MOTORCYCLE DIVISION 4-STROKE

BULLETIN GS/GSX/GSX-R NO. 139 Revised

DATE: 3/21/2006

SUBJECT: GS500F ENGINE KNOCK AT IDLE

AFFECTED UNITS: GS500FK4/K5 - ENGINE NUMBER M504-125865 & EARLIER

REFERENCE: GS500 SERVICE MANUAL (PN 99500-34094-03E)

NOTICE:
This bulletin is a revision to the original Service Bulletin GS/GSX/GSX-R NO. 139 dated
5/2/2005. Please place a copy of this bulletin with your dealerships Service Bulletin binder
and GS500 Service Manual and discard the original bulletins.
Some GS500FK4/K5 motorcycles may exhibit a mild but annoying knocking noise from
the cylinder head area. This sound will be heard only at idle or just off idle.
Solution
This knocking noise may be caused by the camshafts walking side to side during operation
due to excessive end play. The walking movement will not cause damage.
Note: Test the source of the noise for camshaft walking by carefully leaning the
motorcycle over to the left (toward the sidestand) while the engine is running and continue
to listen for the noise. The noise will quiet if the camshafts are loaded toward the left hand
side.
Should you receive a complaint of the above described symptoms, follow the procedure
in this Service Bulletin.
Parts Information
3 4

1
5

2 6

- 1/2 -
Procedure
1. Remove the cylinder head cover, cam
chain tension adjuster and camshafts
(refer to Service Manual beginning on
page 3-10).
Remove the sprockets and the 1.0 mm
thick thrust washers from the original
camshafts. These parts will be reused
with the new camshafts.
2. Replace the exhaust tappets using the original adjustment shims.
3. Assemble each new replacement camshaft with one of the original 1.0 mm thick
washers at the left side and the two 0.7 mm thick washers mounted on each side of
the wave washer on the right side. See Figure 1.
4. Install the cam sprocket with new washers and time the camshafts (refer to Service
Manual, beginning on page 3-56).
In the timing position, the exhaust camshaft lobe presses on the #1 cylinder exhaust
valve lifter. In this position, the bearing surface can easily be damaged by the additional
washers if care is not taken when the camshaft journal holders are installed. To prevent
damage, rotate the crankshaft 90 in the reverse direction while ensuring that the chain
does not become detached from the sprockets.
5. Install the camshaft journal holders and tighten the journal holder bolts to the specified
torque. Install the cam chain tension adjuster (refer to Service Manual beginning on page
3-59), confirm that the cam timing is correct and adjust tappet clearance if required
(refer to Service Manual beginning on page 2-5).

FIGURE 1
Left side Right side

Wave washer

Thrust washer
(t=1.0mm) Thrust wash-
ers
AFFECTED DEPARTMENTS:
The following departments in your dealership should be notified of this information:
Management Service Warranty Sales Parts Accessories

American Suzuki Motor Corporation

Technical Service Department
Motorcycle / ATV

- 2/2 -