User manual SUZUKI GS500ET - SERVICE MANUAL

Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description 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 Page: 1 of 67 GS500ET (GS500ET E28) FIG1 CYLINDER HEAD COVER Ref No 1 2 3 4 5 7 8 9 10 11 12 Part No 11171-01D02 11173-15502 09106-07010 09106-07009 09280-15006 11176-33201 11186-15501 11177-15510-H17 01550-06253 09404-06413 11400-01861 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description 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 Page: 2 of 67 GS500ET (GS500ET E28) FIG2 CYLINDER HEAD Ref No 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 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Cylinder Stud Bolt (l:168) Stud Bolt (l:178) Pin Gasket, Cylinder Page: 3 of 67 GS500ET (GS500ET E28) FIG3 CYLINDER Ref No 1 2 3 4 5 Part No 11210-01D01 09108-10112 09108-10111 04211-11189 11241-01D00 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Crankcase Set · . Pin · . 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 Page: 4 of 67 GS500ET (GS500ET E28) FIG4 CRANKCASE Ref No 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 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description 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 Page: 5 of 67 GS500ET (GS500ET E28) FIG5 CRANKCASE COVER Ref No 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 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description 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 Page: 6 of 67 GS500ET (GS500ET E28) FIG6 OIL FILTER - OIL PUMP Ref No 1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description 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) Page: 7 of 67 GS500ET (GS500ET E28) FIG7 CRANKSHAFT Ref No 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 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Balancer, Crankshaft Gear, Driven (nt:46) Washer Spring Pin Spacer Washer Bolt Bearing (green) Bearing (black) Bearing (brown) Bearing (yellow) Page: 8 of 67 GS500ET (GS500ET E28) FIG8 CRANKSHAFT BALANCER Ref No 1 2 3 4 5 6 7 8 9 9 9 9 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Gear, Starter Idle (nt:55/19) Pin Clutch Set, Starter Clutch Set, Starter Clutch Set, Starter · . Roller · . Spring · . Piece, Push Bolt Shim Page: 9 of 67 GS500ET (GS500ET E28) FIG9 STARTER CLUTCH Ref No 1 2 3 3 3 4 5 6 7 8 Part No 12611-01D00 09206-13003 12600-44831 12600-44832 12600-44833 09261-15001 09440-04015 12633-31000 07130-08163 12649-45000 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description 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 Page: 10 of 67 GS500ET (GS500ET E28) FIG10 CAM SHAFT - VALVE Ref No 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 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description 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 Page: 11 of 67 GS500ET (GS500ET E28) FIG11 CAM CHAIN Ref No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description 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 · . Ring · . Screw · . Washer · . E Ring · . Screw, Pilot (2 1/4) · . Spring · . Washer · . O Ring Spring Spring Screw Plate Screw Hose (5x9x350) Plate Hose Assy Page: 12 of 67 GS500ET (GS500ET E28) FIG12 CARBURETOR Ref No 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 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Seal Nipple Lever Holder Clip Page: 13 of 67 GS500ET (GS500ET E28) FIG12 CARBURETOR Ref No 54 55 56 57 58 Part No 13673-44B00 13685-44B00 13413-01D00 13439-17C00 09401-08410 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Cleaner Assy, Air · . Filter Assy · . Screw · . Tube, Outlet · . Clamp · . Tube, Breather · . Clip · . Tube, Drain · . Clip · . Clamp Screw Clamp Page: 14 of 67 GS500ET (GS500ET E28) FIG13 AIR CLEANER Ref No 1 2 3 4 5 6 7 8 9 10 11 12 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Gasket, Exhaust Pipe Bolt Muffler Assy Bolt (8x40) Washer (8.5x29x1.6) Spacer (8.6x12x20.1) Cushion Nut Page: 15 of 67 GS500ET (GS500ET E28) FIG14 MUFFLER Ref No 1 2 3 4 5 6 7 8 Part No 14181-01D00 07120-08403 14301-01DA0 09103-08256 09160-08002 09180-08152 09320-12048 08316-10083 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description 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 Page: 16 of 67 GS500ET (GS500ET E28) FIG15 CLUTCH Ref No 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 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description 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) Page: 17 of 67 GS500ET (GS500ET E28) FIG16 TRANSMISSION Ref No 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 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description 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 Page: 18 of 67 GS500ET (GS500ET E28) FIG17 GEAR SHIFTING Ref No 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 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description 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 Page: 19 of 67 GS500ET (GS500ET E28) FIG18 STARTING MOTOR Ref No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part No 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 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Stator Rotor Screw Bolt (12x40) Clamp Screw Clamp Screw Clamp (l:45) Page: 20 of 67 GS500ET (GS500ET E28) FIG19 GENERATOR Ref No 1 2 3 4 5 6 7 8 9 Part No 31401-47030 31402-45030 02112-35303 09103-12004 31497-45000 02112-05083 31498-45000 02112-06103 09404-06429 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Igniter Screw Signal Generator Assy Rotor, Signal Bolt (6x60) Screw Clamp (l:45) Page: 21 of 67 GS500ET (GS500ET E28) FIG20 SIGNAL GENERATOR Ref No 1 2 3 4 5 6 7 Part No 32900-01D20 02142-06163 33110-44420 33120-01D00 09103-06064 02112-05103 09404-06429 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Battery (12v,11ah) 10l-b2 Cushion (30x130x3) Protector Hose, Exhaust (l:780->00) Lead Wire, (-) Lead Wire, Battery (+) · . Cap, Starter Relay Terminal · . Cap, Battery (+) Page: 22 of 67 GS500ET (GS500ET E28) FIG21 BATTERY Ref No 1 2 3 4 5 5a 5b 5c Part No 33610-01D00 33652-19B00 33651-37000 33680-16A10 33860-01D00 33870-01D00 33624-01D00 33624-43500 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Relay Assy, Starting Motor · . Terminal, Relay · . Holder, Relay · . Fuse (20a) Nut Wire, Starter Motor Lead · . Cap, Starter Relay Rectifier Assy Screw Coil Assy, Ignition Bolt Spacer (6.2x12x18) Cap Assy, Spark Plug Cap Assy, Spark Plug Seal, Spark Plug Seal, High Tension Cord Page: 23 of 67 GS500ET (GS500ET E28) FIG22 ELECTRICAL Ref No 1a 1b 1c 1d 3 4a 4b 6 7 8 9 10 11 11 12 13 Part No 31800-01D00 31841-01D00 31892-07D00 09481-20101 08361-35066 33850-01D10 33624-01D10 32800-33C00 02142-06203 33410-01D00 01500-06403 09180-06204 33510-38B00 33510-22010 33541-24510 33542-38B00 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Speedometer (kilo) Knob Screw Tachometer Damper Cover Cushion Washer (5.5x16x1.2) Nut Screw Bracket, Meter Socket Bulb (12v,3.4w) Bulb (12v,1.7w) Bolt (6x30) Spacer (6.1x10x15.7) Cushion Washer (6.5x29x1.6) Lock Washer Nut Cable, Speedometer Guide, Cable No.1 Bolt Guide, Cable No.2 Bolt Guide, Cable No.3 Screw Cable, Tachometer Page: 24 of 67 GS500ET (GS500ET E28) FIG23 SPEEDOMETER - TACHOMETER Ref No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24a 25 25a 26 27 Part No 34110-01D20 34124-30B00 09139-02003 34210-01D20 34288-01D20 34193-01D20 34189-01D20 09160-05037 08313-10057 34149-01D20 34950-01D20 34170-01D20 09471-12028 09471-12077 09107-06003 09180-06209 34956-31001 09160-06030 08321-01063 08310-00063 34910-01D02 34938-45100 01550-06163 34938-01D01 01550-06123 34938-01D10 02112-05163 34940-01D02 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Headlamp Assy · . Rim · . Lamp Unit · . Ring · . Ring, Mounting · . Cover, Socket · . Screw · . Lock Washer · . Nut · . Screw, Adjusting · . Nut · . Spring · . Screw · . Setter, Bulb · . Bulb (12v,60/55w,h4) Screw Reflex Reflector, Front Side Nut Page: 25 of 67 GS500ET (GS500ET E28) FIG24 HEADLAMP (MODEL K/L/M/N/P) Ref No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part No 35100-01D30 35111-01D20 35121-34430 35127-45030 35130-45030 35173-45000 35181-15611 08321-21057 08310-11056 35151-45030 35152-15611 35154-31900 02112-04106 35136-34400 09471-12060 02132-05127 35950-43431 08316-26055 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Headlamp Assy · . Rim · . Lamp Unit · . Ring · . Cover, Socket · . Screw · . Lock Washer · . Nut · . Screw, Adjusting · . Nut · . Spring Bulb (12v,60/55w,h4) Screw Reflex Reflector, Front Side Nut Page: 26 of 67 GS500ET (GS500ET E28) FIG24A HEADLAMP (MODEL R/S/T) Ref No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Part No 35100-10D70-999 35111-01D20 35121-10D30 35127-10D20 35173-20A01 35181-15611 08321-01057 08310-00053 35151-45900 35152-15611 35154-31900 09471-12060 02122-05127 35950-43431 08316-20053 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Lamp Assy, Front Turnsignal · . Lens · . Gasket · . Tapping Screw · . Tapping Screw · . Gasket · . Bulb (12v,21w) Cap, Turnsignal Lamp Nut Lamp Assy, Rear Turnsignal · . Lens · . Gasket · . Tapping Screw · . Tapping Screw · . Gasket · . Bulb (12v,21w) Washer Spacer Nut Relay Assy, Turnsignal Page: 27 of 67 GS500ET (GS500ET E28) FIG25 TURNSIGNAL LAMP Ref No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Part No 35601-01D10 35612-17C20 35613-27A00 35623-27A00 35725-40511 35627-27A02 09471-12045 35698-01D00 08316-20103 35601-17C41 35612-17C20 35613-27A00 35623-27A00 35725-40511 35627-27A02 09471-12045 09160-10501 35695-17C00 08310-00103 38610-45D01 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Lamp Assy, Rear Combination · . Lens · . Gasket, Lens · . Socket · . Bulb (12v,21/5w) Cushion Washer (6.5x20x1.2) Cushion Spacer (6.4x9x8.5) Nut Bracket, License Plate Cushion Screw Washer (6.5x20x1.2) Nut Reflex Reflector, Rear Side Bracket, Rear Side Rr Screw Nut Reflex Reflector Assy, Rear Nut Bracket, Rear Reflex Reflector Screw Washer Nut Page: 28 of 67 GS500ET (GS500ET E28) FIG26 REAR COMBINATION LAMP Ref No 1 2 3 4 5 5a 6 7 8 9a 10 11 12a 13 14a 15 16 17 18a 19 20a 21 22 23 24a Part No 35710-01D11 35712-01D10 35713-01D00 35718-01D00 09471-12083 35733-10D00 09160-06077 09320-09009 09180-06152 08310-00063 35927-01D10 09321-06028 02142-06163 09160-06077 08310-00063 35970-24D60 35977-01D11 02142-05123 08310-00053 35970-24D60 08310-00053 35974-01D00 02142-06123 08321-31064 08310-00063 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Harness, Wiring · . Diode Protector, Wiring Harness Protector, Wiring Harness Clip (black) Screw Clamp (l:65) Clamp (l:65) Clamp (l:80) Clamp (l:67) Clamp (l:65) Clamp (l:125) Clamp (l:165) Clamp Lock Assy, Steering Bolt Switch Assy, Stop Lamp Spring Switch Assy, Side Stand Bolt Relay Assy, Side Stand Horn Assy Bolt Key, Blank Page: 29 of 67 GS500ET (GS500ET E28) FIG27 WIRING HARNESS Ref No 1 2 4 5 6 7 8 8 8 8 8 9 9 10 15 15a 16 17 18 19a 20 21 22 23 Part No 36610-01D30 36611-38A00 36611-01D00 36611-01D10 09409-07305-5PK 02142-06123 09404-06431 09404-06432 09404-06434 09404-08413 09404-08418 09407-14403 09407-18403 09403-06310 37100-26D02 09139-06026 37740-24A00 09443-06042 37840-01D01 01550-06303 38740-24X50 38500-01D10 01550-06123 37146-26D10 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Switch Assy, Handle Rh · . Screw Switch Assy, Handle Lh · . Screw · . Lever, Choke · . Piece, Slide · . Spring · . Plate · . Screw Page: 30 of 67 GS500ET (GS500ET E28) FIG28 HANDLE SWITCH Ref No 1 2 3 4 5 6 7 8 9 Part No 37200-01D11 02112-05455 37400-01D12 02112-05455 37481-30B00 37482-30B00 37483-30B00 37486-30B00 03511-04125 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Frame Set (silver) · . Bolt · . Nut Cap Holder, Battery Bolt Washer (6.5x20x1.6) Cushion Spacer Nut Holder, Electric Parts Bolt Page: 31 of 67 GS500ET (GS500ET E28) FIG29 FRAME Ref No 1 4 5 6 7 8 10 11 12 13 14 15 Part No 41102-01870-13L 01550-10357 08319-31107 43585-01D00 41540-01D31 01500-06203 09160-06059 09320-08021 09180-06103 08316-10063 47410-01D00 01550-06167 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Stand, Center Bolt Spacer Spring, Inner Spring, Outer Cushion Stand, Prop (black) Bolt Bolt Nut Spring, Inner Spring, Outer Pedal, Brake Rubber Arm, Brake Rod Washer Bolt Spring, Return Page: 32 of 67 GS500ET (GS500ET E28) FIG30 STAND - REAR BRAKE Ref No 1 2 3 5 6 7 8 9 9 10 11 12 13 14 15 16 17 18 Part No 42100-01D00 01580-10603 09180-10040 09443-14059 09443-22013 09321-10017 42310-01D10-019 09111-10019 09111-10027 09140-10043 09443-15046 09443-22017 43110-01D12 25652-49300 43121-01D00 43212-04A00 01550-06253 09443-13028 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Rubber Assy, Front Rh Rubber Assy, Front Lh Washer, Rubber Pin Washer E Ring Bracket, Front Footrest Rh Bracket, Front Footrest Lh Bolt, Bracket Guard, Front Footrest Rh Guard, Front Footrest Lh Bolt, Guard Footrest Assy, Pillion Rh Footrest Assy, Pillion Lh · . Rubber Washer, Rubber Pin Washer E Ring Page: 33 of 67 GS500ET (GS500ET E28) FIG31 FOOTREST Ref No 1 2 3 4 5 6 7 8 9 10 11 12 13 13 14 15 16 17 18 Part No 43550-01D00 43560-01D00 43631-34A01 09208-06005 08322-01063 08332-11043 43510-01D00-13L 43520-01D00-13L 09106-08094 43586-01D10 43596-01D10 09139-06062 43600-12B00 43700-12B00 43551-12B00 43631-34A01 09208-06005 08322-01063 08332-11043 (silver) (silver) Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Bolt Cushion, Front Cushion, Side Bracket, Rear Bolt, Bracket Cushion, Rear Upper Cushion, Rear Lower Spacer Bolt Hose, Water Drain Page: 34 of 67 GS500ET (GS500ET E28) FIG32 FUEL TANK (MODEL K/L) Ref No 10 11 12 13 14 15 16 17 18 19 Part No 09106-05017 44511-34A00 44545-48B10 44550-01D00 01550-08407 09320-14017 09320-10038 09180-06180 09116-06078 44423-01D00 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Tank Assy, Fuel (green) Tank Assy, Fuel (blue) Tank Assy, Fuel (red) Tank Assy, Fuel (black) · . Tape Set, Fuel Tank · . Tape Set, Fuel Tank · . Tape Set, Fuel Tank · . Tape Set, Fuel Tank · . Emblem, Fuel Tank (silver) · . Emblem (silver) · . Emblem (white) · . Molding, Fuel Tank Cap Set, Fuel Bolt Cushion, Front Cushion, Side Bracket, Rear Bolt, Bracket Cushion, Rear Upper Cushion, Rear Lower Spacer Bolt Hose, Water Drain Page: 35 of 67 GS500ET (GS500ET E28) FIG32A FUEL TANK (MODEL M) Ref No 1 1 1 1 2 2 2 2 3 3 3 4 5 6 7 8 9 10 11 12 13 14 15 Part No 44100-01D70-0FL 44100-01D70-0ZK 44100-01D70-28V 44100-01D70-33J 68110-01D20-F91 68110-01D20-F92 68110-01D20-F89 68110-01D20-3VT 68111-01D00-13L 68111-01D00-0FP 68111-01D00-22R 68241-01D00 44201-01831 09106-05017 44511-34A00 44545-48B10 44550-01D00 01550-08407 09320-14017 09320-10038 09180-06180 09116-06078 44423-01D00 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description · . Molding, Fuel Tank · . Molding, Fuel Tank Cap Set, Fuel Bolt Cushion, Front Cushion, Side Bracket, Rear Bolt, Bracket Cushion, Rear Upper Cushion, Rear Lower Spacer Bolt Hose, Water Drain Page: 36 of 67 GS500ET (GS500ET E28) FIG32B FUEL TANK (MODEL N/P) Ref No 3 6 7 8 9 10 11 12 13 14 15 16 17 Part No 68241-01D00 68241-01D00 44201-01831 09106-05017 44511-34A00 44545-48B10 44550-01D00 01550-08407 09320-14017 09320-10038 09180-06180 09116-06078 44423-01D00 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Tank Assy, Fuel (purple) Tank Assy, Fuel (green) Tank Assy, Fuel (black) · . Emblem · . Molding, Fuel Tank · . Molding, Fuel Tank Cap Set, Fuel Bolt Cushion, Front Cushion, Side Bracket, Rear Bolt, Bracket Cushion, Rear Upper Cushion, Rear Lower Spacer (6.4x9x18) Bolt (m:6xl:30) Hose, Water Drain Page: 37 of 67 GS500ET (GS500ET E28) FIG32C FUEL TANK (MODEL R/S/T) Ref No 1 1 1 2 3 6 7 8 9 10 11 12 13 14 15 16 17 Part No 44100-02D71-1TU 44100-02D71-1ZV 44100-02D71-33J 68111-01D20-D1F 68241-04X50-00B 68241-04X50-00B 44201-01831 09106-05017 44511-34A00 44545-48B10 44550-01D00 01550-08403 09320-14017 09320-10038 09180-06072 09116-06172 44423-01D00 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Cock Assy, Fuel Bolt Hose, Fuel (l:600->80) Clip Hose, Fuel "on" (l:600->20) Hose, Fuel "res" Protector Clip Filter Unit, Fuel · . O Ring Bolt Gasket Page: 38 of 67 GS500ET (GS500ET E28) FIG33 FUEL COCK Ref No 1 2 3 4 5 6 7 8 9 10 11 12 Part No 44300-01D21 01550-06123 09354-70113-600 09401-11413 09354-70113-600 44441-01D00 44461-01D01 09401-11413 44300-01D10 44348-28070 09128-06057 09168-06026 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Protector, Rh Protector, Lh Bolt Washer Spacer Cushion · . Emblem (blue) · . Emblem (white) · . Emblem (silver) · . Emblem (silver) · . Emblem (silver) · . Emblem (white) Screw, Center Cover Washer Cushion Page: 39 of 67 GS500ET (GS500ET E28) FIG34 FRAME COVER (MODEL K/L/M) Ref No 7 14 15 16 17 18 20 20 20 22 22 22 23 24 26 Part No 47119-01D00 47219-01D00 09128-06057 09160-06057 09180-06011 09320-09016 68166-01D00-33N 68166-01D00-064 68166-01D00-742 68166-01D00-13L 68166-01D00-0FP 68166-01D00-22R 03242-05124 09161-05017 09320-08018 Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved. Catalogue Title: Block No. Block Title. Suzuki Worldwide Motorcycle-ATV Description Cover, Frame Rh (purple) Cover, Frame Rh (red) Cover, Frame Rh (black) · . Tape Set, Rh · . Tape Set, Rh · . Tape Set, Rh Protector, Rh Cover, Frame Lh (purple) Cover, Frame Lh (red) Cover, Frame Lh (black) · . Tape Set, Lh · . Tape Set, Lh · . Tape Set, Lh Protector, Lh Bolt Washer Spacer Cushion Cover, Frame Center (purple) Cover, Frame Center (red) Cover, Frame Center (black) · . Emblem (white) · . Emblem (black) Screw, Center Cover Washer Nut Cushion Page: 40 of 67 GS500ET (GS500ET E28) FIG34A FRAME COVER (MODEL N) Ref No 1 1 1 2 2 2 3 4 4 4 5 5 5 6 7 8 9 10 11 11 11 12 12 13 14 15 16 Part No 47110-01D90-1HU 47110-01D90-28V 47110-01D90-33J 68130-01D70-L32 68130-01D70-L34 68130-01D70-L33 47119-01D00 47210-01D90-1HU 47210-01D90-28V 47210-01D90-33J 68140-01D70-L32 68140-01D70-L34 68140-01D70-L33 47219-01D00 09128-06057 09160-06057 09180-06011 09320-09016 47310-01D20-1HU 47310-01D20-38X 47310-01D20-36X 68166-01D00-0JW 68166-01D00-13Z 03241-05125 09161-05017 09148-05004 09320-08018