washer (2.6x32.5x0.3) Holder, Drive Pin Screw Guide, Cam Bolt Bolt Bearing (40x47x12) Stopper, Cam No.1 Spring Stopper, Cam No.2 Holder, Spring Spring Gasket Shaft, Gear Shifting Spring E Ring Spring Spacer (12x20x15.3) Stopper Oil Seal (12x22x9) Lever Assy, Gear Shifting

• . Rubber Bolt Body, Switch O Ring (d:2.4,id:26.2) Screw Contact Spring

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG18 STARTING MOTOR

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 19 of 67

Description

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

31100-20C00 31310-27A01-H17 31153-43400 31170-43400 31264-44110 31132-27A01 31135-65010 31130-38300 31172-38300 31171-38300 31143-38300 31281-88C00 31156-38300 09128-06024 09280-24003 08361-35066

Motor, Starting

• . Armature

• . Oil Seal

• . Shim Set

• . O Ring

• . Brush Holder Assy

•• .. Spring

• . Brush

• . Bushing (a)

• . Bushing (b)

• . O Ring

• . Bolt

• . O Ring Bolt O Ring (d:3,id:24.5) Nut

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG19 GENERATOR

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 20 of 67

Description

1 2 3 4 5 6 7 8 9

31401-47030 31402-45030 02112-35303 09103-12004 31497-45000 02112-05083 31498-45000 02112-06103 09404-06429

Stator Rotor Screw Bolt (12x40) Clamp Screw Clamp Screw Clamp (l:45)

Catalogue Title:

GS500ET (GS500ET E28)

Block No. Block Title.

FIG20 SIGNAL GENERATOR

Ref No

Part No

Suzuki Worldwide Motorcycle-ATV Page: 21 of 67

Description

1 2 3 4 5 6 7

32900-01D20 02142-06163 33110-44420 33120-01D00 09103-06064 02112-05103 09404-06429

Igniter Screw Signal Generator Assy Rotor, Signal Bolt (6x60) Screw Clamp (l:45)