SUZUKI SERVICE MANUALSUZUKI GS550 SERVICE MANUAL FOREWORD Information contained in this Manual is primarily for those whose job is to inspect, adjust and service Model GS550 motorcycles, but users experienced in do-it-your- self servicing of SUZUKI machines too will find this Manual useful as a guide, Model GS550 manufactured to standard specifications is the main subject matter of this Manual. However, the GS550 machines distributed in your country might differ in minor respects from the standard-specification GS550 and, if they do, it is because some minor modifications (which are of no consequence in most cases as far as servicing is concerned) had to be made to comply with the statutory require- ments of your country. This Manual contains up-to-date information at the time of its issue. Lstermade modifications and changes will be explained to each SUZUKI distributor in respective markets, to whom you are kindly requested to make query about updated information, if any. ‘SUZUKI MOTOR CORPORATION Motorcycle Technical Service Department Quoting, copying or otherwise using any part of this manual without explicit authorization from Suzuki Motor Corporation is not permitted.VIEW OF SUZUKI GS550 Right Side123~139 140~144 146~147 148~153 154~156 158~160 161~174 175~204 205~ 234 235~312GROUP INDEX 313-~389 391~501 503~553 555~594 595~641 643~691 693~720CONTENTS SPECIFICATIONS . FUEL AND OILS. x CYLINDER INDENTIFICATION2 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS vera length - 2,175 mm (85.6 in} Overall width < £"B50 mm (33.5 in) Overall height © 155 mm (45.5 in) Wheelbase (436 mm (56.5 in) Ground clearance ‘150 mm (5.9 in) Dry mass 196 kg (432 ibs) ENGINE Type. . Fourstroke cycle, air-cooled, DOHC Number of eytiie's 4 Bore.» UDIIDDUIITDIITIDTITIITDT (58.0 mm (2.206 in) Stroke| DIDI 35.8 mm (2197 in) Piston displacement << 122! S21 BABom (88 eu.) Compression ratio.» : {UMIKUNI_ M2288, four Carburetor Air elesner | 9.5 mm 4a | _oosrossi0 Wheat rim protector14 Ref Ret | Toot number Description 49 | 0963-74111 Front fork oll level gauge 50 | 09960-74510 Tire bead breaker 51_ | 09900-22301 Plasti gauge @ @The materials listed below are needed for maintenance work on the GS550, and should be kept on hand for ready use. They are additions to such standard materials as cleaning fluids, lubricants, emery cloth and the like. How to use them and where to use them are described in the text of this manual. e Part number Descristion or name 1 29000:32040 THREAD LOCK CEMENT 2 9000 32020 SUZUKI LOCK SUPER "13336" 3 20000 31110 SUZUKI BOND No. 1215 3 99000-25110 SUZUKI PoC GREASE 5 900028140 SUZUKI MOLY PASTE 8 89000-25100 SUZUKI SILICONE GREASE 5 0000 32030 SUZUKI Lock SUPER "13038" 3 000 32080 SUZUKI THREAD LOCK "1342" 8 49000-32000 SUZUKI THREAD LOCK SUPER "13928" ® | @ ® | | L @ | ® | [© l © @ © |ENGINE av i a ‘0 we cha a ub at 2 | «neo | m0-as Drees » moa Sich ot 3 No-ms Cont ta on ok 2 to-200 Cam nwt eka ° tong ia 8 Cana srs ot : ra eye at : 1 s0- 80 Cyn ed mt 3 7 | vasse8 yin ed cover ot 3 4 50-80 camer : 2 80 a8 Olt coer at 3 3 a 60 Oipeot é 10 Gren ot : 0 Grate bat 8 Me Ene maug bot ‘0 mo Enno 2 we Corer eto lt | to-ro | teens CHASSIS Item bone kgm Ihe Front otra 3 te-28 | ave Frentad mit 2 ae-sz | 280-278 Frnt for ut upper ph Ree ragtcmserrneine w 20-30 45-218 ni gtetowronh on |g ro-ao | asa Stina sm nh rat 3 0-180 Hana cmo bt 2 ta-20 as-is erate ho non ot Pi tanta a5—r20 Mat tne nig a : os—o8 25-60 Front rakes der a 08-08 45- es Fretiatecaiver memingsot | 10 ze-a0 | e022 Resrsinaoaempwotatioat | 14 so-eo | s80-a80 Rafecketteemiivepes | 4g roo | as-2is few eat 18 so-eo | 360-880 ar oak ut if ro-20 | t4s—zis ear trata ca feb 2 | 08-08 as- 60 Frnt foes at | area | tas—stoTIGHTENING TORQUE 147 For other bolts and nuts not listed above, refer to this chart: ‘ott Conventional or "6" marked bolt marked bolt ® mm kom kom Ife 4 o1- 02 0.15- 03, 10-20 5 02- 04 03 ~ 06 20- 45 8 04-07 og - 12 so- 85 8 10- 16 18 - 28 130-200 10 22-35 40 - 60 290- 435 12 35-55 70 - 100 505-725 14 50- 90 110 ~ 160 795 — 1185 16 80-130 170 ~250 1230-1810 18 130-190 200 ~ 280 144.5 — 202.5 "4" Marked BoltGROUP eo aaa 8 ENGINE AND CHASSIS ame a ar Ceaiwans | “Raniiomernensai miter eee det ee ae sai aS |Z Woman gts ar he extrapot a oeoce tah ki vonitn Deacon owas Sc swipes ores 1 apenas a Weert pe 5 Ge pe iy tela elroy oe eae | No fue rching heures, steele — Reece sone | 2 ieee Oe ia| EO cs, | aan 7 ae: nee | os ce eclarell a oe iota oa Soe nein, | a Jaana een a no enn cmc eee ic Spree ad | 2, Weakened or broken valve springs. Replace. inte ce ee es | 1. Pistons or cylinders worn down. Replace. Sree aTROUBLE SHOOTING 149 Complaint Symptom and possible causes Remedy Noise seems to come from timing chain. 1, Stretched chain, Replace. 2. Worn sprockets. Replace. 3. Tension adjustor not working. Repair or replace. [Noise seems to come from clutch. 1, Worn splines of countershaft or hub. Replace. 2. Worn teeth of clutch dics. Replace. 3, Distorted clutch discs, driven and drive. Repair or replace. "Noise seems to come from crankshaft. 1, Ratting bearings due to wear. Replace 2. Big-end bearinge worn and rapping. Replace. "Noise seems to come from transmi 1, Gears worn or rubbing. Replace. 2. Badly worn splines. Replace. 3. Primary gears worn or rubbing, Replace. Slipping clutch 1. Cluten control out of adjustment or loss of play. Adjust. 2. Weakened clutch springs Replace. 3. Worn or distored pressure plate Replace. 4, Distorted clutch discs, driven and drive. Replace. Dragging clutch 1, Clutch control out of adjustment or too much play. | Adjust. 2. Some clutch springs weakened while the others are not. | Replace. 8, Distorted pressure plate or clutch discs. Replace. ‘Transmission will 1. Broken gearshift cam. Replace. not shi 2. Distorted gearshift forks Replace. ‘Transmission will 1, Broken return spring on shift sha Replace. not shift back. 2. Shift shafts are rubbing or sticky. Repo ‘Transmission jumps 1. Worn shifting gears on drive shaft or countershaft Replace. ‘out of gear. 2. Distorted or worn gearshift forks. Replace. 3, Weakened stopper spring on gearshift cam, Replace. Engine idles poorly. 1. Tappet clearance out of adjustment. Adjust. 2, Poorly seating valves. Replace. 3. Defective valve guides. Replace.150 TROUBLE SHOOTING Complaint ‘Symptom and possible causes Remedy Engine ites 4, Ignition timing our of adjustment Adjust. poorly 5, Contact points improperly gapped. Adjust. 6. Spark plugs gapped too wide Repair. 7. Defective ignition coil or condenser resulting in weak | Replace. sparking, 8, Float-chamber fuel level out of adjustment in carburet- | Adjust. 9, Carburetor pilot screws improperly set Adjust. Engine runs 1. Valve springs are weakened. Replace. poorly in high- 2. Valve timing out of adjustment. Adjust. speed range. 3. Spark plugs gapped t00 narrow. Repair. 4, Ignition not advanced sufficiently due to poorly work- | Repair. {ng advancer. 8, Weakened springs on breaker arms, Replace. 6. Defective ignition col Replace. 7. Float-chamber fuel level too low, Adjust. 8. Ciogged element in ar cleaner. ean. 8. Clogged fuel pipe, resulting in inadequate fuel supply | Clean, and prime. 10 carburetors, 10. Clogged suction cock pipe. lean. Dirty or heavy 1, Too much engine oil in the engine, Check with level gavge; exhaust smoke. rain out excess oil 2. Worn piston rings or cylinders. Replace, 3. Worn valve guides. Replace. 4. Cylinder walls are scored or seutfod Replace. 5, Worn valve stems. Replace. 6. Defective stem seal. Replace. Engine lacks 1, Loss of tappet clearance. Adjust. power. 2, Weakened valve springs. Replace. ‘3, Valve timing out of adjustment. Adjust 4, Worn piston rings or cylinders. Replace, 5. Poorly seating valves Repai 6. Igition timing out of adjustment. Adjust. 7. Contact points improperly gapped Adjust. 8 Spark plugs improperly gapped. Repair. 9. Clogged jets in carburetors, Clean. 10, Float-chamber fuel level out of adjustment. Adjust. 11. Clogged element in ar cleaner. Clean, 12, Carburetor balancing screw loose. Retighten. 13, Too much engine cil Drain out excess oilTROUBLE SHOOTING 151 too stiff Complaint Symptom and possible causes Remedy over. 1. Heavy carbon depasit on piston crowns. Clean. 2. Notenough oll in the engine. Add oil 3. Defective oil pump or clogged oil circuit. Repair or clean. 4, Fue! level too low in float chambers. Adjust. 5. Ignition timing excessively retarded, accompanied by | Adjust pinging. 1. Steering stem overtightsned. Adjust 2. Broken steel balls on steering stem, Replace. 3. Distorted steering stem, Replace. 4, Notenough pressure in tuheel tires. Adjust. | 5, Overtightened steering bal races. Adjust. Wobbly handle 1, Loss of balance between right and left cushions. Replace. 2. Distorted front fork. Repair or replace. 3. Distorted front axle or cocked tire. Replace. ‘Wobbly front 1, Distorted whee! rim. Replace. wheel 2. Worn-down front wheel bearings. Replace. 3. Loose wheel spokes. Retighten. 4. Defective or improper Replace 5. Loose nut on axe. Retighten. Front cushions 1. Weakened springs. Replace. 100 soft 2. Not enough damper oil Refill, Front cushions 1. Damper oil too viscous. Replace. 100 stiff 2. Toomuch damper oil, Remove excess oil | Noisy front 1, Not enough damper cil Refill, | cushions 2. Loose nuts on cushions. Retighten. Wobbly rear 1, Distorted wheel rim, Replace. wheel 2. Worn-down rear wheel bearings Replace 3. Loose wheel spokes. Retighten. 4, Defective or improper tire. Replace. Rear cushions 1. Weakened springs Replace. too soft. 2. Rear cushion adjustors set improperly. Adjust. Fear cushions Fear cushion adjustors set improperly. Adjust.152 TROUBLE SHOOTING Complaint ‘Symptom and possible causes Remedy ee Loose nuts on cushions. Retighten. Poor braking 1, Not enough brake fluid in the reservoir. Refill to level mark. (FRONT & 2. Air trapped in brake fluid circuit. Bleed air out. REAR) 3. Pads or linings worn down. Replace. ELECTRICAL Complaint Possible causes Remedy No sparking or 1. Defective ignition col Replace. oor sparking 2. Defective spark plugs. Replace. Contact points Defective condenser. Replace. burn or pits pre- rmaturely, ‘Spark plugs soon 1, Mixture too rich, Adjust carburetors become fouled 2. Idling speed set too high: Adjust carburetors. with carbon. 3. Improper gasoline. Change. 4. Dirty element in air cleaner. lean. 5. Spark plugs too cold. Replace by hot type plugs. ‘Spark plugs 1, Worn piston rings. Replace. become fouled 2. Pistons or cylinders worn. Replace, ‘90 soon. 3. Too much clearance of valve stems in valve guides. Replace. Spark plug elec- 1. Spark plugs are too hot. Replace by cold type plugs. ‘vodes overheat 2. The engine overheats. Tune up. or burn, 3. Ignition timing out of adjustment. Adjust. 4, Spark plugs loose in place, Ratighten, 8. Mixture too lean. Adjust carburetors, Generator does 1. Open or short in lead wires, or Loose lead connections. | Repti, replace or retighten, rot charge. 2. Shorted, grounded or open generator coils. Replace. 3. Silicon diodes punctured. Replace. 4, Shorted regulator lead wir, Repair or replace.TROUBLE SHOOTING 153 Complaint Possible causes Remedy Generator does 1. Lead wires tending to get shorted or open-circuited or | Repair, or retighter charge, but loosely connected at terminals. charging rate is 2. Grounded or open-circuited stator coils of generator. | Replace. below the spe- 3. Defective silicon diodes. Replace. sification. 4, Defective regulator. Replace '5, Not enough electrolyte in the battery. Add distilled water to rai its level. ©, Defective cal plates in the battery. Replace the bettery. Generator 1. Internal short-circuit in the battery. Replace the battery. overcharges. 2. Goll element in the regulator damaged or defective. | Replace the regulator. 3. The regulator poorly grounded. Clean ard. tighten ground connection. Unstable charging 1, Lead wire insulation frayed due to vibration,, pre- | Repair or replace. senting condition of intermittent short. 2. Generator internally shorted. Replace, 3, Defective regulator. Replace. Starter button is 1, Battery run down. Recharge or replace. not effective 2. Defective switch contacts. Repalce, 3, Brushes not seating properly on commutator in starter | Repair or replace. motor. Battery “sulfation’ 1. Charging rate too low or too high. Replace the battery. (A battery out of use should be recharged at least ‘once a month to avoid sulfation.) 2, Battery electrolyte too much or too little, or its | Keep the electrolyte up to specifiee gravity too high or too low. the prescribed level, or adjust the S.G. by consulting the battery maker's. directions 3, The battery left out of use too long in cold climate. | Replace the battery, if badly sulfated. Battery discharges 1 Clean, itself rapidly. 2. Impurities in the electrolyte or electrolyte S.G. is too | Change the electrolyte by high, consulting the battery maker's directions.SERVICE DATA | eon 8 8} 9 - ITEM STANDARD [service unr Cam height (Base circle + lift) IN. | 35.485 - 35.515 mm (1.3970 - 1.3082 in) 36.190 mm_ (1.3854 in) EX. | 36.285 - 35.315 mm (1.3892 - 1:3904 in} 34.990 mm _ (1.3776 in) Camshaft/journal clearance 0.020 -0.054mm (0.0008 - 0.0021 in) 0.150 mm (0.0059 in) Camshaft journal holder inside diameter] 21,959 - 21.980 mm (0.8645 - 0.86654 in) ‘Camshaft unout 0.03 mm (0.001 in) 0.1mm (0.004 in) Cylinder head distortion 0.03 men (0,001 int 2mm (0.008 in) Thickness of valvehead periphery | 1.2-14mm —_(0.039- 0.055 in} 05mm (0.020 in) Valve stem axis runout 0.05 mm (0.0020 in) Valve stem diameter IN, | 6960-6.975mm —(0.2740-0.2746in) | 690mm (0.2717 m) EX. | 6.945-6.960mm _(0.2734-0.2740 in) | _6.805mm (0.2679 in) Valve guide inside diameter 7.000-7.016 mm (0.2756-0.2762 in) | IN. 7.00 mm (0.2801 n} EX 7.10 mm (0.2798 in} Valve/Valve guideclearance IN. | 0.02-0.08mm (0.0008 -0.0020 in} 0.35 mm (0.014 in) EX. | 0.03-0.06mm (0.0012 -0.0024 in) 0.35 mm (0.014 in) Contact width of valve and valve seat | 1.0-12mm (0.039 - 0.047 in) 1.5mm (0,069 in) Valve spring free length NIHON HATSUJO Make, Inner | 37.00 mm (1.487 in) 338mm — (1.331 in) | Outer | 43.25 mm (1.703 in) 415mm — (1.634in) CHUOH HATSUIO Make, Inner | 35.30 mm (1'390 in) 93.8 mm — (1331 in) Outer | 43.00 mm (11593 in) 415mm (1.634in) Valve spring tension Outer | 50.4 -58.3 kg (111 - 129 Ibs) for fitting length 27 mm (1.08 in} Inner | 29.3- 34.0 kg (65 -75 Ibs) for fitting — length 23 mm (0.91 in} ‘Compression pressure 9-12 kg/em? (128-170 pa) @5kglem?* (92 psi Oil pump discharge pressure cover 0.1 kg/em® (1.42 psi) at 3,000 rpm and at 60°C (140°F) Ovlinder bore {56,000 - 56.015 mm (2.2047 - 2.2063 in) | 66.100 mm (2.2087 in) Piston diameter | 55.945 - 65.960 mm (2.2026-2.2031 in) | 65.800 mm_ (2.1969 in) Cylinder Piston clearance 0.050 -0.060 mm (0.0020 - 0.0024 in) Piston ring thickness 1st ring 1.175-1.190mm (0.0463 -0,0469 in) | 1.100 mm (0.0435 in) 2ndring | 1.170-1:190 mm (0.0461 - 0.0868 in) | 1.100 mm (0.0433 in) Piston ring groove width tstring | 1.21-1.23mm (0,047 - 0,048 in) 130mm (0.081 in} 2ndring — | 121-123mm (0,047 - 0.048 in) 130mm — (0.051 i Ollring 2'51-2.53mm —_(0,099- 0.100 in} 280mm (0.102 in}SERVICE DATA 155 ITEM ‘STANDARD ‘SERVICE LIMIT Piston ring/Ring groove clearance Trevino. | 0020-0.085mm 10.0008 0.0022 n) | o.180mm (0.007 Brdiwg | 0820-0.080mm (0.0008-0.0004 nl | G:gomm (0.0069 in Fionringendosp tetring | 0-03mm (0908-0012 in) 0.7mm (003i) Teddy | 01-03mm (008 -0.012 Simm (eases Tision ng Wee od ga Tet team (028i) S2mm (020in) 2nd ésmn [0-28 in) 52mm —_(020in) Pinon pin dlometer 16905 16,000 mm (0.6207 -0.6200in) | 16.96 mm (0.6203 in) Piston pin bore 16002 - 16.008 mm 0.6300 0.6302 in) | 16.08 mm (0.6381 in) Coanetng rod small end bor 16006 16.014 mm (0.6302 0.6305 in) | 16.08 mm (06310) Connecting rod deflection 3mm (042i) ‘Grankhatt bearing diametral earns | 0016 0.040 mm (0.0008-00016 in) | 008mm (0.0081 in) Connecting rod side clearance 0.10 - 0.65 mm (0.004 - 0.026 in) 1.00 mm _ (0,039 in) Crankiatt runout Beow 0.08 mm 0012 in) {206 mm (0.002 in) ‘Tappet clearance ~~ | 003-0.08 mm {0.001 - 0.003 in) CHASSIS. Tem STANDARD SERVICE Lint Brake die thickness Samm (026i) ‘Under 6.0 mm (0.24 in) Brak deface runout 0.1mm (0.004 in) 230mm —_(0.012in) Andere 0:15 mm (0.006 in) 0.25mm (0.010 in) Tire tod depth Front 16mm (008 in) few 20mm __(008in) Whee rim runout (axial & radial) 20mm (008in) Brake caliper piston diameter Front 42700 - 42.810 mm (1.6046 - 1.6964 in} Under 42.600 mm {1.6807 in) Brake caliper cylinder diameter Front 42.860 - 42.899 mm (1.6874 - 1.6889 in) Over 42.999 mm (1.6929 in) Brake master cylinder piston digmeter ront 13941 - 13.968 mm_ (0.5489 - 0.5499 in) Under 13.620 mm (0.5480 in) Brake master cylinder diameter Front _| 19900- 14.043 mm (0.5472 0.6529 in)_| Over 14.07 mm (0.5547 in) Rear brake drum diameter 180. mm (7.09 in) 180.7 mm (7.11 in) Rear brake lining thickness 4.0mm (0.16 ind 20mm (0.08 in)LUBRICATION The maintenance schedule, which follows, is based on this philosophy. It is timed by odometer indication, and is calculated to achieve the ultimate goal of motorcycle maintenance in the most economical manner. (Engine and body) Tnienal | Vata G00 kn | Joni and every | __laaland every] talloland eve Item {600 miles) _| 2500 km (1 500 miles}| § 000 km (3 000 miles) | 10. 000 km (6 000 miles) Drive chan Motor ol every 1000 Kr (600 miles) Tivotle cab 3 z Mower ot Nowra Trait grip = = a Gree Smale : - = Grease Wheel beorigs Spestometr gear sig Grease evry 2 years oF 20.000 km (12.00 miles ~Swieging ar Bearings] Engine oil Change [Charge Change Change Front fork al Change z = Change Chueh cable : 7 Mote ol Motor ol Brake pedal = = Grea ora Grane oF ol INSPECTION Tatval [inti 1000 km (600 mile Jit and every & 000 km [initia and every 10000 km tem {Bc00 mies) (6.00 mites) Outer Change Change Change Carburetor Adiust Adjust Adjust Contax breaker polit ad timing | Check and adjust Check and adurt Check and ode Spark pug Clem and aust ip | Clean and acust gap | Replace ‘Air dearer eleven? 7 Clean Glen Glutch Talat Adu Adjust Exhaust pipe and mien Retghien Reighien Rerighten Compresion Check Check Check Oi pressure z Check Check Oi sump fer = = Glen Tapoet lerance Chek Cheek Check Drive chain Aalst every 1000 kn (600 miles) Satery Cheek cheek Check Brake system (rontandvear) | Check Check Check Throtle cable [Aalst Adu Adu Tire = Check Check Fuel hose. a | ae. Change every 2 years Seeing Thee Check Check ‘All ots end bolts Retighten Retighten_ RetightenFront tur antl (8) IG] xe wate ce sien USK S CANADA ony) == Font tun gal amp USA & CANADA MARKET 5 oe =o = tl 7 Ena Teen sina site ACQIT Ee — | es [Eiotate ates eae << ———— :WIRING DIAGRAM 153 ‘00 to switch (eee a _| — ear tum al lm (FI ‘eile tmp feo tur nl mp (L) Aepistor Tur Sal ray ‘Sr sen WIRE COLOR 8 ew Sack with white acer we om Green with ed tracer y TIL Green with Yllowe tocar R Grange with White tracer 8 elon with Green tac 8 Yellow with Red tracer & inte with Rea acer er ‘ite with Groen tracer Ge ite with Voto tracer & Fea with Back tracer etiow with Blue tracer Brown with od tracer ‘ite with Blue acer160 WIRING DIAGRAM bb is 211m peo, due yubis win 7/44 UOREUIAWOD 194The information contained here supplements the GS850 Service Manual to render this Manual entirely applicable to the GS550E, and deals with the differences between the GS550 (built to the single-disc speci- fications) and the subject mode!—GS550E. Model GSB5QE incorporates changes in contrast to the single-disc GS550; the changes fall under three head- ings, as follows: 1. Brake system FRONT BRAKE ................From single disc to double disc (for machines shipped to Europe and Australia only) . .From internally expanding type to disc type -From spoke wheel to single-piece casting whee! Spring characteristic altered |for machines shipped to Europe and ‘Australia only) REAR BRAKE......... 2. Wheels (FRONT and REAR). 3. Suspension (FRONT and REAR)162 GSS50E FRONT BRAKE In the GSS5OE machines shipped to Europe and Australia, the front brake is of double-disc type. Its master cylinder and caliper differ from those of the single-disc front brake in regard only to the diameters of piston and cylinder bore. This difference is due to the change in brake operating pressure. MASTER CYLINDER Inspection The only difference is that the bore diameter is larger. Thus, the servicing instructions (on disassembly, reassembly and inspection) set forth in the GS550 Service Manual already in issue (which is originally for singledisc machines) with respect to the master cylinder are applicable to the subject model, DIAMETER STANDARD. SERVICE LIMIT ae 15.870 - 16.813 mm 15.325mm (0.6248 - 0.6265 in.) (0.6270 in.) Peon 16.811 - 15.838 mm 15.799 mm (0.6228 - 0.6235 in.) (0.6220 in.) CALIPER Inspection The bore diameter is smaller, there being no other difference as in the case of master cylinder. DIAMETER. STANDARD. SERVICE LIMIT wa 38.180 - 38.219 mm 38.319 mm | (1.5031 - 1.5047 in.) (1.5086 in.) Piston "38.025 - 38.050 mm 37.825 mm (1.4970 - 1.4880 in.) (1.4931 in.) Reasembly Three brake hoses are tied into the hose joint. One is from master cylinder; One is to the left caliper; and one is to the right caliper. When connecting the hoses to the joint, be sure to make connections as shown.GS550E 163 Air bleeding from brake flud circuit To bleed air out of the calipers, proceed as described in page 115 of the GS550 manual. Bleed out from the left caliper first, and then from the right caliper. WHEEL wheel @Bearing 'Spacer @Front axle ®Bearing spacer @Axle spacer dust seal ‘@Speedometer gear box ass’y Brake dise @Balance weight Tire ‘@inner tube ‘@ Protector @ Right cover For the United State (E03) and Canada (E28) Exploded view of GS550E front wheel164 GSS50E Whee! ] @ Right bearing @ Left bearing @ Bearing spacer @® Bearing holder @ Rear axle DRight spacer @ ett spacer @sprocket mounting drum Bearing DOI seat @Rear sprocket B Cushion Brake dise Caliper bracket BChain adjuster @Chain adjuster supporter | {Balance weight BTire 8 Inner tube 2) Protector Exploded view of GSS5DE rear wheel Disassembly Either right or left caliper must be removed to Axial runout” | Radial rurcout allow removal of front wheel. Rane Bian 2am = 1 limit (0.08 in.) (0.08 in.) Tightening torque for 2.5-4.0 kgm caliper mounting bolt (18,0. 28.0 1b) Inspection 1. Check the wheel for cracks, bends and deflec- tions and replace if such defects are found. Deflected wheel can not be reused after being corrected. 2. CHECKING WHEEL RUN-OUT ‘Measuring axial run-out Measure the run-out of the wheel in the axial and radial directions, Replace when allowable limit is exceeded.GSSS5OE 165 Measuring redial run-out 3. CHECKING THE WHEEL BALANCE Check the wheel balance in the same way as in GS550. Use a balance weight of 20g or 30g when necessary Wheel balancer Weight Part No. 20 q (0.04 tbs) 55411-47000 309 (0.07 Ibs) | 55412-47000 ®@ ae es © 209, © 309 NOTE: — When thnlsting a balance weld to the Wheel weight pliers 4. CHECKING DISC WEAR In the ‘78 machines of the GS series, to which the GS55E belongs, front brake discs are 6 mm thick, that is, 0.7 mm less thick than those of the preceding-year models, in which the thick- ness is 6.7 mm. Because of this change, the service (wear) limit is lowered as indicated here: Front disc thickness STANDARD SERVICE LIMIT 6.0 mm (0.24 in.) 5.5 mm (0.22in.) Service Limit 6.0 mm (0.24 in) |188 _GS550E FRONT SUSPENSION ifications are provided for the ‘one is for machines shipped to the United States (E03) and Canada (E28) and is the same as that for single-disc machines; and the other is for those shipped to Europe and Austra (a) U.S.A. and Canadian specifications (b) European and Australian specifications The difference in spring characteristic will be noted in these two graphs: (a) U. ..and Canadian specifications REAR SUSPENSION Just as for front suspension, the rear shock absorb- er specifications are two, (a) and (b). Specifications (2) are the same as for single-disc machines, spec. (b) being for the machines shipped to Europe and Australia, Note the difference in spring charac- teristic between the two: (a) U.S.A. and Canadian specifications Front fork spring characteristic (b) European and Australian specifications Rear shock absorber spring characteristic, (b) European and Australian specifications ve) & 3 an Front fork spring character Fear shock absorber spring characteristicREAR-BRAKE orn ore 1 Vo U Lo] isc; operating This caliper assembly is of double-piston type. Its two pistons are in opposition across the pressure is admitted into the caliper body from a single line and divided, inside the body, into two paths leading to the respective pistons. The other features are similar to those of the front-brake caliper assembly.168 GS550E CALIPER Disassembly 1. Remove torque link rear nuts. Remove the two bolts securing the caliper assembly in place. 2. Disconnect the brake hose from the caliper assembly by removing the union bolt. Take down the caliper assembly. @ Pea © Left caliper @ Right caliper © Piston Tightening torque 2.0-3.0 kgm | Toraue nk sue tink (14.5-21.8 Ib) 2.5-4.0 kgm Gallperiboe: (18.0- 29.0 1b-ft) 1.8-2.5 kom vaeistt (11.0- 18.0 bf) Torque link nut, ® Union bolt @Caliper bolt 3. Remove the pad inspection cap. Draw out the ‘two pins supporting each pad: a stop pin must be pulled off first from the end of each pin. At the same time, remove two springs. Spring, ® Pin, ® Stop pin 4, Remove the two bolts fastening the two caliper body halves together, and separate the two halves. Caliper axle bolt tightening torque 2.5-3.5 kom (18.0- 265 tb-tt) Caliper axle boltGS5S5OE 169 5. Remove the boot from each piston. Apply compressed air (2 kg/cm? , 28 psi) to the internal fluid passage to force each piston out of its bore. Inspection 1. Mike the cylinder bore and piston to see whether these diameters are within the limits. Replacement is necessary where the limits are exceeded. Dime [Sued | avi sore | 38180-28220 mm] 38.290 mm treat 1sost im) | (100"'m) Faon | 88:116-88:148m | 38.016mm (1.5006 - 1.5019 in.) (1.4967 in.) 2. Inspect the piston boot and seal of each piston for wear and damage. 3. Check brake pads for wear. Each pad is stepped at its edge to present two edge faces, one being painted red and the other being 1.5 mm (0.06 in.) thick. The pad may be kept in service until this 1.5 mm (0.06 in.) face disappears due to wear. Wear limit line110 GS5S5OE Reasembly Reassemble in the procedure reverse to disassembly paying attention to the following points. 1. Wash the pistons, piston boots, rubber seal and caliper body halves with fresh brake fluid just before using each in reassembly: reassemble while washing. 2. Fit a brake pad shim to the backside of the brake pad so that ‘* Be hole” in the shim points frontward. Hole 3. When feconnecting the brake hose to the caliper body, be sure to point the hose in the direction shown, IMPORTANT: Most of the steps enumerated for teassembly of the frontbrake ‘caliper assembly are applicable to ‘this rear-brake caliper asembly. Be sure 10 carry out those applicable ‘ones. | PARALLEL, seed Air bleeding of the brake fluid circuit Refer to the procedure outlined in FRONT- BRAKE ASSEMBLY; the underlying principles are the same. Differences, however, are due to ‘the fact that the master oylinder is actuated by a pedal and that there are two bleeder valves. Bleed air out from the inboard valve first, and then from the outboard valve. Operate the pedal in the way the brake lever is operated to drive air out. The pedal being de- pressed will yield and go down as the fluid is spilled into the receptacle; in the case of the front brake, the lever touches the handle. When the pedal comes within 10 mm (0.39 in.) from the footrest in so yielding, close the bleeder valve and release the pedal. Repeat the process of pumping and depressing the pedal fully to spill more fluid until air bubbles disappear in the fluid being spilled into the receptacle.‘GAUTION: “As in the case of front brake eal assembly, it is highly DUpper level, @Lower level Brake pedal adjustment Adjust the pedal height in the following manner: 1. Loosen lock nut “3”. Loosen the return stopp. er bolt on the brake pedal. Lock nut “A”, @ Lock nut “B”, @ Push rod @Brake pedal 2, Loosen lock nut “A”. Rotate the pushrod to bring the pedal to the elevation 10 mm (0.39 in.) below the top face of the footrest; and secure the pedal there by tightening the nut oa 3. Adjust the clearance between pedal arm and return stopper to 0.5 mm (0,02 in], and tighten lock nut “B", GSS5S5OE 171 Pad replacement The pads can be replaced from the caliper assembly in place, by removing the pins supporting the pads and their stop pins and springs, but this method is not recommendable because the piston boots too might come off: it is almost impossible to accurately refit the boot when the assembly is in place. The reliable and accurate replacement is ensured by removing the caliper assembly and by installing the replacement pads in the assembly off the ‘machine.171_GS550E MASTER CYLINDER 3. Remove the oil union boit on the master cylind: er, and disconnect the brake hose. 4. Disconnect the oil hose. 5. Remove the two bolts securing the master cylinder to the frame, and take down the cylinder. Pp ; o © Mester cylinder as'y @ Piston & cup set peas | Sea L, e Disassembly 1, Remove the rear brake pedal 2. Pull off the split pin from the lower end of pushrod, and disconnect the master cylinder rod from the brake pedal arm, Pash rod ®@Brake pedal arm 15-25 kom Tightening torque enenine ees (11.0- 18.0 1b-f) Master cylinder bolt, @Oil union bolt 6. Take off the boot, and pick out the circlip by using the special tool. (09900-06105 Circlip remover 7. Take out piston, check valve, coil spring and primary cup from the cylinder. ‘Using ‘a wood of softmetal stick, push these internals out of the cylinder bore, $0 5 not to nick or mar bore wall. Be Careful, too, not to damage them. NOTE:GSS5S50E 173 Inspection 1, Mike the cylinder bore and piston to see wheth- er these diameters are within the limits; if not, replace the cylinder or piston or both. Diameter Stendord Service limit ies | Over 14.000 -14.043mm | Bore | 14.055 mm (0.8512-0.5629 in) | (geen ~ | Under 13.941 -13.908 mm Piston 13.929 mm (0.5489-05409 in) | roan) Reassembly Reassemble the master cylinder by reversing the sequential steps of disassembly and by taking the following additional steps: 1. Be sure to apply brake fluid to the cylinder bore and all the internals to be inserted into the bore. 2. Combine the check valve, coil spring and prima- Ty cup outside the cylinder, and insert the combination into the bore, taking care not to unseat the coil spring off the check valve Remember, the spring could readily come off the valve. Be careful not to allow the primary cup to cock inside the bore, 3. It is @ good practice to use a replacement prima- ry cup unless the cup removed in disassembly is perfectly in good condition. 2. Inspect the primary cup and boot for wear and damage and, as necessary, replace them. 4. After fitting the circlip, try to turn it in place ‘to make sure it is snugly seated in the groove. Use of a replacement circlip is preferred to re-using the one removed in disassembly.114 GSS5SOE 5.Mount the master cylinder on the frame first and make up the connection between its push rod and the brake pedal next. Be sure to lock the link pin by bending the legs of split pin apart and around the link pin. 6.When installing the brake pedal, be sure to align the match marks at the pivot part, thereby Positioning the pedal correctly. 7. Carry out an air bleeding operation as out- lined previously. 8. Adjust the breke pedal height as outlined previously. BRAKE PARTS TO BE PERIODICALLY REPLACED GS550E employs hydraulic brake for both front and rear wheels. Replace the piston and seal etc. of the master cylinder and caliper periodically once every two years. Refer to GS550 Service Manual as for the front master cylinder, caliper, piston and seal etc. Rear master cylinder and caliper to be replaced periodically are as follows. REAR MASTER CYLINDER J ® | Q OFiston @secondary cup @Primary cup @Spring Check valve REAR CALIPER @Pad @Piston seal © Rubber seal @Piston @Piston bootsection provides new technical informations for GS55OL, under E-03 specification, which differ from those of the GS55O and GS55OE. CONTENTS GENERAL INFORMATION SPECIFICATIONS ........2.202055 “177 SERVICE DATA . 22179 EMISSION CONTROL CARBURETOR COMPONENTS............. 185 CHASSIS FRONT FORK = 186 REAR SHOCK ABSORBER . cece ee ee ee esse 187 WHEELS FRONT WHEEL ............ 188 TIRE AND TUBE REMOVAL . ++ 189 ELECTRICAL CHARGING SYSTEM ........ -- 191 INSPECTION AND SERVICING . ++ 192 COMBINATION METER ..... ++ 196 FUEL GAUGE ..........0000 ++ 197 WIRE AND CABLE ROUTING .. WIRING DIAGRAM ....178 GS55OL(E-03) VIEW OF GSS550L Right SideGS55OL(E-03) 177 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length .......0..000 Overall width . veeeeees 2190 mm (86.2 in) 890 mm (35.0 in) Overall height 1215 mm (47.8 in) Wheelbase... 1480 mm (58.3 in) Ground clearance . 165 mm ( 6.5 in) Dry mass; ... 206 kg (454 Ibs) ENGINE Type... Fourstroke cycle, air-cooled, DOHC Number of cylinders . 4 Bore . 56.0 mm (2.205 in) Stroke .. Piston displacement . Compression ratio Carburetor . Aircleaner . 55.8 mm (2.197 in) 549 ml (33.5 cu.in) 86:1 MIKUNI VM22S5, four - Polyurethane foam element Starter system Electric and kick Lubrication system Wet sump. TRANSMISSION Clutch. - Wet multi-plate type Transmission... 6-speed constant mesh Gearshift pattern 1-down 5-up Primary reduction . 1.97 (87/44) Final reduction 3.333 (50/15) Gear ratios, Low . 2.666 (32/12) 2nd. 1.777 (32/18) 3rd... 1.380 (29/21) 4th 1.173 (27/23) 5th 1.045 (23/22) Top 0.956 (22/23) Drive chain... DAIDO D.I.D. 5OHDL or TAKASAGO RKS5OSHO,110 links CHASSIS. Front suspension Rear suspension . Steering angle . Caster Trail... ‘Tuming radius Front brake Rear brake . Front tire size .. . Rear tire size Telescopic, oil dampened ‘Swinging arm, oil dampened, spring §-way adjustable 40° (Right and Left) 62°00" 118 mm (4.6 in) 2.6 m (8.5 ft) Disc brake Disc brake 3.25H19-4PR 3.75H18-4PR178 GS55OL(E-03) ELECTRICAL Ignition type . Ignition timing Spark plug Battery . Gonerator . Fuse . Headlight . Tail/Brake light . Turn signal light . Speedometer light Tachometer light ‘ Neutral indicator light . High beam indicator light . Turn signal indicator light. Oil pressure light... .. CAPACITIES Fuel tank including reserve reserve . Engine oil . Front fork oil .. « Battery ignition «17° B.T.D.C. below 1 500 r/min and 37° B.T.D.C. above 2 500 r/min . NGK B8ES or NIPPON DENSO W24ES + 12V 12Ah/10HR « Three-phase A.C. generator = 15/10/1008, - 12V 60/55W « 12V 8/23W (3/32 cp) = 12V 23W (32 op) - 12V3.4W . 12V3.4W - 12V3.4W . 12 3.4W . 12V3.4W . 12V3.4W = 13 L (3.4 US gal) = 3.0L (3.2 US at) 2.4L (2.5 US qt) = 217 ml (7.33 US oz ) in each legGS55OL(E-03) 179 SERVICE DATA Valve + Guide mm (in) ITEM. STANDARD LIMIT Valve lift IN 7.2 (0.28) me EX 7.0 (0.27) faa Tappet clearance or valve clearance IN (0.03 — 0.08 (0.001 — 0.003) (cold engine) EX 0.03 — 0.08 (0,001 — 0.003) Valve guide ~ Valve stem clearance IN jones = cored eon ex 0.040 — 0.070 0.35 {0.0016 — 0.0028) (0.014) Valve guide 1.D. IN&EX Stern “ Valve stem 0.D. IN (enn Oona 2s eX 6.945 — 6.960 Z | (0.2734 — 0.2740) Valve stem deflection IN & EX - 0,05 (0.002) Valve head thickness ____IN&EX ee | 0.5 (0.02) Valve seat width IN & EX. 1.0 — 1.2 (0.04 — 0.05) Valve head radial runout IN & EX - 0.03 (0.001) Valve spring free length INN 35.3— 37.0 (1.39 - 1.46) 33.9 (1.33) OUT 43.0 — 43.25 (1.69 — 1.70) 41.3 (1.63) m 29.3 — 34.0 kg/23 Valve spring tension INN (e507. ie (0.91) - 50.4 — 58.3 kg/27 our (111.11 ~ 128.53 Ibs)/(1.06) = ‘Camshaft mm (in) ITEM STANDARD LIMIT 35.485 — 35.515, 35.190 Caan: hetohit mn (1.3970 ~ 1.3982) (1.3854) Ex 35.285 — 35.315 34.990 (1.3892 — 1.3904) (1.3776) Camshaft — Journal clearance IN & EX ope cea (a008) Camshaft journal holder |.D. IN & EX aoe Caen - Camshaft journal 0.D. IN &EX ee en a Camshaft deflection INSEX | = [0.10 10.004) Cam chain 20 pitch length = 157.80 (6.213)180 GSS55OL(E-03) Piston + Ring + Cylinder rom tin) ITEM STANDARD Limit ; 9 — 12 kglem? 6.5 kg/om® Sonprenion preaue (128 = 171 psi (92.4 psi) Difference between cylinders = 2 kglem? (28.5 psi) 0.050 — 0.060 0.120 Piston ~ Cylinder clearance ee 8ee ona) 56.000 — 56.015 56.080 Cylinder bore (2.2047 — 2.2053) (2.2079) , , 55.945 — 56.960/15 56.880 Piston dle. /Mesetrienent point (2.2026 — 2.2031)/(0.59) (2.2000) Cylinder distortion = 0.2 (0,008) Cylinder head distortion = 0.2 (0.008) Piston ring free end gap ist ‘Approx. 6.5 (0.26) 5.2 (0.20) and ‘Approx. 6.5 (0.26) 5.2 (0.20) Piston ring end gap ist 0.1 — 03 (0.004 — 0.072) 0.7 (0.08) 2nd 0.1 = 0.3 (0.004— 0.012) 0.7 (0.03) . 0.020 — 0.085 0.180 Piston ring— Groove clearance 1st ie nee ay sal 0.020 — 0.060 0.150 (0.0008 — 0.0024) (0.0059) Piston ring groove width ist 121 — 1.23 (0.047 — 0.048) = and 1.21 = 1.23 (0.047 — 0.048) = oil 251 — 2.53 (0.099 — 0.100) = Piston ring thickness ist idiots poet = ond 1.170 1.190 ~ (0.0461 = 0.0469) Piston pin — Pin bore clearance japon poeaei (Don Piston pin bore I.D. oo ee - 76.005 — 16.000 Piston pin 0.D. (0.6297 — 0.6300)GSSS5OL(E-03) 181 Crankshaft ‘ean ITEM STANDARD Limit Con-rod small end bore — 0.006 — 0.019 0.080 Piston pin clearance (0.0002 — 0.0007) (0.0031) 16.006 — 16.014 Con-rod small end bore I.D. lonson ane - e ‘5 15.995 — 16.000 Pistonpin'0.D. (0.6297 — 0.6300) i Big end side clearance (010 - 0.65 (0.004 - 0.026) 1.00 (0.039) Con-rod big end wear = 0.08 (0.003) Crankshaft runout - 0.05 (0.002) il Pump mm (in) ITEM STANDARD LIMIT Oil pump reduction ratio Oil pressure (for 60°C) 1.821 (87/44 x 35/38) ‘Above 0.1 kg/em* (1.42 psi), Below 0.5 kg/em? (7.11 psi) at 3.000 r/min Tip clearance = 0.20 (0.008) Outer rotor clearance = 0.25 (0.010) Side clearance = 0.15 (0.006) Clutch mm (in) ITEM STANDARD LIMIT Drive plate thickness 2.9 — 3.1 (0.11 — 0.12) 2.6 (0.10) Drive plate distortion = 0.2 (0.008) Driven plate thickness 1.6 (0.06) = Driven plate distortion = 0.1 (0.004) Drive plate claw width 11.8 = 12.0 (0.46 — 0.47) 11.0 (0.43) Clutch spring free length 38.4 (1.51) 35.9 (1.41) Pri. drive — Driven gear backlash 0 — 0.03 (0 - 0.001) (0.08 (0.003)182 GS5S5OL(E-03) ‘Transmission rom (in) ITEM STANDARD LIMIT. Primary reduction 1.977 (87/44) Final reduction 3.333 (50/15) Gear ratios, Low 2.666 (32/12) 2nd) 1.777 (32/18) 3rd 1.380 (29/21) 4th 1.173 (27/23) Sth 1.045 (23/22) Top 0.956 (22/23) ‘Gear backlash 1st, 2nd, 3rd and 4th (0— 0.04 (0 — 0.002) (0.09 (0.004) ‘th and Top (0.05 — 0.10 (0.002 — 0.004) (0.15 (0.006) Shift fork — Groove clearance 0.1 — 0.3 (0.004 — 0.012) 0.5 (0.020) Shift fork groove width 5.5 — 5.6 (0.217 — 0.220) = Shift fork thickness 5.3 — 6.4 (0.209 — 0.213) = Drive chain size DAIDO SOHDL or TAKASAGO RKSOSHO, 110 links 20pitch length 317-1 — 317.7 (1248 — 12.51) 320.0 (12.60) Carburetor: mm (in) = ITEM ‘SPECIFICATION Idle r/min 1.000 — 1.200 r/min Carburetor type MIKUNI_VM225S 1D. No. 47110 Bore 22 (0.87) Float height 24.0 + 1.0 (0.95 + 0.04) Fuel level 4.0 + 1.0 (0.16 0.04) Air screw PRE-SET. Cut away 15 “Jet needle 5DL373, Pilot screw _ PRE-SET Pilot jet #15 Pilot outlet 06 Needle jet o-4 Bypass o7 #80 Main jetGS5S5OL(E-03) 183 Electrical mmiin) ITEM ‘STANDARD LIMIT niin 17 Bro ge | oa ee Firing order 1.2.4.3. Spark plug NGK BBES or NIPPON DENSO W24ES ‘Spark plug gap 0.6 — 0.8 (0.024 — 0.031) Contect point gap 0.3 — 0.4 (0.012 — 0.016) Dwell angle 190° | Spark performance (Over 8 (0.3) at 1 atm Condensor capacity 0.25 + 0.03uF Ignition coil resistance (primary) ‘Approx. 42 Ignition coil resistance (secondary) ‘Approx. 15 k® Battery capacity 12V 43.2kC (12 Ah)/10 HR Specific gravity 1.28 at 20°C Regulated voltage 14 — 15.5V at 5 000 r/mi Fuse size 15/10/1070 Generator no-load data More than 70V (AC) at 5 000 r/min ‘Starter motor brush length 12-13 (0.47 — 051) 6 (0.24) st MITSUBA 14 (0.55) . .. DENSO 9 (0.38) Brake + Wheel aan) ITEM STANDARD LIMIT ‘Axle runout Front & Rear = (0.25 (0.010) Brake disc thickness Front 6.5 — 6.9 (0.26 - 0.27) 6.0 (0.24) Rear 65 — 6.9 (0.26 — 0.27) 6.0 (0.24) Brake disc runout Front & Rear = 0.30 (0.012) Master cylinder cylinder dia. Front 14.00 (0.651) = Rear 14.00 (0.551) = Master cylinder piston dia. Front 13.96 (0.550) = Rear 13.96 (0.550) = Brake caliper cylinder bore Front 42.85 (1.687) = Rear 38.18 (1.503) = Brake caliper piston dia. ‘Front 42.82 (1.686) = Rear 38.15 (1.502) = | Wheel rim runout Radial & Axial = 2.0 (0.08) Tire size Front - 3.25H19 — 4PR Rear 3.75118 — 4PR Tire tread depth Front = 1.6 (0.06) Rear = 2.0 (0.08)184 GS55OL(E-03) Tire air pressure FRONT. REAR Cold Inflation aya Preaine Solo Riding Dual Riding Solo Riding Dual Riding kPa | psi | kg/em?]_kPa| psi | kg/em?| kPa | psi | kg/em?| kPa | psi | ka/em™ Normal Riding | 175| 25 | 1.75 | 175| 25 | 1.75 | 200| 28 | 200 | 225 | 32 | 2.25 Seaegtt'9 | 200) 28 | 2.00 | 200] 28 | 2.00 | 225| 32| 225 | 280 | 40] 280 ‘Suspension mm(in) ITEM STANDARD LIMIT Front fork stroke 160 (6.30) Rear wheel travel 100 (3.9) Front spring free length Lower 467.0 (18.39) I 451 (17.76) Upper 165.8 (6.53) 153 (6.02) Fork oil level 229 (9.02) ‘Swinging arm pivotshaft runout | = I 0.3 (0.012) Capacity mm (in) ITEM SPECIFICATION Fuel tank including reserve 13 L (3.4/2.9 US/Imp gal) reserve 3.0L (3.2/2.6 US/Imp qt) Engine oil Change c 2.4 L (2.5/2.1 US/Imp qt) Filter change 2.6 L (2.7/2.3 US/Imp qt) ‘Overhaul 2.7L (2.8/2.4 US/imp qt) Front fork oil (each leg) 217 mi (7.33/7.64 US/Imp oz) Fuel type Use only unleaded or low-lead type gasoline of at least 85-95 pump octane (®™ method) or 89 octane or higher rated by the Research method. Engine oil type SAE 10W/40 Front fork oil type Mixture ratio SAE 10W/30 : SAE 5W/20 = Wattage (W) Head light HI 6 Lo 55. Tail/Brake light 8/23 Tum signal light 23 Tum signal indicator light 34 Neutral indicator light 34 High beam indicator light 34 Speedometer light 34 Tachometer light 34 Oil pressure light 34GSS55OL(E-03) 185 EMISSION CONTROL CARBURETOR COMPONENTS The GS550L utilizes a specially manufactured carburetor to limit emissions. Emission type carburetors require different components and other special adjustments if they are to perform properly. There are seven (7) carburetor mixture control components in each carburetor assembly. Three (3) of these ‘components are machined to much closer tolerances than standard carburetor jets. These three (3) jets, MAIN JET, NEEDLE JET, PILOT JET, must not be replaced by standard jets. To aid identification of these three (3) jets a different style letter and number are used. If replacement of these close tolerance jets be- ‘comes necessary, be sure to replace them with the same type of close tolerance jet marked in the same manner as the examples shown below. Eniission Type Figures Used On Close Tolerance /e?emwg4¥5 68 718690 Jet Components The throttle Slide and the Jet Needles are not special tolerance components. Either of these two parts may be replaced by standard tolerance parts, provided that they are the same size. The carburetor specifications for the emission-controlled GS550L are as follows. Carburetor | Main Needle set ink Pitot Air Pitot 1.0, No. Jet Jet Needle wey Jet Screw ‘Screw 1 | PRESET | PRESET am0 #80 o-4 | spis7-3 18 #15 | DO NOT ADJUST DO NOT ADJUST THE AIR SCREW AND PILOT SCREW. Adjusting, interfering with, replacing, or reset- ting of either of these adjustable metering components may affect the carburetor performance adversely and ‘cause the machine to exceed the emission levels. Tampering with either of these two adjustments may also subject the person to fines under the federal emission regulations and also the state regulations regarding tempering. The air screw and pilot screw are pre-set by the factory using specialized testing and adjusting procedures. It is not possible to duplicate these adjustments. If persons, who are unaware of these special adjustments or the anti-tampering laws, have tampered with the carburetor adjustments, the Suzuki dealer should contact the distributor's representative for further technical information and assistance.186 GS55OL(E-03) FRONT FORK ® cap bolt ® olseat Oring ® Oil seal spacer Upper spring ® Oitock piece Warher ® Outer woe © omer spring 4B Pinen bore Piston ring D Washer ® Resound spring 4D Lock washer © Damper rod 8 Nut ® toner tube ® Alten bott Dust seal Drain pug D Oitseal stopperring a Gasket (ks) 120 100 | - Loap (FORCE Le 0 20 40 6) 80 100 120 140 160 COMPRESSION (LENGTH) (mmm) FRONT FORK SPRING CHARACTERISTICS 20REAR SHOCK ABSORBER GS5S501(E-03) 187 Hydraulic dampers, each fitted with a coil spring, absorb road shocks in the rear suspension. The spring preload can be varied in five steps. The total damping stroke is 85 mm (3.35 in). Cushion Spring Oil seat Adjuster cam eee a) 240 220 180 160 140 120 100 Loan (Force) 80 60 40 20 CCharacteritic of p ° 2 40 ~«6O ‘COMPRESSION (LENGTH) own)188 _GSS5S5OL(E-03) FRONT WHEEL ® cowrsin — (@ Tube @ Axon Tre @ Waarer Spacer @ Axterpscer 13 Brake dsc @ Rignteover 8 washer © 1 Bot ® 16 Speedomster ® rorbox ® 1p Washer ® Axestar DISASSEMBLY 1. Lift the front wheel off the floor by raising up the engine, with the center stand and jack resting firmly on the floor. 2. Loosen axle nut ® after pulling off cotter pin @ , and loosen axle pinch bolt@ 3. Draw out the axle shaft and take off the wheel. Tightening torque 16-28 ate inch bot "s=28irn B-aiim (sao asiGS5S5OL(E-03) 189 TIRE AND TUBE REMOVAL © Mark the position of the valve stem and rota- tional direction of the tires with chalk, © Remove the valve cap and let out the air. ‘® Remove the valve fastening nut and fully loosen the bead protector nut. Weel 0 ¢ Step on the tire bead, push it down and as shown below, install the five wheel rim pro- tectors (special tools) to the wheel. (09941-94510 (09960-74510 Wheel rim protector Tire bead breaker ‘© Remove the tube, ‘© Remove the tire from the wheel. A | 4 ‘© Using flat tire levers, work the tire bead over the im, starting near the valve stem. REASSEMBLY © Inflate the tbe sufficiently so that the tube does not fold. ‘© Push one side of the tire beads into the wheel rim. Be sure that the embossed arrow mark on the tire faces toward the rotational direction of the wheel.190 GS55OL(E-03) © Noxt, install the tube, insort the valve into the rim, and tighten the valve nut temporarily. An arrow indicating the rotational direction is mark- ed on the rear tire. Ayyellow mark is provided on the valve portion to aid checking of the tire balance. les SZ ‘© Apply soapy water to the tire bead. ‘¢ Hook the bead protector on the bead portion of the tire. ‘© Fit the rest of the tire using tire levers in a posi- on well away from the valve. By pushing the tire, confirm that the tube is not ‘caught between the rim and tire. * Inflate the tire to the specified pressure (see page 184), © Tighten the bead protector nut and then the valve nut. ‘© Fit the valve cap to the valve.GSS5S5OL(E-03) 191 CHARGING SYSTEM The GS550E is provided with a regulator and a rectifier but the new GS55OL with an integrated type regulator/rectifier. The following diagram shows the charging circuits for both model Regulator/Rectifier WIRE COLOR Ren Red wr Y rons Yellow wis .. W/BI ... White with Blue tracer B/W GSS50L Rectifier Lighting Switch i (hep) peor (oui) peor WIRE COLOR Regulator Rus Red WIR .... White with Red tracer Y suo Yellow WIG ... White with Green tracer W/BI ... White with Blue tracer B/W .... Black with White tracer GS850E192 GSS5S5OL(E-03) INSPECTION AND SERVICING Due to modifications of the charging circuit, the procedure for inspection of the A.C. generator, regulator and rectifier has been changed as described below. ‘As the GS55OL has an integrated type regulator/rectifier, both regulator and rectifier can be inspected at the same time. AG. Generator test: — Disconnect lead wires, Y, W/G and W/BI from the A.C. generator. — Start the engine and keep it running at 5 000 min, — Using the pocket tester (range: A.C. 250V) mee. sure the A.C. voltage between Y — W/G, W/G — W/BI, and Y — W/BI. Engine | AC. Line Electrical condition of Speed _| “Veitage ‘AG. generator 5000 | 70Vororer| A.C. generator is satisfactory rimin |"70V under_| A.C. generator is faulty ‘09900-26002 Pocket Tester AC. Generator wis: I+ e w/a 1+ WIRE COLOR Y sus Yellow W/BI ... White with Blue tracer WIG. White with Green tracerGS55OL(E-03) 193 Stator test: Rotor test: Using the Pocket Tester, check continuity — If the stator is in good condition but the A.C. between the lead wires, Y, W/G and W/BI. Also generator is faulty, replace the rotor with anew check that the stator core is insulted. one. — If there is no continuity between the lead wires, or if there is continuity between the lead wires and stator core, replace the stator with a new one. we———} wat 1+ WIRE COLOR Tester Range: 9 x1 WIG ... White with Green tracer194 GS55OL(E-03) Regulator/Rectifier test: — Start the engine and keep it running at 5 000 r/min with the lighting switch turned OFF. — Contact the (+) lead probe of the Pocket Tester to the (+) terminal of the battery, and connect the (-) lead probe to the (—) terminal, then measure the D.C. voltage. — If the A.C, generator is in good condition but the regulator/rectifier is faulty, replace the latter with a new one. (09900-25002 Pocket Test Engine speed | DG. li voltage Electrical condition of Regulator/Rectifier [v= 155V, Regulator/Rectifier is satisfactory Soom 14V under, or 15.5V or over Rogulator/Rectifier is faulty 1 i 1 Regulator/Rectifier | i 1 1 i -4 + atery | © Tester Range: DC 25VGSSS5OL(E-03) 195 — Check resistance between the lead wires using the Pocket Tester. If the resistance measured is incorrect, replace the regulator/rectifier. To make this check-up, refer to the charts below: ‘Tester Range: 9 x 1000 oT we | Y [weil rn | ew wR oFF | ON | ON | OFF Y | OFF ‘on | ON | OFF Wisi | OFF | OFF ‘on | OFF R_| OFF | OFF | ON OFF sw | on | on | on | ON Red weet Yellow wr lack with White tracer White with Blue tracer White with Red tracer196 GS550L(E-03) COMBINATION METER © Speedometer ® Tachometer @ Ureer cover @ Indicator light upper ease ® Ueder cover © Krob D Gaxr position indicator tight assy @® ‘securing crew @ Incicator bulb socket Meter bracket {D) Meter cushion ® Mater eushion 1B Waher B Caprut {IS Speedometer eable {] Tochometer cable Maer bub socket {Securing serew INDICATOR LIGHT BULB REPLACEMENT © Remove the four indicator light upper case securing screws and take off the upper case. © After installing a new bulb, check for continuity. If the bulb does not light, inspect the wiring for open or short circuits. METER DISASSEMBLY ‘© Disconnect the speedometer cable and tachometer cable. ‘© Loosen the four under-cover cap nuts. Pull out the speedometer and tachometer.FUEL GAUGE WIRING GS55OL(E-03) 197 3. Construction of each portion and operating meter. Tachometer \ Gasge unit} © Beery @ Fur! indicator @® Voltage regulator @ Float 1. The above drawing is a schematic of fuel gauge wiring. The internal resistance value of the gauge unit is adapted to vary with the height of the float. It is difficult for current to pass through the it when the resistance value is high, and consequently the swing of the meter is small {close to point E). The more current passes through the circuit, increasing the swing of the pointer (close to Point F), when the resistance value is low. 2. The relationships between the amount of gaso- line and meter indications are as follows: @ Temperature compensating bimeal © Pointer @ Needle @ Main bimetat ‘© Main operation Current passing through the heater wire deflects the main bimetal causing the pointer to move. ry operation This compensates for variations in temperature and voltage. A temperature compensating bimetal is provided so that no ‘occur due to temperature changes ‘The meter points to E —2°30' when the amount of gasoline is between 0 to 1.5 liters. Also the meter points to F +5° when the amount of gasoline in the tank is botwoon 9.1 liters and full. meter: “Amount of gssoline SS w Metering 15 Point € 2°30" 19 E 36 Red zone max. limit Kamen) Ot 48 2 82 F En Point F+5" Foadgoint ff -—~ [Rina er] Witrout temperature compensation (attired positon of nee)198 GS5S5OL(E-03) Tempersture Fixed peint With temperature compensation (constant position of nee) Even if the temperature rises inside the meter ‘and causes the main bimetal to deflect as shown in the above drawing, the temperature compen- sating bimetal will deflect to the same degree as ‘the main bimetal, in the reverse direction, to keep the needle position constant. * Voltage regulator The passage of current through the heater wire deflects the bimetal and causes point separation. This point separation stops the current until the bimetal begins to cool which causing the point to connect again. A large amount of current passes through the heater wire when the supply voltage is high, causing the bimetal to deflect quickly, and the points to separate. This is illustrated in the following drawing which shows that the average current is constant. f | Atamaovotae : é Time ‘Average output woltage: 7 © Gauge unit The displacement of the float changes the posi- tion of the contact plate which slides on a wire wound resistor causing the resistance value to vary. Tometer INSPECTION OF FUEL METER AND GAUGE The fuel meter is enclosed within the tachometer assembly. The following table is used for troubleshooting. Amount of sasoline | 15/19/36] 48 |82| 91 i) Resistance (9) [ito | 95 | s0/s2s[7 | 3GSS55OL(E-03) 199 Pointer failure and minus nection (1) Meter pointer fails to move. {2} Moter hes @ substantia! minus indica tion when Key is sured on. | Checking method (0) Betemine wheter rouble within Remove gauge connector to shortciruit Meter pointer fis © |= stersie defective [-—=) Check (2) Sue tel ofan conc Graa gane tmawoncn eqat to sero DY, snd Soe Base etcston “ened. _-| weerpoine sine LL Gauge tect Lom check) aE SESS rer sek seat eta rca: | oleh | erate [ofa indication. aoe: Merooiner sang |__[ Wingham a a ‘to extreme position defective SEN, (contest of connator rin (a) Gnu cock Measure resitance value between two ange, unetae | aug detective H Replace gauge tert fps tid caesar Ravcarecenesital iors an FV) se = ‘Normal resistence | firing harness: “no a9 —O5 1 je ee Lf cree a seve DOD, a= 17% (Contact of connector terminal) TO Connacan contac chek olin ‘rend sires tity premise til Singha soe cates tee | fre cone nd tar aaa EF poet a) [ee 1B) Connector contact check wiring |__| Meter pine ine ‘Sram ‘Senreme poston Stren ing prmir sine terminal Sry coker why barn oe orterove Contes and Shasa er Connector contet detective Scien " 140 120 Loan (FORCE) 8s aes (om) o 2 4 60 COMPRESSION (LENGTH)GSS5S5OL(E-28) 217 FRONT WHEEL © cotwrpin Tube @ Axterst 1) Tie @ Washer 0 Spacer @ aAxiespacer 19 Brake disk ® Right cover 18 Washer © Bearing spacer 3 Bolt D Bearing 16 Speedometer gear box 1) Washer B® Axeshar. DISASSEMBLY 1. Lift the front wheel off the floor by raising up the engine, with the center stand and jack resting firmly on the floor. 2. Loosen axle nut @ after puliing off cotter pin © , and loosen axle pinch bolt@ 3. Draw out the axle shaft and take off the wheel. Tightening torque - 15 25 Nem ‘Axle pinch bolt 1.5-25kgm 11.0 - 18.0 tb-ft ‘36 — 52 Nem Axle nut (eee 26.0375 lb-ft218 GS5SOL(E-28) TIRE AND TUBE REMOVAL ‘© Mark the position of the valve stem and rota- tional direction of the tire with chalk. ‘¢ Remove the valve cap and let out the air. ‘¢ Remove the valve fastening nut and fully loosen the bead protector nut. Weel ien than 069) Mesure fesitancevaie of gnuge Secor {Empey simon 1020) ing ‘Normal reiince [+ ‘check (8) (6) ae se oe leer han Tngereinwrned |__ Te artectve fe] chan mee teint Seek mae atinan Wotieen gente Som. (Even when meter is normal, interrupted mina (Yellow tick laed wits) of mater or a (vellonfedack tan nica) of rater of Voltage can be obtained. However, here, sae Has el of the metor is detective because eeter for anvoe an creund wings to extreme patito) Tagicates consent Jageets Ho} creek i) (9) Meter sie check Remove ‘pole meter sie connector and meanre reistence value betwern positive {erminal and ground terminal Large resistance {ae aon, lee 2 Tease [cf eee = (65 rine defective ‘Check (10) {10) Ground connetor tec Gmee Seung onditon” of ground Serine Sa marie comer ot {ek side, Mesure resstnce wot Giaeinniae etween ground terminal shown in drow: Sette Tag! end fame grounding, ro conductance Le} creek (19) Resistance 0 L___ | detective contact of L__ meter tide connector Greek (11230 GSS55OL(E-28) ins meter inceation|—=| A change meter 111) Connsctor contact check. wi i seizure of meters bere mar fccaon efter correcting Seizure of merc somal engl ‘Normal me seh Lfcneck wiring heres Inebeation OK Seusd mer (cheng (Cnacaeren—] Chock of resistance value betwen terminals Meter side Orange— Yellow/Black 4565.0 range Bisck/White 552502 Gouge sie Fu 1-50. Emory 108-1170GSSS5OL(E-28) 231 WIRE AND CABLE ROUTING / Clamp position Positive lead wire232 GSS55OL(E-28)GSSS5OL(E-28) 233 WIRING DIAGRAM234 GSSSOT(E-O1)Please refer to the sections 1 through 14 of this service manual except for the items described in this section. This section covers three models of the GSS5O series: GS550, GS550D and GS55OE for the specifications except U.S.A. GS550: _ Spoked wheel and front single disc brake model GS550D: Spoked wheel and front double disc brake model GS55OE: Cast wheel model CONTENTS GS550T SPECIFICATIONS ............5 SERVICE DATA ...........0-55 TORQUE TABLE .. SPECIAL MATERIALS MODIFICATIONS .... FUELSYSTEM ........ CHARGING SYSTEM ... FULL-TRANSISTORIZED IGNITION SYSTEM STEERING STEM FRONT MASTER CYLINDER ... FRONT CALIPER ........ WIRE AND CABLE ROUTING . WIRING DIAGRAM ...... 250 +259 | - 276 seeeeee es 287 GS5501LT SPECIFICATIONS . SERVICE DATA .. FUELCOCK ivirsiccvsseeeny WIRE AND CABLE ROUTING . WIRING DIAGRAM .........-.55236 GS5S5OT(E-01) GS550T Right sideGSS5S5OT(E-O1) 237 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length . sees 2175mm (85.6 it Overall width . 850 mm (33.5 Overall height . 1155 mm (45.5 Wheelbase Z 1.435 mm (56.5 in) Ground clearance . . 150 mm ( 5.9 in) Dry mass .. 196 kg (432 Ibs) . . . GS550, GS550E (Only for Canada) 205 kg (452 Ibs) . .. GS550D, GS550E Gross vehicle weight rating . .. 365 kg (804 Ibs) ENGINE Type... Four-stroke, air-cooled, DOHC Number of cylinders... 4 Bore .... = 56.0 mm (2.205 in) 55.8 mm (2.197 in) 549 cm? (33.5 cu.in) 86:1 Stroke ... Piston displacement Compression ratio. . Carburetor . MIKUNI 8S32SS, four Air cleaner ....... Polyurethane foam element Starter system .... Electric Lubrication system Wet sump TRANSMISSION Clutch : Wet multi-plate type 6-speed constant mesh 1-down, 5-up 1.977 (87/44) 3.333 (50/15) 2.666 (32/12) Transmission. Gearshift pattern . Primary reduction Final reduction... Gear ratios, Low .. 2nd... 1.777 (32/18) 3rd. 1.380 (29/21) 4th 1.173 (27/23) bth. 1.045 (23/22) Top . 0.956 (22/23) Drive chain... eo DAIDO D.1.. SOHDL or TAKASAGO RK5OSHO, 110 links CHASSIS Front suspension .............+sse+s0+ Telescopic, oil dampened Rear suspension ... Steering angle . Caster... Trail . g Turning radius ‘Swinging arm, oil dampened, spring 5-way adjustable 40° (right and left) eae BIE OD. sees 120mm (4.72 in) . 26m (85 ft)238 GS5SOT(E-O1) Front brake Rear brake . . Fronttire size ... se Rear tiresize ...... Front tire pressure .. Rear tire pressure . .. ELECTRICAL Ignition type Ignition timing Spark plug .. Spark plug gap . Battery . . Generator . Fuse... CAPACITIES Fuel tank including reserve ........ 202-045 reserve ....... Engine oil change filter change ....... 6.56 overhaul , Front fork oil ..... «Disc brake - . GS550, GS550E (Only for Canada) Disc brake, twin . . . GS550D, GS550E . Internal expanding . . . GS550, GS550D Disc brake . . . GSB50E . 3.25H19-4PR 3.75H17-4PR «175 kPa (1.75 kg/cm? , 25 psi) (Normal solo riding) + 200 kPa (2.00 kg/em?,, 28 psi) (Normal solo riding) - Battery ignition Transistorized (Only for Canada) + 17° B.T.D.C. below 1.500 r/min and 37° B.T.D.C. above 2 350 r/min + 18° B.T.D.C. below 1 500 r/min and 40° B.T.D.C. above 2 360 r/min (Only for Canada) NGK B8ES or NIPPON DENSO W24ES-U = 0.6 — 0.8 mm (0.024 — 0,031 in) both NGK and NIPPON DENSO. = 12V 43.2kC (12Ah)/10HR . Three-phase A.C. generator = 10/10/10/154 16 L (4.2/3.5 US/Imp gel) - 4.0 L (4.2/3.5 US/Imp qt) 24 L (25/21 US/Imp at) +++ 26 L (27/23 US/Imp at) + 2.7L (2.8/2.4 US/Imp qt) + 165 mi (5.58/5.81 US/Imp 02) in each leg * Specifications subject to change without notice.SERVICE DATA GSSSOT(E-O1) 239 VALVES + GUIDES Unit: mm (in) ITEM STANDARD Limit Valve Dia, N. aap 27.0 BX | (1.08) Valve lift ] 7.2 Re | (0.28) 1 70 Ee (0.27) Valve clearance or Tappet | 0.03 — 0.08 clearance (when cold) SEN: (0.001 — 0.003) Valve guide to Valve stem | 0.025 — 0.055 0.35 clearance Ns | (0.0009 — 0.0022) (0.014) 0.040 — 0.35 x | (0.0016 — (0.014) Valve guide |.D. ieee ae Valve stem 0.D. ] 6.960 — 6.975 IN, (0.2740 - 0.2746) 6.945 — 6.960 Be (0.2734 — 0.2740) Valve stem runout | 0.05 IN, BEX. — | (0.002) Valve head thickness | 05 IN. & EX. — | | (0.02) Valve seat width T ineex. | Valve heed radial runout | 0.03 IN, & EX. — | | (0.001) Valve spring free length | 339 (IN. & EX.) INNER (1.33) a3 OUTER —_— (1.63) Valve spring tension 29.3 34.0 kg (IN, & EX.) INNER (64.59 — 74.96 Ibs) — at length 23 mm (0.91 in) | 50.4 — 58.3 kg OUTER (111.11 = 128.53 Ibs) = at length 27 mm (1.06 in)240 GS55OT(E-O1) CAMSHAFT + CYLINDER + HEAD Unit: mm (in) ITEM STANDARD: LIMIT Cam height IN, 35.485 — 35.515 35.190 % (1.3970 — 1.3982) (1.3854) x 26.286 — 36.216 24,090 if (1.3892 — 1.3904) (1.3776) Camshaft journal oil clearance Pr 0.032 — 0.066 0.150 a z (0.0013 — 0.0026) (0.0059) Camshaft journal holder 1.D. 22.012 — 22.025 SERS (0.8666 — 0.8671) Camshaft journal 0.0. 21,959 — 21.980 INES (0.8645 — 0.8654) Camshaft runout On IN. & EX. — (0.004) Cam chain 20 pitch length 157.80 (6.213) ‘Cam chain pin (at arrow “3"*) 20th pin ——- Cylinder head distortion 02 (0.008)GSS55OT(E-O1) 741 (0.6297 — 0.6300) PISTON + RING + CYLINDER Unit: mm (in) ITEM STANDARD LIMIT ‘Compression pressure 900 — 1 200 kPa 650 kPa (9 12kg/em?, 128-171 psi) __| (6.5 ka/em*, 92.4 psi) | ‘Compression pressure difference 200 kPa (2 kg/em?, 28 psi) Piston to Cylinder clearance (0.080 — 0.060 0.120 (0.0020 — 0.0024) (0.0047) Cylinder bore 56.000 — 56.015 56.080 (2.2047 — 2.2053) (2.2079) Piston Dia, 35.945 — 55.960 55.880 (2.2026 — 2.2031) (2.2000) | Measure the 15 (0.59) | from piston skirtend, Cylinder distortion 0.2 = (0.008) Piston ring free end gap 5.2 1st | N Approx. 6.5 (0.26) (0.20) | 5.2 ee | eee | N Approx. 6.5 (0.26) (0.20) Piston ring end gap is 0.10 -0.30 07 | (0.004 — 0,012) (0.03) | 0.10 —0.30 07 | ans (0.004 - 0.012) (0.03) Piston ring groove clearance ta 0.180 ma (0.0071) 0.150 ane —_ (0.0059) Piston ring groove width ie 1.21 =1.28 . (0.047 - 0.048) | 1.21 -1.23 2nd (0.047 — 9.048) | i oi 2.51 - 2.53 a (0.099 - 0.100) ie 1.175 — 1.190 (0.0463 — 0.0469) 1.170 — 1.190 2nd (0.0461 — 0.0469) ~ Piston pin bore 1.D. 16.002 — 16.008 16.030 (0.6300-0.6302) (0.6311) Piston pin O.D, 15.995 — 16.000 15.980 (0.6291)242 GS55OT(E-O1) CRANKSHAFT Unit: mm (in) ITEM ‘STANDARD Limit Conrod small end I.D. 16.006 — 16.014 16.040 (0.6302 — 0.6305) (0.6315) Conrod deflection _— 3.0 (0.12) Conrod big end side clearance 0.10 — 0.65 1.0 __ (0.004 — 0.026) (0.039) | Crankshaft runout 0.05 | (0.002) lL PUMP. Unit: mm (in) ITEM STANDARD Limit Oil pump reduction ratio 1.821 (87/44 x 35/38) = Oil pressure (at 60°C, 140°F) 10 kPa Above (0.1 kg/ern®, 1.42 psi) Bel 50 kPa a oe (0.6 kg/cm? , 7.11 psi) | at 3.000 r/min, | Tip clearance [020 | | (0.008) ‘Outer rotor clearance | 025 == | 01) | Side clearance | 016 l [___ (0.006) CLUTCH Unit: mm (in) ITEM STANDARD. Limit Clutch cable play 2-3 (0.08 — 0.12) Drive plate thickness 29-31 26 (0.11 -0.12) (0.10) Drive plate claw width 118-120 11.0 (0.46 — 0.47) (0.43) Drive plate distortion 0.2 —_ (0.008) Driven plate thickness 1.6 = 0.06 (0.06 + 0.002) —_ Driven plate distortion 0.1 (0.004) Clutch spring free length 36.9 —_ aan Primary drive to Driven gear ~ 0=0.03, a 0.08 backlash (00.001) (0.003)GSSSOT(E-O1) 243 TRANSMISSION Unit: mm (in) ITEM STANDARD Limit Primary reduction 1.977 (87 / 44) sy Final reduction 3.333 (50 / 15) = Gear ratios Low 2.666 (32 / 12) — 2nd 1.777 (32 / 18) amet 3rd 1.380 (29/21) —- 4th 1.173 (27/23) — Sth 1,045 (23 / 22) patient Top 0.956 (22 / 23) - Gear backlash a 0.04 (0.09 ow (0.002) (0.004) 0.04 | 0.09 | ‘and. (0.002) (0.004) | 0.04 0.09 | ae (0.002) (0.004) | | I 0.04 0.09 | | (0.002) (0.004) = 0.05 — 0.10 0.15 (0.002 — 0.004) (0.006) 0.05 — 0.10 0.15 ie (0.002 - 0.004) (0.006) Shift fork to Groove clearance 01-03 O5 | _ (0.004 — 0.012) (0.020) Shift fork groove width 5.5 -5.6 _ (0.217 — 0.220) Shift fork thickness 5.3-5.4 | L (0.195 — 0.199) Drive chain. Ty D.I.D.: SOHDL | ype _TAKASAGO: RK50SHO Links 110 = ; 320.0 20 pitch length — (12,60) | Drive chain slack 20-30 | (0.8 — 1.2) J244 GS55OT(E-O1) CARBURETOR Unit: mm (in) ITEM SPECIFICATION Carburetor type MIKUNI BS32SS Bore size 32 (1.26) 1.0. No, 47090 Idle r/min, 1.100 + 100 r/min. Fuel level 5.0+0.5 (0.20 + 0,02) Float height 22.44 1.0 (0.88 + 0.04) |__ Main jet #92.5 Main air jet 1.6 Jet needle 5F42-3 Needle jet x6 Pilot jet 40 By pass 1.0, 0.8, 0.8 Pilot outlet 07 Valve seat 2.0 Starter jet 38 Pilot screw 3% Throttle cable play 0.5—1.0 (0.02 — 0.04)GS55OT(E-O1) 245 ELECTRICAL Unit: mm (in) ITEM SPECIFICATION Ignition timing .C. Below 1 500 + 100 r/min. Firing order ‘Spark plug NGK: B8ES. ‘Type N.D.: W24ES-U G 0.6 —0.8 ae (0.024 — 0.031) Spark performance Over 8 (0.3) at 1 atm Contact point gap 0.35 + 0.05 (0.014 + 0.002) (Except for Canada) Dwell angle N.D. 190° Condensor capacity ND. 0.25 0.03 uF Signal coil resistance 60-802 Approx, Br—-B/W and GW—B8/W (Only for Canada) Ignition coil resistance OMW-W or B . Approx. 3.5 - 4.52 rimary OW or BY Approx. 3.5 — 4.5 9 (Only for Canada) Plug cap —Plug cap Approx. 34 — 36 k Secondary Plug cap — Plug Approx. 35 — 38 k® (Only for Canada) Generator No-Load voltage More than 80 V (AC) at 5 000 r/min. Regulated voltage 14.0 = 15.5 V at 5 000 r/min. ‘Starter motor Brush length Limit: 9 10.35) ‘Commutator under cut Limit: 0.2 (0.008) Starter relay resistance 3-42 Battery Type designation YBI0L ~ A2 Capacity 12V 43.2kC (12Ah)/10HR Standard electrolyte 1128 at 20°C tea") 5.G. Fuse size Main 15A Headlight 10A Turn signal 10A Ignition 10a245 GSS5SOT(E-O1) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal free travel 20-30 For GS550 & GS550D (0.8 — 1.2) Rear brake pedal height 10 (0.04) —_ Brake drum 1.D. Rear 180.7 For GS550 & GSS50D a — (2.41) Brake lining thickness Rear 1.5 For GS550 & GSE50D eat —_ (0.06) Brake disc thickness 6.7 + 0.2 (0.26 + 0.008) For GS550 & GS550E (Canada) 5.0 + 0.2 (0.20 0.008) For GS550D & GS550E Front -sr ore ee (0.18) 6.7 + 0.2 (0.26 + 0.008) Rear For GS550E 6.0 (0.24) Brake disc runout 0.30 (0.012) ‘Master cylinder bore 14.000 — 14.043 (0.5512 ~ 0.5629) | For GS550 & GS550E (Canada) Front 15.870 — 15.913 (0.6248 — 0.6265) For GS550D & GSB50E Rear | 14000 — 14.043 (0.6512 — 0.529) eee” | For GS550E Master cylinder piston dia, | 13.941 — 13.968 (0.5489 — 0.5499) | |__ For GS550 & GS55OE (Canada) | Front | 15.811 — 15.838 (0.6225 — 0.6235) For GS550D & GS550E 13.987 — 13.984 (0.5495 — 0.5506) For GS550E Brake caliper cylinder bore 42.860 — 42.899 (1.6874 — 1.6889) For GS550 & GS550E (Canada) 38.180 — 38.219 (1.5031 — 1.5047) For GS550D & GS550E 38,180 — 38.256 (1.5031 — 1.5061) Heer For GS550E Brake caliper piston dia, 42.785 — 42.810 (1.6844 — 1.6854) For GS550 & GS550E (Canada) Front 38.025 — 38.050 (1.4970 — 1.4980) For GS550D & GS550E 38.098 — 38.148 (1.4999 — 1.5019) For GS550E | Rear _t -GSSSOT(E-O1) 247 Unit: mm (in) ITEM ‘STANDARD Limit Wheel rim runout : 20 Axial — (0.08) | : 20 Radial é& Wheel axle runout eat 0.25 (0.010) 0.26 iar (0.010) Tres Front 3.25H19-4PR — | Rear 3.75H184PR — hy TTire treed depth From as 20 ial (0.08) SUSPENSION Unit: mm (in) ITEM ‘STANDARD LIMIT Front fork stroke 750 (6.9) Front fork spring free length 93.0 (3.66) = | S560, Upper GS55OE (Only for Canada) | 121.0 4.80) GS550D, GS550E 393.0 (15.47) | — S550, | ower GS5BOE (Only for Canada) _ 365.0 (14.37) GS550D, GS550E Front fork oil level 208 (8.03) Rear wheel travel 100 | (39) ‘Swinging arm pivot shaft runout 03 (0.012)248 GS5S5OT(E-01) FUEL + OIL + CAPACITY Unit: mm (in) ITEM SPECIFICATION Fuel type Gasoline used should be graded 90 or higher octane in Research Method Fuel tank including reserve 16L (4.2/3.5 US/Imp gal) reserve 40L I (4.2/3.5 US/Imp qt) Engine oil type SAE 10W/40 Engine oil capacity | 2.400 mi | change (2.5/2.1 US/imp qt) 2.600 mi | eis cheno (2.7/2.3 US/imp at) 2.700 ml Oyen (2.8/2.4 US/imp at) Front fork oil type Mixture ratio SAE 10W/30 : SAE 5W/20= 1:1 Front fork oil capacity (each leg) 165 ml (5.58/5.81 US/Imp oz) | SAE J1703 |[_ Brake fluid typeGSS5S50T(E-01) TIRE PRESSURE NORMAL RIDING CONTINUOUS HIGH SPEED RIDING COLD INFLATION SOLO RIDING DUAL RIDING SOLO RIDING DUAL RIDING TIRE PRESSURE 7 ae a 2 Wa [ealon™] ost | ePa lon? | ost | WPa [baler | oat | WPa [kaon | oa FRONT 175 | 1.75 | 25 | 175 | 175 | 25 | 200| 200 | 28 | 200 | 200 | 28 REAR 200 | 2.00 | 28 | 225 | 225 | 32 | 225| 225 | 32 | 260 | 2.0 | 40 WATTAGE Une wi SPECIFICATION eM E-01 | €-02 | E-04 |E-15 |/E-18 |E-21| £-22 | E-24 | E-25 | E-26 | E-28 | £-30| £34 Headlight wm | so] 4{-|-|-|-|+|s|«[-|0|~| 6 to [fas tol=(-l=|-l-|-[-|-]-[- ing or ely Haht I cee ate mle all/Brake light emleal~l-1=1=1 = les feal = lena] ~ leat Turn signal light afilaj+l<|+[+[<-|3lal+[3lela Speedometer ight wfl-(-l=l-l-l-l|-l-l-l-l-l- “Tachometer light fal Hele le lela lel elele lle Turn signal indieawortignt [aa] -|=[+l-l[-|-l+|-l-|-1 [= fale le=l=(=l=l*\lelelelelele “Tsalethe hed alee Pelee Lel= fel Git pressure indicator tight | 34 | ~|+|=|+[+|+|+| + |+|+[<+][e= Gear position indiestore Pia = |= t=l=l-l=l-L-l*L] L=l= COUNTRY OR AREA E01....... General E-24 Australi E02 . England E-25 The Netherlands E04 France E-26 ....... Denmark E15....... Finland Canada E18 ....... Switzerland Singapore E21 Belgium Italy E-22 West Germany250 GSSSOT(E-O1) TORQUE TABLE ENGINE ITEM Nm kom tft Cylinder head cover bot 7-11 7-14 50- 80 Cylinder head bolt 71 7-14 50- 80 Cylinder head rut 23-27 165-195 ‘Camshaft bearing cap bolt 8-12 08-12 60- 85 Camshaft sprocket bolt an oa-14 0-80 Contact breaker cam bolt 18-28 18-28 130-200 (Cam chain tensioner lock nut 10-12 19-12 70- 85 Generator rotor bolt, 60-70 60-70 435 — 605 ‘Advance governor bolt 18-23 18-23 130-165 Starter motor bolt a7 30- 50 Starter clutch bolt 15-20 15-20 110-148 Clutch sleeve hub aut 40-60 40-60 200-435 Clutch spring bolt 6-10 06-10 45-70 ‘Oi strainer serew ‘7 04-07 30-60 ae SanN eam sos Sha 18-28 18-28 130-200 Gearshift arm stopper bolt 15-23 15-23 110-165 Crankease bolt (6 mm) 6-10 06-10 45-70 Crankease bott (8 mm) 18-2 18-22 130-160 Engine mountirg nut (8 mm) 13-23 13-23 95-165 Engine mounting nut (10 mm) 26 — 46 25-45 18.0 — 32.5 Exhaust pipe bolt ona 65~ 100 Muffler bott 18-28 18-28 130-200 Gear shift lever bott 6-10 06-10 45-70 Engine sprocket nut 50-70 360-505GSSS5OT(E-O1) 251 CHASSIS ITEM Nm kgm Ibe Handlebar clamp bolt 12-20 12-20 85-145 ‘Steering stem upper clamp bolt 16-25 15-25 11.0 18.0 Front fork upper bracket bolt (R, L) 20-30 20-30 145-215 Front fork lower bracket bolt (R, L) 20-30 20-30 145-215 Front fork cap bolt (R, L) 15-30 16-30 11.0 - 21.5 ‘Steering stem head nut 36-52 36-52 26.0 -37.5 Front fork axk holder nut 15-25 15-25 11.0 18.0 Front axle shaft nut 36-52 36-52 26.0-375 ‘Swinging arm pivot nut 50-80 50-80 36.0— 58.0 Rear torque link nut 20-30 20-30 145-215 Rear axle nut 50-80 50-80 36.0 - 58.0 Rear shock absorber nut 20-30 20-30 145-215 Footrest bolt 27-43 27-43 19.5 31.0 Front brake caliper mounting bolt 20-40 20-40 145 ~ 29.0 Front and rear brake dise plate bolt 15-25 15-25 11.0 18.0 Front brake caliper axle bolt 40-55 40-55 29.0 - 40.0 Front beta mene indy mothe ge Geo ae. ab ko Front and rear brake hose union bolt 13-18 13-18 9.5 ~13.0 Front and rear brake air bleeder bolt o- 9 06-09 45 65 Rear brake caliper mounting bolt 20-30 20-30 145-215 Rear brake caliper axle bolt 25-35 25-35 18.0 ~ 25.5 a ba i air esetng a6 ig228 110x480252 GS55OT(E-O1) SPECIAL MATERIALS ‘The materials listed below are needed for maintenance work on the GS5S0 series, and should be kept on hand for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery cloth and the like, How to use them and where to use them are described in the text of this manual. Material Part Carburetor bracket screw a * Oi filter cap nut # Front fork damper rod bolt ‘Cam shaft end cap screw B pes 3 pes. 2s, B pes. ‘99000-32040 THREAD LOCK CEMENT * Generator lead wire guide screw 2.0.2... eee sees Spee * Generator stator securing serew . . . 3 pes. * Gearshift cam stopper belt... 2 pes * Countershaft bearing retainer... . 4 pes. * Starter motor securing bolt . * Gearshift fork shaft stopper screw * Engine oll pump set screw... ‘99000-32050 THREAD LOCK 1342" * Gearshift cam retainer scew . .. cesses TRO. * Cam chain sprocket allen bolt .. : 2+ 2pes * Cam chain guide bolt... ..- tan cne sci] Bee * Starter clutch allen bolt : 3 pes. + Gearshift stopper 1 pe. * Muffler cover screw... 0. eee e ee eeee cece ees POS ‘99000-32020 THREAD LOCK SUPER “13338” : * Generator rotor securing bolt 99000-22000 THREAD LOCK SUPER “13328”GS55OT(E-O1) 253 Material o | Sa 99000-25010 ‘SUZUKI SUPER GREASE “A” Oil seals, Throtle grip Cables (speedometer and tachometer) Clutch release mechanism Goarshift lever linkage and shaft Speedometer gearbox ‘Whee! bearings ‘Swinging arm bearing and dust seal Rear brake cam Brake pedal shaft Contact points cam Governor link Centerstand spacer ‘Steering stem bearings 99000-31110 SUZUKI BOND No. 1215 Mating surfaces of upper and lower crankcase. ac ‘99000-25100 SUZUKI SILICONE GREASE Apply to caliper axle bolt * Brake fluid | & | 0000-23021 | SUZUKI BRAKE FLUID | + Valve stm * Cam shaft 99000-25140 SUZUKI MOLY PASTE Chain tensioner adjuster shaft254 GS5SOT(E-O1) MODIFICATIONS ENGINE © On the engine starter system, the combines electric and kick starter system has been replaced by the electric starter system; that is, the kick starter system is discontinued. As a result, generator has been replaced by high performance type. ‘GS550T MODEL ¢ No. 2and No, 3 exhaust pipes are connected, GSs50T MODEL GSS50N MODELGSSS5OT(E-O1) 255 FUEL SYSTEM © The carburetor has been changed from MIKUNI VM22SS to MIKUNI BS32SS. v =. 4 Dyer needle Decale jet Oman jet @Needie vave Orwrottle valve Needle jet @Main jet Needle vaive OThrottle valve BS-TYPE VM-TYPE ‘GS5SOT MODEL GS550N MODEL, ‘The carburetor choke system has been changed from lever to knob. GSS50T MODEL GSS50N MODEL,256 GS55OT(E-01) © Fuelcock has been changed as shown below. GS5S0T MODEL GSS50N MODEL ELECTRICAL ‘© Charging system has been changed as shown below. GS550T MODEL GS850N MODELGSSS50T(E-01) 257 © The right and left handlebar switches have been changed to a multiple type as shown below: Right Right Left GS550T MODEL Left GSS5ON MODEL ‘© The ignition system has been changed from the battery ignition system to the maintenance-free transis- torized ignition system. (Only for Canada) | GSS50T MODEL GS550N MODEL258 GS5SOT(E-01) CHASSIS ‘* Steering stem bearing has been changed from steel ball type to taper roller bearing type. SS LA GSSs0T MODEL GSS50N MODEL ‘© The front master cylinder cap has been changed trom a screwing-in type to a 4-sorew fastening type. GS5E0T MODEL GS850N MODEL © Front brake caliper has been changed as shown below. GSss0T MODEL GS850N MODELGSS5S5OT(E-O1) 253 FUEL SYSTEM When turning starter motor, negative pressure is generated in the combustion chamber. This negative pressure works on the diaphragm of fuel cock through passageway provided in the carburetor main bore and vacuum Pipe, and diaphragm builds up a negative pressure which is higher than the spring pressure. Fuel valve is forced to open due to diaphragm operation, and thus allow fuel to flow into carburetor float chamber,260 GS55OT(E-01) CARBURETORGSSSOT(E-O1) 261 © Carburetor, No. 1 @ Needle jet @® Carburetor, No. 2 @ Pug Carburetor, No. 3 s Gasket @ Carburetor, No. 4 Pilot jet © Diaphragm Fost Jet Need Pin Spring GD Throtte valve @® Washer D Shaft QE ring @ Lever ® ® Lever © Guide hoider @ Storer shaft @ ctip ®E ring Spring @ Pin @E ring & Lever @ Gasket @ Lever Seat @ Screw GB Necdte vee 4@ Bracket 9 0 ring @ Bracket 29 Finer @ Nipple @ Plate @ Piste @ Main jot @ Piste ® Washer SPECIFICATIONS tem Specification eam Specification Type MIKUNI BS328S Needle je (Nal) x6 Bore size 32 mm (1.26 in) Pilot jet (P..) #40 1.0, No, 47090 By pass (B.P.) | 1.0,0.8,0.8 Ide ein 1.100 £ 100 r/min Pilot outlet (P.0.) 07 Fuel level 5040.5mm Valve seat (V.S.) 20 (0.20 # 0.02 in) Starter jet (G.S.) #35 Float height BAriire, Pilot screw (PS) 3% urs back Main jt (M1) #925 Main air jet (M.A) 18 Jet needle (.N,) BFa23 |262 _GS550T(E-01) FUEL cock @ Fuel vave — @ Oring © Diaphragm @ Spring @ One way valve @ Fuelfiow — @ Vacuum © Chamber RES ° When the engine is not running with the lever in the ON or RES position, the valve is kept in the closed position by applying pressure utilizing a spring so that no fuel will flow to the carburetors. When the engine is engaged, a negative pressure is generated in the diaphragm’ chamber “C” through the vacuum (negative pressure) pipe which is connected to the carburetor, and builds up a negative pressure which is higher than the spring pressure so that the diaphragm is forced to open the valve and thus allows the fuel to flow to the carburetors, oO ® Diaphragm Air return orifice ® One way valve @® VacuumGSSS5OT(E-O1) 263 DIAPHRAGM AND PISTON OPERATION The carburetor is of a variableventuri type, whose venturi cross section area is increased or decreased automatically by the piston according to the vacuum present on the downstream side of the venturi, Vacuum is admitted into the diaphragm chamber through an orifice provided in the piston. Rising vacuum overcomes the spring force, causing the piston to rise to increase the said area and thus prevent the air velocity from increasing, Thus, air velocity in the venturi passage is kept relatively constant for improved fuel atomization and for securing an optimum ratio of fuel to air in the mixture.264 GSSSOT(E-O1) SLOW SYSTEM This system supplies fuel during engine operation with throttle valve closed or slight opened. The fuel from float chamber is first passed through main jet and metered by pilot jet where it mixes with air coming in through pilot air jet. This mixture, rich with fuel, then goes up through pilot pipe to pilot screw. A part of the mixture is dis- charged into the main bore out of bypass ports. The remainder is then metered by pilot screw and sprayed out into the main bore through pilot outlet. 2 Fuel/air Mintre FutGSS5SOT(E-O1) 265 MAIN SYSTEM As throttle valve is opened, engine speed rises, and this increases vacuum in the venturi. Consequently the piston valve moves upward. Meanwhile, the fuel in float chamber is metered by main jet, and the metered fuel enters needie jet, in which it mixes with the air admitted through main air jet to form an emulsion. The emulsified fuel then passes through the clearance between needle jet and jet needle, and is discharged into the venturi, in which it meets main air stream being drawn by the engine. Mixture proportioning is accomplished in needle jet; the clearance through which the emulsified fuel must flow is large or small, depending ultimately on throttle position. (for No. 4) ae QQ 08 10mm (0.02 ~ 0.04 in) 2. After adjusting, tignten throttle valve balancing screw lock nut. 3. After this adjustment, adjust the idling speed 3: After adjusting the slack, tighten the lock nut. to somewhere between 1.000 and 1 200 r/min with throttle stop adjusting screw. reg =GSS5S50ET/LT(E-O3) 359 CHARGING SYSTEM DESCRIPTION This motorcycle, the circuit of its charging system is indicated in the figure, is composed of AC generator, regulator/rectifier unit and battery. ‘The AC current generated from AC generator is rectified by rectifier and is turned into DC current. then it charges the battery. | Lighting switch Load (night) Funetion of Regulator While the engine r/min is low and the generated voltage of AC generator is lower than the adjusted voltage of Regulator, the regulator does not function, incidentally the generated current charges the battery directly. ighting switch AC. Generator Load (day) Loed (night)380 GS5S50ET/LT(E-03) When the engine r/min becomes higher, the generated voltage of AC generator also becomes higher and the voltage between points @ and @) of regulator becomes high accordingly, and when it reaches the adjusted voltage of regulator, ZD (Zener diode) sends signal to the gate of SCR (Thyristor). Then the SCR becomes conductive to the direction from point © to point © . Namely at the state of this, the current generated from the AC generator gets through SCR without charging the battery and returns to AC generator again. At the end of this state, since the AC current generated from AC generator flows into the point ©), reverse current tends to flow to SCR, then the circuit of SCR turns to OFF mode and begins to charge the battery again, Thus these repetitions maintain charging voltage to the battery constant and protect it from over- charging, Lighting switch Poss pScnar icons Load (day) Load (night)GS5S5OET/LT(E-O3) 361 INSPECTION CHARGING OUTPUT CHECK © Start the engine and keep it running at 5000 r/min with the lighting switch tumed ON (High position). © Using pocket tester, measure the DC voltage between the battery terminals. If the tester reads under 14V or over 15.5V, the 18.5 V (DC) STD cherclon tsa at 5.000 r/min AC GENERATOR NO-LOAD PERFORMANCE © Disconnect the three lead wires of the AC generator terminal. © Start the engine and keep it running at 5.000 r/min. © Using the pocket tester, measure the AC voltage between the three lead wires. If the tester reads under 80V, the AC generator is faulty. {80 V (AC) or Over STD No-oad performance | SO oO Hin | AC. Generator Rome] (09900-25002 Pocket tester 4+ @ @ wre WIRE Y.. wrt wiG. COLOR + Yellow “White with Blue tracer = White with Green tracer362 GSSSOET/LT(E-03) Using pocket tester, check the conti the lead wires of the stator. Also check that the stator core is insulated. ry between Specification Approx. 19 Tester Range: 9 x1 ! wi 1 \ \ e 1 ¥ 1 ® 1 8 ! was 1< 4 WIRE COLOR Yellow White with Blue tracer White with Green traver REGULATOR/RECTIFIER Using pocket tester, check the continuity between the lead wires as shown, Regulator/Rectifier checking chart: NORMAL DIRECTION: CONTINUITY REVERSE DIRECTION: NO CONTINUITY (+) probe of tester | _(-) probe of tester (+) probe of tester_| (—) probe of tester Y ¥ w/et w/Bt R WIR wR R BW Bw Y w/Bl w/e! Bw Bw WR WIR yY |GSS550ET/LT(E-O3) 363 FULL-TRANSISTORIZED IGNITION SYSTEM DESCRIPTION A fully transistorized ignition system is now employed on the GS5BO. Its primary advantages are: + Trouble free operation due to elimination of contact breaker points which can become contaminated. is maintained properly at all times and requires no maintenance. ing and provides the ignition coil with stable secondary voltage. * Excellent vibration and moisture resistance. TRANSISTOR Transistor functions can be divided into four main functions: 1: amplification 3. oscillation 2. switching 4, modulation ‘These functions are utilized in the ignition system employed on the GSB5O. Transistors are divided into two groups, those being of the NPN and PNP types, and the transistors used in the GS550 model is of the NPN type only, works an amplifier and switching device. c B B: BASE t : COLLECTOR E: EMITTER Each transistor has three ter as follows: ‘On @ NPN type the base is the controlling terminal of the transistor operation. On this type, the base utilizes only a positive or incoming signal to do the “ON”, or “OFF” switching. The coHector is the terminal where voltage is supplied to the transistor and the emitter is the terminal for passing this current for useage when the base has the proper “signal”. Usually the voltage applied across the collector to the emitter is much larger than that needed at the base. This allows a relatively low voltage at the base to control large working voltages across the collector to the emitter. The transistor ignition system used on the GS550 is the KOKUSAN brand and consists of a signal generator, which employs. rotor and two pick-up coils, the transistor unit, ignition coils, and spark plugs. Is identified as the Base (B), Collector (C), and Emitter (E), and operation is364 GSSSOET/LT(E-O3) SIGNAL GENERATOR ‘The signal generator is mounted on the right hand side of the engine in the area commonly used for the contact breaker points. It is comprised of a magnet embedded rotor attached to 2 mechanical advance mechanism and two pick-up coils, with iron plates at their bases, affixed to a plate. Each pick-up coil consists of a coil or wire and a yoke or coil and is mounted 180° apart on the pl As the rotor magnet is turned past the coils, AC current is produced and used for switching within the transistor unit. ‘The transistor unit controls power to the ignition coils and causes the spark plugs to fire at the proper time. rome rr ave 6 FUSE IGNITION SWITCH IGNITOR wt ood Lew-o opp IGNITION COIL TearTery SIGNAL GENERATOR ” INSPECTION ‘Measure the resistance between lead wires. If the resistance noted to show infinity or too low a resistance value must be replaced. (09900-25002 Pocket tester S.T.D. resistance GW — BW 60-802GSS5S5OET/LT(E-O3) 365 ‘STEERING STEM @ Handlebar clamp ® Steering stem upper bracket @® Headlight bracket (R) © Headlight bracket (L) ® Steering stem bearing (Upper! © Steering stem bearing (Lower) © Steering stem lower bracket © Front fork cover Tightening torque | Nem kom oft ® 12-% | 12-20 85-145 ® | %-% | 36-52 | 260-a75 © 6-2 [19-780 © 20-30 145-215 © | 0-8 | 40-50 | 295-360 © 2-30 | 20-30 | 145-218366 GSSSOET/LT(E-O3) REMOVAL AND DISASSEMBLY ‘© The steering stem can be removed from the machine in the same manner as in the page 85. ‘Therefore, we discuss the subsequent operations. © Remove the screw and disconnect the choke cable from the carburetor. @ Loosen the lock nut, turn the choke knob body counterclockwise, and remove the choke cable from the steering stem head pipe, ‘© Remove the steering stem head nut and loosen clamp bolt. © Take off the steering stem upper bracket. '* Remove the steering stem nut by using special tool.GSS55OET/LT(E-O3) 367 * Draw out the upper bearing and the steering stem lower bracket. Head pipe Steering bearing installer Bearing outer © Draw out the lower bearing by using special tool. i 09941-84510 Bearing inner race remover © Draw out the bearing outer races upper and lower by using special tool. 09941-54910 Steering race remover (09941-74910 ‘Steering bearing installer388 GSSS5OET/LT(E-03) REASSEMBLY Reassemble and remount the steering stem in the reverse order of disassembly and removal and also, carry the following steps: OUTER RACES Press in the upper end lower outer races using special tool. 09941-34511 ‘Steering outer race installer - Steering race installer Head pipe BEARINGS Press in the lower bearing by using special tool. 09941-74910 ‘Steering bearing installer Apply grease upper and lower bearing before remount the steering stem. | enna ‘Suzuki super grease “A” |GS5S5OET/LT(E-O3) 363 ‘STEM NUT Tighten the steering stem nut by using special tool with specified torque. 40-50 Nm Tightening torque ( 4.0-5.0 kgm 28.0 - 36.0 Ib- ‘Tum the steering stem left and right, lock-to-lock, five or six times to seat the bearings. Loosen the steering stem nut approximately 1/4 — 1/2turn. After performing the adjustments and installing the steering stem head, “rock” the front wheel assembly backward and forward to ensure that there is no play and that the procedure was accomplished correctly. If play is noticeable, repeat the above steps. With the front wheel off the ground, check that the front fork turns smoothly and easily left to ight. With a slight amount of pressure being applied to the end of the handlebars, the weight of the front wheel alone should allow the front forks to slowly move to their extreme position either left or right.310 GS55OET/LT(E-03) FRONT MASTER CYLINDER @ Piston & cup set @ Reservoir ® Diaphragm one Tightening torque Ocw Nm | km ibe Dore @ 5-8 | 05-08 35-60GS550ET/LT(E-03) 371 MASTER CYLINDER REMOVAL AND DISASSEMBLY © Take off front brake light switch. ‘© Remove master cy! ‘two fitting bolts, ‘© Remove front brake lever. ‘© Remove filler cap and drain brake fluid, Place a rag underneath the union bolt on the master cylinder to catch spilled drops of brake fluid, Unscrew the union bolt and disconnect the brake hose/master cylinder joint.312_ GS5SOET/LT(E-03) © Remove the two screws. © Remove citclip by using sp tool. (09900-06108 ‘Snap ring pl el © Pull out the reservoir and O ring. © Pull out piston, primary cup and spring. © Draw out dust seal boot.GSS5S5OET/LT(E-03) 373 MASTER CYLINDER INSPECTION MASTER CYLINDER REASSEMBLY © Inspect the cylinder bore wall for any scratch or Reassemble the master cylinder in the reverse ‘other damage. orders of disassembly and by taking the follow- ing steps: @ When remount the master cylinder to the handlebars, first tighten the clamp bolt for up- side as shown, «inspect the piston surface for serstch or other damage. Master cylinder Inspect the primary cup, secondary cup and dust after installation. seal boot for damage, : Bleedina the ai after reassembling ‘master cylinder. (See page 115) 1 = &314 GSSSOET/LT(E-O3) FRONT CALIPER ®roor DBieeder (Bleeder cep ®cover Baote oor Tightening torque Nm kom Ibe @ | 20-40 | 20-40 | 145-200 @ | ws | 40-65 | 200-400GSS550ET/LT(E-O3) 315 BRAKE PAD REPLACEMENT ‘© Remove two bolts and take off cal © Pull out brake pads. © Tighten the caliper axle bolts with specified torque. "18 20Nem Tightening torque |316 GSSSOET/LT(E-O3) CALIPER REMOVAL AND DISASSEMBLY © Disconnect brake hose and catch the brake fluid in a suitable receptacle. ‘¢ Remove piston boot and piston seal. Boo ‘© Remove caliper axle bolts and take off caliper. Place a rag over the piston to prevent popping up. Draw out the piston by using air gun,GSS5S5OET/LT(E-O3) 377 CALIPER AND DISC INSPECTION CALIPER REASSEMBLY @ Inspect the cylinder bore wall for nick, scratch ¢ Reassemble the caliper in the reverse orders of or other damage. disassembly and by taking the following steps: © Apply grease to the caliper axle bolts. ‘99000-25100 Brake pad grease © Inspect the piston surface for any flaw or other Ly damage. iia === @ Tighten the caliper axle bolts and caliper mounting bolts with specified torque. Tightening tor 40-55 N Caliper axle bolt (2 -5.5 kgm 2 9.0- 40,0 Ib-Fe 20-40 Nm wear. Caliper bolt 2.0-4.0 kgm 14.5 - 29.0 Ibe ‘© Inspect the each rubber parts for damage and318 GSSS5OET/LT(E-03) WIRE AND CABLE ROUTINGGS5S5OET/LT(E-O3) 379380 GSSSOET/LT(E-O3) WIRING DIAGRAMGS550ET/LT(E-03) 361 GS550LT Left side382_ GS550ET/LT(E-03) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length + 2.190 mm (86.2 in) Overall width + 890 mm (35.0 in) Overall height + 1215 mm (47.8 in) Wheelbase . + 1480 mm (58.3 in) Ground clearance . 180 mm ( 6.3 in) Dry mass... 205 kg (452 Ibs) ENGINE Type. + Four-stroke, air-cooled, DOHC ‘Number of cylinders . Bore . Stroke . Piston displacement . ‘Compression ratio. Carburetor Air cleaner .4 + 56.0 mm (2,205 in) + 55.8 mm (2.19; = 549 em? (33.5 cu,in) s+. 86:1 . MIKUNI 8S32SS, four + Polyurethane foam element Starter system « Electric Lubrication system - Wet sump TRANSMISSION Clutch. . Wet multi-plate type ‘Transmission « 6-speed constant mesh Gearshift pattern . « 1-down Sup Primary reduction = 1.977 (87/44) Final reduction .. 3.400 (51/15) Gear ratios, Low 2.666 (32/12) 2nd, 1.777 (32/18) 3rd 1,380 (29/21) 4th 1.173 (27/23) 5th 1.045 (23/22) Top 0.956 (22/23)GS55OET/LT(E-O3) 383 CHASSIS Front suspension Rear suspension . Steering angle . Caster. Trail. . Turning radius . Front brake . Rear brake Front tire size. Rear tire size. . Front tire pressure Rear tire pressure . . ELECTRICAL Ignition type .. Ignition timing . Spark plug . . Spark plug gap .... Battery ... Generator . Fuse .. CAPACITIES Fuel tank ...... Engine oil change .. filter change overhaul . Front fork oil ..... « Telescopic, oil dampened « Swinging arm, oil dampened, spring S-way adjustable «40° (right and left) 60° 00" + 114 mm (4.49 in) + 2.6m (8.5 ft) Disc brake » Disc brake 3.25H19-4PR 4.50H17-4PR 175 kPa (1.75 kg/om® , 25 psi) (Normal solo riding) 200 kPa (2,00 kg/em?, 28 psi) (Normal solo riding) + Transistorized . 18° B.T.D.C. below 1 500 r/t and 40° B.T.D.C. above 2 350 r/min - NGK BBES or NIPPON DENSO W24ES-U 0.6 — 0.8 mm (0.024 — 0.031 in) both NGK and NIPPON DENSO. + 12V 43.2 KC (12Ah)/10HR . Three-phase A.C, generator 10/10/10/154, 13L (3.4 US gal) 2.4L (2.5 US at) 2.6L (2.7 US qt) 2.7L (2.8 US qt) 217 ml (7.33 US 02) in each leg * Specifications subject to change without notice.384 GSSSOET/LT(E-O3) SERVICE DATA Please refer to the service data of GS550T except for the service data shown below. TRANSMISSION Tem STANDARD Limit Final reduction 3.400 (61/16) = WHEEL 1TEM STANDARD. Limit Tire size Rear 4.50H17-4PR — SUSPENSION Unit: mm (in) ITEM STANDARD LIMIT Front fork stroke 160 (6.30) = Front fork spring jee length 183 Upper = (6.02) 451 Lower’ (17.76) Front fork oil level 229 (9.02) — FUEL + OIL CAPACITY ITEM SPECIFICATION Fuel tank 13 L (3.4 US gal) Front fork oil capecity (each leg) 217 ml (7.33 US 02)GSS5S5OET/LT(E-O3) 385 WATTAGE Unit: W (CP) ITEM SPECIFICATION Headlight HI 60 Lo 55 Teil/Brake light 8/23 (3/32) Turn signal fight 23 (32) ‘Speedometer light 34 Tachometer light 34 “Turn signal indicator light 34 High beam indicator light 34 Neutral indicator light 34 Oil pressure indicator light 34 Fuel meter light 34 ar position indicator light 1 ‘The GS550LT is now equipped with BS type carburetors which are identical to the GSB50ET. Please refer to. pages 344 thru 358, ‘The “L” version of the GS550ET is also equipped with tapered type steering stem bearings. Please refer to pages 365 thru 369.386 GS5SOET/LT(E-03) FUEL COCK © Fuelvalve @ O-ring Cer Co @ Fuel flow ® Vacuum When the engine is not running with the valve in the ON position, the fuel valve is kept in the closed ion by applying pressure utilizing a spring so fuel will flow to the carburetors. When the engine is engaged, a negative pressure is generated in the diaphragm chamber “©” through the vacuum (negative pressure) pipe which is connected to the carburetors, and builds up a Negative pressure which is higher than the spring Pressure so that the diaphragm is forced to open the fuel valve and thus allow the fuel to flow to the carburetors. On the other hand, setting the valve in the ON position keeps the air return orifice open. Negative pressure does not accumulate on the diaphragm at the time of engine stopping, and then the spring pressure actuates the diaphragm to move back to its original position and closes the fuel valve, However, setting the valve in PRI position with a screwdriver causes the air return orifice to close, resulting in negative pressure in the chamber “©.” under the diaphragm. This negative pressure doesn’t allow the fuel valve to close and therefore the fuel keeps flowing to the carburetors. Air return orificeGSSS5OET/LT(E-03) 387 WIRE AND CABLE ROUTING388 GSSSOET/LT(E-03)GSSS50ET/LT(E-03) 389 WIRING DIAGRAMFOREWORD The SUZUKI GS550-series and GS500-series are new 1981 models and incorporate many refinements and technical changes from the previous models. This section has been produced to aid SUZUKI mechanics in propery maintaining and reparing these motorcycles. which incorporate so many new and invovative changes. These technical improvements have further enhanced the comfort, handling and overall performance of these outstanding models, This section covers four models of GS55O series; GS550E, GS550T, GS55OL and GS550M, and three models of GS500 series; GS500, GS500L and GS500M, This section has been written primarily for the experienced SUZUKI mechanics but will also be very useful even for the do-it-yourself mechanics. Please refer to the entire GS55O Service Manual for all other arees of information not covered in this manual.GS500X/550X(E-01) 383 CONTENTS MODEL IDENTIFICATION: SPECIFICATIONS. MODIFICATIONS: SERVICE DATA GS500X ---- GS500LX GS500MX- GS550X- GS550L X -- GS550TX.- GS550MX- WIRING DIAGRAM. CABLE ROUTING --- BRAKE HOSE ROUTING -- ‘WIRE HARNESS ROUTING ----394 GS500X/550X(E-01) MODEL IDENTIFICATION GS500 AND GS550 GS500M AND GS550MGS500X/S50X(E-01) 395 Gsss0T GS500L AND GS550L396 GSSOOX/550X(E-O1) SPECIFICATIONS GS500E DIMENSIONS AND DRY MASS ELECTRICAL Overall length. = 2.195 mm {onition type Tramsistorized ‘Overall wigth 755 mm Ignition timing . <>... 15" B.T.D.C. below, Overall height "| 24120 mm 1.500 r/min and 40° 8.7.0.6. Wheelbase TIT 1.435: mm above 2 360 r/min. Ground clearance 11) 165mm Spark plug.........+.. NGK DRBES-L or NIPPON Dry mass. S201 kg DENSO X24ESR-U % sees TRVAG2KC (12an)/1OHR 1 Thtes phase A.C. generator ENGINE 10/10/10/158 Tyee . - Fourstroke, sircooled, DOHC CAPACITIES. Number of eylinder...... 4 Bares cens + 53.0 mm Fuel tank including reserve . 16L Stroke 2 835.8 mm reserve... 4.0L Piston displacement | |. | 492m? Engine oit Dat Compression ratio. De6:t Front fork oil. 1 206 mi Carburetor ) MIKUNI 889255, four Air cleaner Polyurethane foam element Starter system - Electric Lubrication system Wet sump TRANSMISSION Clute co vceees Wet multiplate type Transmission | 211111111 Gapeed constant mesh Gearshift pattern - down, Sup Primary reduction | 1977 (67/44) Final redu 31500 (49/14) Gearratios, Low | 2.666 (32/12) 2nd | 4.777 (32/18) 3rd | 1/380 (29/21) ath 1.173 (27/23) Bh) 1.045 (23/22) Top 1 01956 (22/23) Drive chain 2 DAIDO D..0. SHDL or TAKASAGO RKSOSHO, TO Tinks: CHASSIS Frontsuspension ....... Telescopic, oi! dampened Rear suspension... Swinging arm, spring B-way adjustable Steering angle. ++ AOE (right & left) Caster. 8 61°40" Trail. | 2116 mm Turning radius 125m Front brake 5 ise brake, twin Rear brake Dise brake Front tire size 1 3.25H194PR Rear tire 1 3I75H18 4PR 0018 4PR.Only for E22 Front fork stroke 160 mm Rear wheel travel | 100 mmGS500L DIMENSIONS AND DRY MASS ‘Overall length 2210mm ‘Overall width . tee 820mm Overall height. 2 1165.mm Wheelbase... - 1.445 mm Ground clearance... +... 170mm Dry mas... 205 kg ENG'NE TPR vceee news + Four-stroke, air-cooled, DOHC. Number of cylinder... .. 4 Bor ceeeeee sees, 83.0mm Stroke... ++ 85.8mm Piston displacement. .... 42cm? Compression ratio 86:1 Carburetor MIKUNI BS32SS, four Air cleaner Polyurethane foam element Starter system + Electric Lubrication system + Wet sump TRANSMISSION Clutch «Wet multi-plate type Transmission 6-speed constant mesh Gearshift pattern... .... T-down, 5-up Primary reduction - + 1.977 (87/44) Final reduction . 3.500 (49/14) Gear ratios, Low 2.666 (32/12) 2nd 1.777 (32/18) Srd 2.22... 1,380 (29/21) 4th 000022 1.173 (27/23) Sth 2.22... 1,045 (23/22) Top ....... 0.956 (22/23) Drive chain. ++ DAIDO D.I.D. SOHDL or TAKASAGO RKSOSHO, 110 links CHASSIS Telescopic, oil dampened + Swinging arm, spring 5-way adjustable Front suspension... . . Rear suspension Steering angle + 40° (right & teft) Caster... 1 61°00" Tei S200) 122mm Turning radive || 25m Front brake 12 Dise brake, twin Rear brake 1 Disc brake Front tie size + 3.25H19 4PR Rear tire size . a’50H18 4PR. Front fork stroke |... 1. 160mm. Rear wheel travel: 2100 mm GS500X/S550X(E-O1) 387 ELECTRICAL Ignition type Ignition timing | «+ Transistorized 2 18° B.1.D.C. below, 1.500 r/min and 40° B.T.0.C, above 2 360 ¢/min. Spark plug NGK DRBES-L or NIPPON DENSO X24ESR-U Battery. . + 12V 432kC (12Ah)/10HR Generator | Three-phase A.C. generator Fuse... roNOnO/IsA CAPACITIES Fuel tank including reserve . 12.5L reserve 4oL Engine oi vetoes) Bab Front fork oil 196 mi398 GS5OOX/550X(E-01) GS500M DIMENSIONS AND DRY MASS Overall length 2.145 mm Overall width 730 mm Overall hei 1110 mm Wheelbase . 21.455 mm Ground clearance | 160 mm Dry mass 205 ka ENGINE Type... - Fourstroke cycle, air-cooled, DOHC 4 53.0 mm 2 858mm Piston displacement 492 cm? Compression ratio . 86:1 Carburetor Air Geaner Starter system ||| Lubrication system . ‘TRANSMISSION Clutch ‘Transmission’ ° Gearshift pattern’ << Primary reduction . Final reduction Gearratios, Low... - 3rd- 2. ath 8th 2 Top |: Drive chain . CHASSIS. Front suspension . . Rear suspension Caster Steering angle Front brake Rear brake Front tre si Rear tre size MIKUNI 885285, four Polyurethane foam element 1 Electric Wet sump ‘Wet multi-plate type speed constant mesh ‘down, 5-up 1.977 (87/44) 31500 (49/14) 2.666 (32/12) 1.777 (32/18) 1.380 (29/21) 1173 (27/23) 1.045 (23/22) 0.956 (22/23) II DAIDO D.1.0. SOHDL or TAKASAGO RK5OSHO, 110 links Telescopic, ol dampened ‘Swinging arm, automatic dual damping, spring Sway adjustable cee e AOE (right & left) TIT 61°50" 115 mm 25m 1 Disc brake, double * Disc brake 3.25H19 4PR : B75H18 4PR 4.00H18 4PR.Only for E-39 ELECTRICAL Inition type Ignition timing. Spark plug Battery : Generator 2222222 Fuse CAPACITIES Fuel tank including reserve - Engine oil Front fork oil Teanwistorized 2 18° 8.7.0. below, 1.500 r/min and 40° B.T.0.c. above 2 350 r/min « NGK DR8ES-L or NIPPON DENSO X24ESR-U = 12V43.2kC (12Ah)/10HR ‘Three-phase A.C. generator 10/10/10/154 23L, 4.0L 2aL 4195 miGS500X/550X(E-01) 399 GS550 AND GS550E DIMENSIONS AND DRY MASS Overall length. = 2150mm Overall width 222" 850 mm. Overall height ¢ 21160 mm. Wheelbase y 21440 mm_ Ground clearance 150 mm Seat height. 780 mm Dry mass. 203 kg ENGINE Type. Four-stroke, air-cooled, DOHC Number of cylinders... 4 oh TL 56.0mm 1 55.8mm 549 cm? 86:1 ! MIKUNI BS32Ss, four Air cleaner Starter system - Electric Lubrication system Wet sump TRANSMISSION Clutch Transmission | : Gearshift pattern down, 5-up Primary reduction «+ 1.977 (67/44) Final reduction. + 31393 (50/15) Gear ratios, Low .:..... 2.666 (32/12) 2nd 1.777 (32/18) Bed 222222. 1-380 (29/21) ath 2000025: 1173 27/23) Sth 2222021 1.045 (23/22) Top :... 1... 0.956 (22/23) Drive chain DAIDO D.1.D. SOHDL or TAKASAGO RKEOSHO, 110 Tinks CHASSIS Front suspension . ...... Telescopic, oll dampened Rear suspension. * Swinging arm, oll dampened, spring S-way adjustable Steering angle + 40% (right & left) Caster 61°30" Turing Front brake Rear brake F Intemal expanding...GS550 ise brake... GSEBOE Front tiresize ......... 3.25H194PR Rear tre size . III, B75H18 4PR 4.00418 4PR. Only for €-22 = 180.mm (6.97 in) 100 mim (3.94 in) Front fork stroke . Rear wheel travel | ELECTRICAL Ignition type Ignition timing | | below, 1.500 r/min and 40° B.T.0.c. above 2350 r/min ‘Spark plug . NGK B8ES or NIPPON DENSO W24ES-U Battery. 32V 43.2kC (12Ah)/10HR Generator ‘Three-phése A.C. generator Fuse . TONO/O/IEA CAPACITIES Fuel tank including reserve. 16L reserve 4.0L 2aL Engine oll Front fork.400 GSSOOX/550X(E-01) GS550T DIMENSIONS AND DRY MASS Overall length 2.200 men Overall width 850 mm Overall height 180 mm Wheelbase 1435 mm Ground clearance 150 mm ‘Seat height 780 mm Dry mass... 200 ka ENGINE Type Four-stroke, air-cooled, Number of cylinders Bore. Stroke 21121! Piston dispiace ‘Compression ratio Carburetor cleaner |. Starter systern Lubrication system « - ‘TRANSMISSION Clutch. Transmission», Gearshift pattern Primary reduction reduction . Gearratios, Low. 2nd ard ath 5th Top | Drive chai CHASSIS Front suspension Rear suspension . Steering angle Caster... Teall 525s Turning radius + Front brake... Rear brake ||. Front tire size. Rear tire size. | Front fork stroke . Rear wheel travel DOHC MIKUNI BS32SS, four Polyurethane foam element Electric Wet sump, Wet multi-plate type Gspeed constant mesh 1-down, Sup 51,977 (67/44) 3.333 (60/18) 2.666 (32/12) 777 (32/18) 1/380 (20/21) 1.173 (27/23) 045 (23/22) 0.956 (22/23) DAIDO D..0. S0HDL or TAKASAGO RK50SHO, 110 links Telescopic, ol dampened ‘Swinging arm, automatic dual damping, spring 6-way adjustabl 1 Disc brake Disc brake 3.25H19 4PR 4.2517 4PR 150 mm 100mm ELECTRICAL Ignition type... Ignition timing | | Spark plug. . Battery Generator |: Fuses ees CAPACITIES Fuel tank including reserve . 2 4.0L 1 zat 5 180%mt Engine oil - Front fork oil + Tegnsistorized 1 18° B.T.D.C. below, 1.500 r/min and 40° B.T.0.C. above 2 350 r/min. - NGK B8ES or NIPPON DENSO W24ES-U = 12V43.2kC (12An)/10HR ‘Three-phase A.C. generator D roro/io/isa raeGS500X/SSOX(E-O1) 401 GS550L DIMENSIONS AND DRY MASS. Overall length. 2.185 mm Overall width 870 mm 1.200 mm. 1.455 mm. Ground clearance 160 mm ‘Seat height 800 mm Dry mass 202 kg ENGINE ‘Type Four-stroke, air-cooled, DOHC 4 TTL 66.0 mm. 558mm 549 om? Number of cylinders Bore... Stroke” bebe Piston displacement - ‘Compression ratio 86:1 Carburetor ‘MIKUNI BS328S, four Air cleaner. Polyurethane foam element ‘Starter system « Electric Lubrication system |. 1 Wet sump ‘TRANSMISSION Clutch . ‘Transmission Gearshift pattern” <* Primary reduction « - I reduction Gear ratios, Low ‘Wet multi-plate type G-speed constant mesh ‘down, 5-up 1.977 (87/44) 3.400 (51/15) + 2.666 (32/12) 11.777 2/18) 1380 (29/21) 1.173 (27/23) 1.045 (23/22) 0.956 (22/23) { DAIDO D.1.D. 50HDL or TAKASAGO RKSOSHO, 110 links Drive chain . CHASSIS Front suspension Rear suspension . Telescopic, oil dampened dampened, S-way adjustable Steering angle. Caster: Tre Turning radius | Front brake . 1 Disc brake, twin Rear brake | 1 Internal expanding Front tr 3.25H19 4PR Rear tire size Front fork stro Rear wheel travel. | 4/50H17 4PR. 160 mm 100 mm ELECTRICAL Ignition type Ignition timing « Transistorized 1 18° B.D. below, 1.500,/min and 40° 8.7.D.C. above 2 350 r/min - NGK B8ES or NIPPON DENSO W24ES-U = 12V 43.2kC (12Ah)/10HR ‘Three-phase A.C. generator 2 10/OO/5A CAPACITIES Fuel tank including reserve. 12L reserve ..... 4.0L, Engineoil .. 0... 012) 24 Front fork oil 1106 mt402_GS500X/550X(E-01) GS550M DIMENSIONS AND DRY MASS Overall length + 2145 mm ‘Overall width + 730mm Overall height + 1110mm_ Wheelbase 1.485 mm Ground 160. mm ‘Seat height ++ 780 mm Dry mass + 205 kg ENGINE Type seen ee « Four-stroke, air-cooled, DOHC Number of cylinders ..... 4 Bore... sever es 56.0 mm Stroke feces 55.8 mm Piston displacement. : | 549m? 86:1 Compression ratio. . Carburetor. ‘MIKUNI BS32SS, four Air cleaner ° 1 Polyurethane foam element Starter system C1 Electric Lubrication system Wet sump ‘TRANSMISSION Clutch = Wet multi-plate type ‘Transmission | * | * G-speed constant mesh Gearshift pattern’ <2.) 1-down, 5.up Primary reduction 21.977 (87/48) Final eduction + 3.333 (60/15) Gear ratios, Low 2.666 (32/12) 2nd 1.777 (32/18) 3rd 1380 (20/21) 4th 21.173 (27/23) th 2+ 1.045 (23/22) Top + 0.956 (22/23) Drive chain. + DAIDO D.1.D. 50HDL or TAKASAGO RK5OSHO, 112.links CHASSIS Frontsuspension ....... Telescopic, oil dampened, spring 2-way adjustable Swinging arm, oil dampened, damper 4-wayispring S-way adjustable 40° (right & let) 61°50" Rear suspension ‘Steering angle. 15 mm 125m Disc brake, twin Disc brake Ll 325H104PR 1 3.75H18 4PR 4,00H18 4PR..Only for €-22 150 mm 105 mm Front tre size Rear tie size . 1.2 Front fork stroke Rear wheel travel ELECTRICAL ‘Transstorized 18° BT.D.C. below, 1.500 r/min and 40° B.T.D.C. Ionition type Ignition timing. above 2 350 r/min Spark plug. - NGK B8ES or NIPPON DENSO W24ES.U Battery . 12V 43.2kC (12Ah)/10HR Generator 1 Threepphase A.C. generator Fuse... 10/10/10/164 CAPACITIES Fuel tank including reserve 23L 4.0L Daa 1195 mi Engine oil . Front fork oiGS500X/550X(E-01) 403 MODIFICATIONS CAMSHAFT, SPROCKET AND BOLT As the illustrated, the sprocket tightening bolt and method has been changed from @ to @), to ©. ‘Therefore, tightening torque should be observed. Type ® Part Neme Tightening torque 6 mm Allen bolt + ae ieee Thread lock super "13038" | 08 —2hem Type @ Part Name Tightening torque {6 mmbolt + Lock wather saan + Thread lock super “19098” | 16 ~ 70807 Type © Port Name Tightening torque = 26Nm 7mm 7 nn ange bl + Banke Thread lock super “1g0g8" | 287 TO kom Type @ Type @ Type © fearon Part Number Part Number Part Number Bolt 09106-06024 09111-08033, 08103-07001 Lock washer = 12747-44000 2 IN, Cam sprocket 12741-47001 + 12741-47002 IN, Camshaft 12711-47000 + 1271147001 EX, Cam sprocket 12751-47010 + 1275147011 EX, Camshaft 12721-47010 + 1272147011 NoTE: Both @ type and ®) type have an interchangeability by exchanging bolt for lock washer + bolt, However © type has screw thread diameter of 7 mm, and bore diameters of the sprocket and the camshaft are also 7 mm, so there is no interchangeability with neither ® type nor ® type.404 GS500X/550X(E-01) STEERING STEM @Steoring stem head nut steering stem clamp bolt @Steering stem upper bracket @Front fork upper clamp bolt @Steering stem nut ©Upper bearing Lower bearing @Headiight bracket Steering stem lower bracket @Front fork lower clamp bolt ‘Tightening torque: 36—52Nm (36-52 kom) 40— 50 Nm (40 —5.0 kam) Tightening torque: N 20— 30 Nem (20-30 kgm) ‘Tightening torque: 4 —20N-m (142.0 kom)SERVICE DATA GS500 GS500X/550X(E-O1) 405 Model: GS500 VALVE + GUIDE Unit:_mm (in) 1TeM STANDARD LIMIT Valve diam. in 30.0 (8) 25.0 ae (098) Valve lift 72 MN (0.283) 7.0 ee (0.276) Tappet clearance (when cold) IN. & EX. 0.03 - 0.08 Valve guide to valvestem clearance | 1, 01025 — 0.055 0.35 (0.0010 ~ 0.0022 ) (0014 ) = (0.040 — 0.070 0.35 ( 0.0016 — 0.0028 ) (0014 ) Valve guide ID. 7.000 — 7.015 IN&EX: | (02756-02762 ) Valve stem 0.0. iN 6.960 — 6.975 : (0.2740 ~ 0.2746 ) er 6.945 — 6.960 = { 0.2734 ~ 0.2740 ) Valve stem runout 0.05 IN BEX. (0.002 ) Valve head thick: 08 IN. &EX. cee Valve stem end length 40 IN. &EX. iy Valve seat width 09-11 IN&EX | (0035-01043) Valve head radial runout 0.03 IN & EX (0.001 ) Valve spring free length Men 35.5 (IN, & EX.) (140) 415 OUTER (163) Valve spring tension 106-128 ka (IN, & EX.) INNER (234-282 Ibs) — at length 31 mm( 1.2 in) 224-262 kg ouTER (494-578 Ibs) — atlength 35. mm (1.4 in)408 GS5SO00X/550X(E-01) CAMSHAFT + CYLINDER HEAD Unit:_mm (in) Cylinder distortion TEM STANDARD, LIMIT Camm height WN], 35485 38516 35.190 = | ( 1,3970 - 1.3982 _) (1.3854 ) ex | 35.285 — 35.315 34.990 ~ (1.3892 - 1.3904 } (1.3776 ) Camshaft journal oil clearance IN. & EX. 0.032 - 0.066 0.150 : { 0.0013 ~ 0.0026 ) (0.0059) | Camshaft journal holder 1.D. | 22.012 — 22.025 IN REX. | 0.8666 0.8671 ) Camshaft journal .D. | 21.959 — 21.980 (Meee | ( 0.8645 - 0.8654 ) Camshaft runout ] 0.10 IN: BEX, | (0.004 ) ‘Cam chain 20 pitch length ] 157.80 | { 6.213 } Cam chain pin (at arrow 3") 20 thpin St Gylinder head distortion | 1 1 CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD. I Limit ‘Compression pressure 9-13 kg/em™ | 7.0 kglem* - (128-185 psi) (100 _p: Compression pressure difference 2.0 kal (28 sil Piston to cylinder clearance 0.050 — 0.060 0.120 {0.0020 — 0.0024 ) ih (0.0047 ) Cylinder bore 53.000 — 53.015 | 53.080 ( 2.0866 ~ 2.0872 ) _ (2.0898) Piston diam. 52.945 — 62.960 Of a 52.880 ( 2.0844 — 2.0850 ) (30818) Measure at the 16 ( 0.69 ) from skirt end. 0.20 {0.008 }GS500X/550X(E-O1) 407 ITEM STANDARD LIMIT Piston ring free end gap ia 50 4.0 T| Approx. (0.20 ) (0.16 85 68 2nd | T | Approx. (033 ) (027) Piston ring end gap ‘Ist 0.10 — 0.30 0.70 ( 0.004—0.012 _) ( 0.028 ) ond 0.10 = 0.25 0.70 ( 0.004-0.010 ) { 0.028 ) Piston ring to groove clearance 4st 0.180 (0.0071) 0.150 ate (0.0059 ) Piston ring groove width ie 1211.23 (0.0476 — 0.0484 ) — 1.21 — 1.23 aed (0.0476 - 0.0484 ) — Oil 2.51 — 2.53 (0.0988 — 0.0996 ) Piston ring thickness 4st 1.175 — 1.190 ( 0.0463 — 0.0469 ) 1.170 — 1.190 2nd (0.0461 — 0.0469) Piston pin bore 16.002 — 16.008 16.030 { 0.6300 — 0.6302 ) (0.6311) Piston pin O.D. 15.995 — 16.000 15.980 (0.6297 — 0.6300 ) (0.6291) CONROD + CRANKSHAFT Unit:_mm (in) TEM STANDARD LIMIT Conrod small end I.D. 16.006 — 16.014 76.040 (0.6302 — 0.6305 ) (06315) Conrod deflection 3.0 (012) Conrod big end side clearance 0.10 — 0.65 1.0 (0.004 = 0.026) (0.039 ) Crankshaft runout 0.10 (0.004 )408 GSSOOX/550X(E-01) OIL PUMP 1TEM STANDARD uMIT il pump reduction ratio 1821 | 87/44x 35/38) Oil pressure (at 60°C, 140°F) 0.1 kg/em? Above (1.42 psi) 0.3 kg/em* — Below (4.27 psi) at_3000_«/min. CLUTCH Unit:_mm (in) TEM ‘STANDARD LIMIT Clutch cable play 2~3 (008-012) Clutch release screw WR Thm back Drive plate thickness 29-31 26 (0114-0122) (0.10) Drive plate claw width 11.8 — 12.0 11.0 (0.465 -0.472_) (043) Driven plate thickness 1.6 = 0.06 (_ 0.063 + 0.002 _) Driven plate distortion ot ( 0.004} 36.5 Clutch spring free length —s . L144)GS500X/550X(E-01) 409 TRANSMISSION + DRIVE CHAIN Unit:_mm (in) ITEM STANDARD LIMIT Primary reduction ratio 1977 ( 87/44 ) Final reduction ratio 3500 ( 49/14 } == Gear ratios Low 2666 ( 32/12 ) — 2nd 1.777 (32/18) = 3rd 1.380 ( 29/21 ) | —_—— 4th 1.173 (| 27/23) —_—_ 5th 1.045 ( 23/22 ) pa Top 0.956 ( 22/23 } Shift fork to groove clearance 01-03 0.5 (_ 0.004—0.012 ) (0.020 ) Shift fork groove width 5.5-5.6 (_0.217— 0.220) —_— ‘Shift fork thickness 535.4 (_ 0.195 0.199) Drive chain Type Links 108 i os 320.0 20 pitch length eS 2608 Drive chain slack 20-30 (08-12) |410 GS500X/550X(E-01) CARBURETOR Unit: mm (in) ITEM SPECIFICATION Carburetor type MIKUN!_8S32SS, Four Bore size 32 1. D. No. 47150 Idle r/min. | 1150 + 50 r/min. Fuel level 5.0210 | (020004) Float height | 22.4410 (0882004) Main jet (M. J.) #975 ‘Main air jet (M. A. J.) 1.6 Jet needle (JN) 5F42 - 3rd Needle jet (N. J.) x-6 Throttle valve #135 Pilot jet (P. J.) #40, By pass (B.P.) 1.0,0.8,08 Pilot outlet _(P. 0.) 07 Vaveseat —(V.5) | 20 Starter jet (GS) (#35, 0.5 Pilot screw (Ps) | "PRE-SET Pilot airjet_ (P.A.J.) | #120 Throttle cable play 05-10 (002-004 ) _ Choke cable play 05-10 (002-004)ELECTRICAL GS500X/5S5OX(E-O1) 411 Osi mm (in) ITEM ‘SPECIFICATION Ignition timing Below 1500 = 1004/min and 40° B.T.D.C. Above 2350 + 100 r/min. Firing order 1.2.4.3 sor we wor oe oe (00240028 ) Spark performance Over 8 (0.3) at 1 atm Signal coil resistance Approx. 60 — 80 2 Ignition coil resistance Primaey “asi onw = Wor BY Sesonden | poprons 50 98 eo Generator no-load voltage More than 80 V (AC) at 5000 r/min. Regulated voltage 14.0-14.5 Vat 5000 r/min. iStatecimotor [Brush length, N. D. limnesee oat Starter relay resistance Approx. 3-4 a2 Battery Type designation YB10L—A2 [Capacity 12V 43.2kC (12Ah)/10HR sana: | 1.28 at 20°C (68°F) Fuse size Main 15 A Headlight 0 A Turn signal 10 A tgnition to A Power source 10 A4M12_ GS500X/550X(E-01) BRAKE + WHEEL Unit:_mm (in) 1TeM STANDARD LIMIT Rear brake pedal height 4 i 5020. Brake dise thickness Front 1 tees 9 (oni a 67202 60 iear ( 0.26+0.008_) (0.24 ) Brake disc runout oe, Mesos cvlinces bore a ( tare rons ) 14.000 — 14.043 - ae a (0.5512 ~ 0.5529 ) _ Master cylinder piston diam. Foi ( (eae = 16854 a 13.959 — 13.984 zat (0.5495 — 0.5506 ) = Brake caliper cylinder bore Front ( 100 = ae ) 38.180 — 38.256 Rear (1.5031 — 1.5061 } Brake caliper piston diam. 38.098 — 38.148 | __ rake caliper piston diam. Front (14969 — 18010) | 38.098 — 38.148 Rear (1.4999 — 1.5019 ) —_ Wheel rim runout aa oe , Radial oe i a j ‘Wheel axle runout crane ane 0.25 i woe fi (FOOTY Tite size Front 3.25H18 4PR = 3.75H18 4PR — Rear { 4.00H18 4pR OPYfor) Tire tread depth ont __ aay Rear — i on ;GS500X/550X(E-01) 413 SUSPENSION Unit:_mm (in) ITEM STANDARD MIT Front fork stroke 180 : (59) Front fork spring free length Short 54.9 | (216) | 434.4 hone (17.10) Front fork oil level 1748 al (688 ) 2 Rear wheel travel | 100 _ (3.94 ) Swing arm pivot shaft runout 03 ( 0912} FUEL + OIL ITEM SPECIFICATION Fuel type Use gasoline with an octane number of 85 —95 (Research Method), Preferably unleaded or low-lead type. Fuel tank including reserve 16 U (42/35 _US/imp gal) reserve 40 U (42/35 _us/imp at) Engine oil type | SAE 10W/40 Engine oll capacity a 2400 mil Sharee(25/2.1__US/Imp at Filter 2600. mi change (2.7/2.3 _US/Imp qt) 2700 mi Overhaul (28/24 _ uS/Imp ath Front fork oil type Fork oll #15 or SAETOW/30:A.T.F=1:1 Front fork oil capacity (each leg) 204 mi - (__6.90/7.18 _US/Imp 02) Brake fluid type SAE J1703, DOT3 or DOT4414 GS500X/550X(E-01) TIRE PRESSURE NORMAL RIDING CONTINUOUS HIGH SPEED RIDING SARE PRESSURe. | SOLO RIDING | DUAL RIDING | SOLO RIDING | DUAL RIDING KPa _|kg/em?| psi ‘kPa |kg/em?| psi kPa |kg/cm?| psi ‘kPa |kg/em?| psi FRONT 175 | 1.75) 25 | 175 | 1.75} 25 | 200| 2.00} 28 | 200 | 2.00] 28 REAR 200 | 2.00 : 28 2.50 | 2.50| 36 | 225 | 2.25| 32 | 280 | 2.80| 40 WATTAGE (w) rem SPECIFICATION Headlight HI 60 LO 55 Parking or city light 4 [ Tail/Brake light 5/21 - Turn signal light 2 Speedometer light 34 Tachometer light 34 Turn signal indicator light 3.4 High beam indicator light 34 Neutral indicator light 34 Oil pressure indicator light 34 Gear position 14GS500X/SS5OX(E-O1) 415 GS5O0L Model: GS500L VALVE + GUIDE Unit:_mm (in) ITEM STANDARD Limit Valve diam. N. 30.0 = (418) 25.0 Ex. (098 ) Valve lift 72 is (0283) 7.0 EX. (0276 ) Tappet clearance (when cold) IN. REX. 0.03 — 0.08 Valve quide to valve stem clearance IN. 0.025 — 0.055 0.35 i (0.0010 — 0.0022 ) (0014 Ex 0.040 - 0.070 0.35 " {0.0016 — 0.0028 ) (0.014 ) Valve guide I.D. 7.000 — 7.018 IN-GEX. | (0.2786 — 0.2762 ) Valve stem 0.D. i 6.960 — 6.975 Z (0.2740 ~ 0.2746 ) ey 6.945 — 6.960 " (0.2734 — 0.2740 ) Valve stem runout inva. ene Valve head thickness 05 IN. & EX. — (0.02 ) Valve stem end length week. 40 sae (0.16 ) Valve seat width 09-11 IER (_ 0.035 ~ 0.043 _) Valve head radial runout eek. or Valve spring free length 355 (IN. & EX.) INNER (1.40) eres a (163) Valve spring tension 106-128 ko (IN. & EX.) INNER (| 234-282 Ibs) — at length 31. mm( 1.2 in) 224-22 kg OUTER ( 49.4-578 Ibs) — at length 35 mm (1.4 in)416 GS500X/550X(E-01) CAMSHAFT + CYLINDER HEAD Unit:_mm (in) ITEM STANDARD LIMIT Cam height IN. (35.485 — 35.515 35.190, : (1.3970 ~ 1.3982 ) (1.3854 ) a 35.285 ~ 35.315 34.990 |_ (1.3892 ~ 1.3904 ) (13776 ) Camshaft journal oil clearance MeEX 0.032 — 0.066 0.160 _— _ = EX: |__ (0.0013 - 0.0026 ) (0.0059 ) Camshaft journal holder I.D. 22.012 - 22.025 IN SEX. | ( 0.8666 - 0.8671 ) Camshaft journal 0.0. 21.959 — 21.980 IN-&EX. | (0.8645 - 0.8654 ) Camshaft runout 0.10 IN. & EX. (0.004 ) Cam chain 20 piteh length 157.80 ( 6.213 ) Cam chain pin (at arrow “3”) 20 thpin Cylinder head distortion 0.2 {0.008 ) CYLINDER + PISTON + PISTON RING Unit:_mm (in) ITEM. STANDARD LIMIT Compression presture 9-13 Kglem* 7.0 kalom? (128-185 psi) (100 “psi Compression pressure difference = 2.0 kg/em* (28 psi Piston to cylinder clearance (0.050 — 0.060 0.120 {0.0020 — 0.0024 } (0.0047 ) Cylinder bore 53.000 — 53.015 53.080 | 2.0866 — 2.0872 ) (2.0898 } Piston diam. 52.045 — 52.960 52.880 ( 2.0844 — 2.0860 ) (Sere Measure at the 15 ( 0.59 ) from skirt end. Cylinder distortion 020 (0.008 }GS500X/550X(E-01) 417 Unit:_mm (in) ITEM STANDARD LIMIT Piston ring free end gap 5.0 4.0 i Approx. (0.20 ) (016) 85 68 2nd | T | Appr 033) (027) Piston ring end gap ie 0.10 — 0.30 0.70 (0.004 ~0.012_) (0.028 ) 2nd 0.10 — 0.25 0.70 ( 0.004-0.010 ) ( 0.028 ) Piston ring to groove clearance 4st 0.180, (0.0071) 0.150, a8 (0.0059 } Piston ring groove width ti 121-128 (0.0476 — 0.0484 ) — 1.21 - 1.23 2nd (0.0476 - 0.0484 ) oil 2.51 -—2.53 (0.0988 — 0.0996 ) Piston ring thickness 4st 1.175 — 1.190 (0.0463 — 0.0469 ) 1.170 1.190 2nd (0.0461 — 0,046 ) Piston pin bore 16.002 — 16.008 16.030 {0.6300 — 0.6302 ) (0.6311) Piston pin O.D. 15.995 — 16.000 15.980 ( 0.6297 — 0.6300 ) (0.6291) CONROD + CRANKSHAFT Unit:_mm (in) ITEM STANDARD LIMIT Conrod small end 1.D. 16.006 — 16.014 16.040 (0.6302 ~ 0.6305 ) (0.6315 ) Conrod deflection 3.0 ( 012 ) Conrod big end side clearance 0.10 — 0.65 1.0 | (0.004 0.026 _) (0.039 } Crankshaft runout 0.10 ( 0.004 )418 GS500X/550X(E-01) OIL PUMP ITEM ‘STANDARD LIMIT il pump reduction ratio 1821 ( 87/44x 35/38) Oil pressure (at 60°C, 140°F) ‘Above , 0:1 ka/em? (1.42. psi) 0.3 kg/em? — Below (457 psi) at_3000_+/min. CLUTCH Unit:_mm (in) ITEM ‘STANDARD LIMIT Clutch cable play 2-3 (008-012) Clutch release screw 4 —% Turn beck Drive plate thickness 29-31 26 (0.114 ~0.122_) | ot0) Drive plate claw width 118-120 11.0 (0.465 -0.472_) (043) Driven plate thickness 1.6 + 0.06 {0.063 + 0.002 _) Driven plate distortion 01 (0.004 } Clutch spring free length 36.5 (144)GS500X/S550X(E-01) 419 TRANSMISSION + DRIVE CHAIN Unit:_mm (in) ITEM STANDARD LIMIT. Primary reduction ratio 1977 (87/4) Final reduction ratio 3642 ( 51/14 ) — Gear ratios Low 2666 ( 32/12 ) —— 2nd 1.777 ( 32/18 ) — 3rd 1.380 ( 29/21 ) = ‘4th 1.173 ( 27/23 ) —_—, Sth 11045 (23/22 ) — Top 0966 ( 22/23 ) — Shift fork to groove clearance 01-03 05 ({_ 0.004—0.012 ) (0.020 ) Shift fork groove width 55-56 ___ (_ 0.217—0.220 ) Shift fork thickness 536.4 =e (0.195 —0.199 ) Drive chain D.LD.: S0HDL Type | TAKASAGO: RKSOSHO Links 110 — 20 pitch length ce i Drive chain slack 20-30 (08-12)420 GS500X/550X(E-01) CARBURETOR Unit:_mm (in) ITEM ‘SPECIFICATION | Carburetor type MIKUNI BS328S, Four Bore size 32 1. D. No. 47150 Idle r/min. 1150 + 50 r/min. Fuel level 5.0210 (_ 020+004_) Float height 22.4410 (0880.04) Main jet (M. J.) #975 Main air jet (M.A. J.) 1.6 Jet needle WN) BF 42 — 3rd Needle jet (N. J.) X-6 Thiottle valve #195 Pilot jet (PJ) ‘#40 By pass (BP) 1.0,08 08 Pilot outlet _(P.0.) 07 Vaveseat —_(V.S.) 20 Stererjet (G.-S) | #35,0.5 Pilot screw (P.S.) | PRE-SET Pilot air jet (P.A.J.) | #120 Throttle cable play 0.5—1.0 (002-004) Choke cable play 0.5—1.0 0.02-0.04 )ELECTRICAL GS500X/550X(E-O1) 421 Unit:_mm (in) ITEM SPECIFICATION Ignition timing 15° B.T.D.C. Below 1500+ 100 "r/min and 40° B.T.D.C. Above 2350 + 100r/min. 1.2.4.3 NGK DR8ES—L or ire N.D. X24ESR—-U 06 — 0.7 Gop { 0.024~-0.028 } Signal coil resistance ‘Approx. 60-80 2 Ignition coil resistance O/W — Wor B/Y Primay: Approx. 3-5 2 Plug cap — Plug cap Secondai | Approx. 30-35 ka Generator no-load voltage More than 80 V (AC) at 5000 */min. Regulated voltage 140-145 Vat 5000 r/min, Starter motor IBrush length) ND. Limit: 6 ( 0.24) Commutator under cut Limit: 0.2 (0.008) Starter relay resistance Approx. 3-4 2 Battery, Type designation ‘YBIOL—A2 Capacity 12V 43.2kC (12Ah)/10HR darine 865 1.28 at 20°C (68°F) Fuse size Main 1B OA Headlight 10 A Tur signal 10 A Ignition 10 A Power source 10 A422. GSS00X/550X(E-01) BRAKE + WHEEL Unit: mm (in) Tem ‘STANDARD LIMIT Rear brake pedal height t a j ats 5 50r02 r Brake disc thickness Front i Oa s0nu i one j R 67202 60 = (0.26 + 0.008 {0.24 ) Brake disc runout —_ j oan j Master evlinder bore From | aan = 74,000 — 14.043 Rear (0.5512 ~ 0.5529 ) Master cylinder piston diam Front ( eae 16854 meu fi 13.959 — 13.984 ear (0.5495 ~0.5506 ) Brake caliper cylinder bore Front _ Sa100 98.256 __ 38.180 — 38.256 __ Rese (1.5031 — 1.5061 ) Brake caliper piston diam. Front ; oe ee ’ po 38,098 — 38.148 se (1.4999 1.5019 } Wheel rim runout ca | aay Radial — ‘am ’ Wheel axle runout Front 23, 0.25 Rese (0.010 ) Tire size Front 3.25H18 4PR — Rear 450H17 4PR — Tire tread depth Front ( a ) Rear — 1 oOGS5OOX/550X(E-01) 423 SUSPENSION Unit:_mm (in) ITEM STANDARD LIMIT Front fork stroke 180 (59) Front fork spring free length 152.4 Short ee) 373.4 tong (1470) Front fork oil level 2196 ( 865) Rear wheel travel 100 (3.94 } ‘Swing arm pivot sheft runout 03 (0.012 ) FUEL + OIL ITEM ‘SPECIFICATION Fuel type Use gasoline with an octane number of 85 — 95 (Research Method), Preferably unleaded or low-lead type. Fuel tank including reserve a (32/26 _US/Imp gai) ‘reserve 40 Li (32/26 _US/Impat) Engine oil type ‘SAE 10W/40 Engine oil capacity 2400 Change (25/21 _US/Imp at) Filter 2600. mi I 2700 mi 2 Overhaul (28/24 _ US/Imp at) Front fork oil type Fork oil #15 or SAE1OW/30:A.T.F.=1:1 Front fork oil capacity (each leg) 196ml (662/690 _US/Imp o2) Brake fluid type SAE J1703, DOTS, or DOT4424 GS500X/550X(E-O1) TIRE PRESSURE NORMAL RIDING CONTINUOUS HIGH SPEED RIDING SRE PRESeURe | SOLO RIDING DUAL RIDING SOLO RIDING DUAL RIDING kPa |ks/em'| psi | KP= |kaiem®] psi | kPa |ko/em@] psi | kes |ka/em?| psi FRONT 175 |1.75| 25 | 175 | 1.75| 25 | 200| 200) 28 | 200 | 2.00/ 28 REAR 200 | 2.00] 28 | 225 | 2.25| 32 | 225 | 2.25| 32 | 280 | 2.80) 40 WATTAGE ww) ITEM SPECIFICATION Headlight HI 60 [to 55 Parking or city light 4 Tail/Brake light 5/21 Turn signal light 2 Speedometer light | 34 Tachometer light 34 Turn signal indicator light 34 High beam indicator light 34 Neutral indicator light 34 Oil pressure indicator light 34 Fuel meter light 34 Gear position indicator light 14GS500X/550X(E-O1) 425 GS500M VALVE + GUIDE 1TEM STANDARD Valve diam, i 30.9 7 118) 25.0 ex. (O98) Valve lift ik bone) ~~ ~F9 EX (0276 ) Tappet clearance (when cold) IN. REX. 0.03 - 0.08 _ Valve guide to valve stem clearance if 0025-0055 =| 0.35 7 (0.0010 - 0.0022 } (9.014 ) EX. 0.040 — 0.070 0.35 _ 2 (0.0016 ~ 0.0028 ) (0.014 ) Valve guide I.D. iNeER oN 705 Valve stem 0.0. - in, (aE 0.2740 ~ 0.2746 EX. “6.945 — 6.960 - 7 ( 0.2734 — 0.2740 ) Vaive stem runout IN. & EX. oi s .002 Valve head thickness IN. REX 0s - (002 } Vaive stem end length IN. REX. 40 i (0.16 ) Vaive seat width waex| ; 9@o-bie 4 Valve head radial runout IN. REX. \ on , Valve spring free length NNER 355 (IN. & EX.) (1.40) OUTER — ( aia ’ Valve spring tension 106-128 kg (IN, & EX.) INNER (234-282 Ibs) — at length 31. mm (_1.2 in) 224-262 kg OuTER (494-578 Ibs) — at length 35 mm (1.4 i428 GS500X/550X(E-01) CAMSHAFT + CYLINDER HEAD Unit:_mm (in) ITEM ‘STANDARD LIMIT ‘Cam height ia 35.485 — 35.515 35.180 a (1.3970 - 1.3982 ) (4.3854) me 35.285 — 35.315 34.990 = (1.3892 - 1.3904 ) (1.3776) ‘Camshaft journal cil clearance iN. MEX 0.032 — 0.066 0.160 VEX | (0.0013 - 0.0026 } (0.0059 ) Camshaft journal holder 1.D. 22.012 - 22.025 IN &EX.| (08666-08671) Camshaft journal 0.. 21.959 — 21.980 IN-&EX: | ( 0.8645 - 0.8654 ) Camshaft runout 0.10 IN, & EX. waeee f Cam chain 20 pitch length _ 157.80 (6.213 ) Camichain pin (at arrow 3") 20 th pin Cylinder head distortion 02 (0.008 } CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM. ‘STANDARD [timit Compression pressure 9-13 kglem™ 7.0 kglem* (128-185 _ psi) ( 100 psi Compression pressure difference 2.0 kg/em? (28 psi) Piston to cylinder clearance 0.050 — 0.060 0.120 {0.0020 — 0.0024 ) (0.0047) Cylinder bore 53.000 — 53.015 53.080 ( 2.0866 — 2.0872) (2.0898 ) roo diam: 2.945 — 52.960 ia (2.0844 — 2.0850 ) (seer Measure at the 15 ( 0,59 ) from skirt end. 0.20 Cylinder distortion (0.008 }GS500X/550X(E-O1) 427 Unit: mm (in) ITEM STANDARD LIMIT Piston ring free end gap st |T 5 50 40 Ns Apron (020 ) (0.16) 85 68 god [T] Appr {0.33} (027) Piston ring end gap te 0.10 — 0.30 0.70 ( 0.004 —0.012_) ( 0.028 ) =P 0.10 — 0.25 0.70 ( 0.004~—0.010 } { 0.028 ) Piston ring to groove clearance 1 0.180 (0.0071) 0.150 2nd (0.0059 } Piston ring groove width 4st 1.21 -1.23 ( 0.0476 — 0.0484 ) 1.21 = 1.23 2nd (0.0476 — 0.0484 ) — on 251-253 (0.0988 — 0.0996 ) Piston ring thickness Ist 1.175 — 1.190 (0.0463 - 0.0469 ) 1.170 — 1.190 oa (0.0461 — 0.0469 ) Piston pin bore 16.002 — 16.008 16.030 (0.6300 — 0.6302 ) (0.6311) Piston pin .D. 15.995 — 16.000 15.980 ( 0.6297 ~ 0.6300 ) (0.6291) CONROD + CRANKSHAFT :_mm (in) 1TEM STANDARD. LuiMIT Conrod small end I.D. 16.006 — 16.014 16.040 (0.6302 — 0.6305 ) (0.6315 ) Conrod deflection 30 (012) Conrod big end side clearance 0.10 — 0.65 1.0 (0.004 0.026 (0.039 ) Crankshaft runout 0.10 ( 0.004 )428 GSSOOX/550X(E-01) OIL PUMP. ITEM ‘STANDARD LIMIT Oil pump reduction ratio 1821 (87/44 x 35/38 Oil pressure (at 60°C, 140°F) ‘Above, 0:1 kg/em? | (1.42 psi) 0.3 kg/cm? — r Below (4.27 psi) at_3000_r/min. CLUTCH Unit:_mm (in) ITEM STANDARD [imi Clutch cable play 2=3 T (008-012) | Clutch release screw ee Tar back Drive plate thickness 29-31 26 (0.114 ~0.122_) (0.10 ) Drive plate claw width 11.8 —12.0 11.0 (0.465 -0.472_) (043 ) Driven plate thickness 1.6 + 0.06 (_ 0.063 + 0,002 _) Driven plate distortion — 01 (0.004 ) ‘Clutch spring free length 36.5 (144)GS500X/SS5OX(E-O1) 428 TRANSMISSION + DRIVE CHAIN Unit:_mm tin) ITEM STANDARD LIMIT Primary reduction ratio 1977 (87/44) Final reduction ratio 3500 ( 49/14 ) — 3571 ( 50/14 ) — |(Gearratios = Low 2666 ( 32/12 ) — 2nd 1777 (32/18) == 3rd 1.380 ( 29/21) =— 4th 1.173 (27/23) — sth 1.045 (23/22 ) — Top 0.956 ( 22/23 ) — Shift fork to groove clearance 01-03 05 (0.004 ~0.012_) (0.020 ) Shift fork groove width j ae A — Shift fork thickness 53-54 as {_ 0.195 0.199) aia Tee TAKASAGO: AKSOSHO _—_ Links 110 — £-39 | Links 112 20 pitch length ee een Drive chain slack 20-3430 GS500X/550X(E-01) CARBURETOR Unit:_mm (in) ITEM SPECIFICATION Carburetor type | MIKUNI_ BS328S, Four Bore size 32 1.D.No. 47150 Idle r/min. 1150 + 50 r/min. Fuel level 50210 (0.204004) Float height 22.4210 (_088+0.04 ) Main jet (Med) #975 Main air jet (M.A. J.) 1.6 Jet needle Cr) 5F42— 3rd Needle jet (Wd) x-6 Throttle valve | #135, Pilot jet (Pd) #40 By pass (BP) 1.0, 0.8, 08 Pilot outlet (P. 0.) 07 Valve seat (V.S.) Starterjet_ (G.S.) Pilot screw (P.S.) Pilot air jet (P.A. J.) Throttle cable play ( , Choke cable play \ )GS500X/5S50X(E-O1) 431 ELECTRICAL Unit:_mm (in) ITEM SPECIFICATION Tgnition timing 15 B.1.D.C. Below 1500 = 100 7min: and 40° B.T.D.C. Above 2350 + 100.r/min. Firing order 1.2.4.3 Spark plu NGK DR8ES—L or pee Tee N.D. X24ESR—U a 06-07 - (0.024 -0.028 ) Spark performance Over 8 (0.3) at 1 atm ‘Signal coil resistance ‘Approx. 60-80 2 Ignition coil resistance | ‘OW — Wor BY " rome Approx. 3-5 9 Plug cap — Plug cap ds Secondary Approx. 30-35 ka Generator no-load voltage More than 80 V (AC) at 5000 #/min, Regulated voltage 14.0-14.5 Vat 5000 r/min. Starter motor lprush tenath] ND. (028) Commutator under cut Limit: 0.2 ( 0.008) ‘Starter relay resistance Approx. 3-4 2 Battery Type designation YB10L—A2 Capacity 12V 43.2kC (12Ah)/10HR, Standard dace s 6 1.28 at 20°C (68°F) Fuse size Main 15 OA Headlight to A | Turn signal 10 A Ignition 10 A Power source to A432. GS500X/550X(E-01) BRAKE + WHEEL Unit: mm (in) TEM STANDARD LIMIT Rear brake pedal height i ) i a a "6.040: Brake disc thickness Fron ( aon eabe j jl ae ‘ R ~ 6.7402 6.0 ah (0.26 +0008 ) (0.24 ) Brake disc runout | 4 oa Master cylinderbore | egg eam Teas 14.000 — 14.043 Bem (0.5512 ~ 0.5529 ) —_ Master eylinder piston diam. Front (CRT i 13.959 — 13.984 | ear (0.5495 0.5506 ) | Brake caliper cylinder bore Front | 38.180 — 38.256 iad (15031-15061) Brake caliper piston diam. 38.098 — 38.148 ] rte REE Sem Front (1.4999 — 1.5019 ) 38.098 — 38.148 | Fieee: ( 1.4999 — 1.5019 ) | ‘Wheel rim runout T pact : 20 Radial — tion i Wheel axle runout Front i ay - 0.25 Rear - (0.010 ) Tiesiee Front 3.25H18 4PR — 3.75H18 4PR aoe Rear £-39 4.00H18 4PR as ——F Tire tread depth kare aan ~[ iaGS500X/550X(E-01) 433 SUSPENSION Unit:_mm [in) ITEM STANDARD Limit Front fork stroke 150 (59) Front fork spring free length 57.1 Spon (225) 423.2 tong (16.66 } Front fork oil level 194 Ss (7.64) Rear wheel travel 105 Z (413) ‘Swing arm pivot shaft runout 03 (0012 ) FUEL + OIL ITEM SPECIFICATION Fuel type Use gasoline with an octane number of 85 — 95 (Research Method), Preferably unleaded or low-lead type. Fuel tank including reserve 23 L (_6.1/5.1__US/Imp gal) reserve 40 L ( 42/35 US/Imp qt) Engine oil type SAE 10W/40 Engine oil capacity 2400 mil Grange 25/2.1__US/Impat) Filter 2600 mi change (27/23 US/Imp qt) 2700 ml Overhau! wermeul (28/24 _US/Imp at) Front fork oil type Fork oil #15 or SAE10W/30:A- a Front fork oil capacity (each leg) 195 mi (659/687 __ US/Imp 02) Brake fluid type SAE J1703, DOT3, or DOT4434 GS500X/550X(E-01) TIRE PRESSURE NORMAL RIDING | CONTINUOUS HIGH SPEED RIDING SURE PRESoUNC. | SOLORIDING | DUALRIDING | SOLO RIDING | DUAL AIDING Pa [kaon] psi | Pa fkafom] psi_| KPa |kafom’] psi | Pe |kalem?| psi FRONT 175 | 1.75| 25 | 175 | 1.75] 25 | 200) 2.00] 28 | 200 | 200] 28 REAR 200 | 2.00] 28 | 250| 2.50] 36 | 225| 2.25| 32 | 280|2.00| 40 WATTAGE (Ww) abi SPECIFICATION Headlight HI | 60 Lo 55 Parking or city light | 4 Tail/Brake light, | 5/21 ‘Tum signal light | 21 Speedometer light | 34 Tachometer light | 34 Turn signal indicator light | 34 High beam indicator light 34 Neutral indicator light 34 Oil pressure indicator light [ 34 License light | 5 Gear position indicator light 14GS500X/550X(E-O1) 435 GS550 VALVE + GUIDE ITEM STANDARD. Valve diam: 320 enews IN (126) 27.0 __ Ex (1.06) lumen 72 ve poe Valve lift IN. uaa 4 7.9 EX. (0.276 ) Tappet clearance wea tee (when cold) IN-&EX.| (9.001 0.003) Valve guide to valve stem clearance 1N. 0.020 = 0.050 0.35 a (0.0008 ~ 0.0020 ) (0014 ) EX 0.030 — 0.060 0.36 _ : (0.0012 ~ 0.0024 ) (0.014 ) Valve guide I.D. 7.000 — 7.015 __ . IN@EX: | (02756 —0.2762 ) Valve stem 0.0. 6.965 — 6.980 anesrem IN| (02742-02748 nT 6.955 — 6.970 : (0.2738 - 0.2744 ) Valve stem runout IN. & EX. gay ‘ oo i Valve head thickness IN. REX. aaa i a i Valve stem end length IN. & EX. ‘ on : Valve seat width 09-11 __ ane see IN-SEX | (0.035 —0.043_) Valve head radial runout IN. &EX. ( we j Valve spring free length INNER ne 39 AN, & EX.) (133 ) OUTER — mon Valve spring tension 89-125 kg (IN. BEX.) INNER (196-276 Ibs) — at length 31. mm(_1.2 in) 224-271 ko ouTER ( 48.7-§9.7 bs) — at length 35. mm(_1.4 in)436 GS500X/550X(E-01) CAMSHAFT + CYLINDER HEAD Unit:_mm (in) ITEM STANDARD LIMIT Cam height a 35.485 — 35.515 35.190 “(1.3970 - 1.3982 ) (4.3854 ) ex. | 35.285 - 35.315 34.990 “| __ (1.3892 - 1.3904 } (1.3776 ) Camshaft journal oil clearance IN: EX. 0.020 — 0.054 0.160 LEE | (0.0008 - 0.0021 } ( 0.0059 ) ‘Camshaft journal holder 1.0. 22.000 - 22.013 ( 0.8661 ~ 0.8667 ) Camshaft journal 0.D. 21.959 — 21.980 IN. & EX. (0.8685 — 0.8654 ) Camshaft runout IN. & EX. ‘Cam chain 20 pitch length ‘Cam chain pin (at arrow Cylinder head distortion CYLINDER + PISTON + PISTON RING Unit: mm (in) item STANDARD Limit Compression pressure 90-130 kglem™ 7.0 kglem® _ (128-185 psi) (100 _ psi) ‘Compression pressure difference 2 kglem* |___ — | | _| Piston to cylinder clearance 0.045 — 0.055 0.120 _ (0.0018 — 0.0022 ) _ (0.0047 ) Cylinder bore 86.000 — 56.015 7 56.085 ( 2.2047 — 2.2053 ) (2.2081) _| Piston diam. 55.950 — 56.965 20008 = 2: 55.880 ( 2.2028 — 2.2033 ) (2008) Measure at the 15 ( 0.59 ) from skirt end. Cylinder distortion 0.26 {0.008 )GS500X/550X(E-O1) 437 Unit:_mm (in) TEM STANDARD LIMIT Piston ring free end gap 65 52 te (ee 0.28 1 (020 ) 65 5.2 ApPreS.¢ oz810 (0.20 ) 65 5.2 Sra Approx: (0.26 ) (0.20 } 65 5.2 Approx (0.26 ) (0.20 ) Piston ring end gap ia 01-03 0.70 (0.040.012) (0.028 ) 01-03 0.70 Poe (0.004 0.012_) (0.028 ) Piston ring to groove clearance 4st 0.180 (0.0071 } 0.150 aa (0.0059 ) Piston ring groove width 4st 1.21 —1.23 (0.0476 ~ 010484 ) 1.21 -1.23 ae (0.0476 — 0.0484 ) __ rn 2.51 — 283 (0.0988 — 0.0996 ) Piston ring thickness 4st 1.175 — 1.190 (0.0463 ~ 0.0469) 1.170 = 1.190 ond ( 0.0461 — 0.0469 ) Piston pin bore 16.002 — 16.008 16.030 7 (06311) Piston pin O.D. 15,995 — 16.000 15.980 (0.6297 — 0.6300 ) (0.6291) CONROD + CRANKSHAFT Unit: mm (in) 1TeM STANDARD LIMIT Conrod small end 1.D. 16.006 — 16.014 16.040 (0.6302 ~ 0.6305 ) (06315 } Conrod deflection 3.0 (012 ) Conrod big end side clearance 0.10 — 0.65 1.0 ( 0.004-0.026 ) ( 0.039 ) Crankshaft runout 0.10 (0.004 )438. GS500X/550X(E-01) OIL PUMP Tem STANDARD LIMIT (Oil pump reduction ratio 1821 | 87/44 35/38) Oil pressure (at 60°C, 140°F) Above, Ot Kalem® (1.42 psi) 03 kg/om? — Seow 427 a at_ 3000 1/min. Clutch spring free length CLUTCH Unit:_mm (in) ITEM STANDARD LIMIT Clutch cable play 2-3 (0.08 — 0.12) Clutch release screw eo TENGE Drive plate thickness 29-31 26 | 0.114—0.122 ) ( 0.10 ) Drive plate claw width 11.8 — 12.0 11.0 | 0465-0472 ) ( 0.433 ) Driven plate thickness 1.6 + 0.06 | 0.063 + 0.002) —_ Driven plate’ distortion O14 (0,004 ) 365 (1.44)GS500X/550X(E-01) 439 TRANSMISSION + DRIVE CHAIN (unten aD ITEM STANDARD LIMIT Primary reduction ratio 1977 (87/44) Final reduction ratio 3333 ( 50/15 ) — Gear ratios Low 2666 ( 32/12 ) — 2nd 1777 (32/18) — 3rd 1.380 ( 29/21 ) i 4th 1173 (27/23) — sth 1.045 (23/22 ) — Top 0956 ( 22/23 } Shift fork to groove clearance 01-03 05 (0.004~0.012_) {0.020 ) Shift fork groove width 55-56 (0.217~0.220 ) Shift fork thickness 53-64 _ {0.195 0.199) — Drive chain D..0.: S0HDL Type | TAKASAGO: RKBOSHO Links 110 20 pitch length ease ( = j Drive chain stack 20-30 (08-12)440 GS500X/550X(E-01) CARBURETOR Unit: mm (in) Item SPECIFICATION Carburetor type MIKUNI BS32SS, Four | Bore size 32 1.D. No, | 47090 Idle r/min. | 1100 + 50 r/min. rate Tor Float height 22.4210 (_ 088+0.04 ) Main jet (M. J.) #925 Main air jet (M. A. J.) 1.6 Jet needle (LN) 5F42—3rd Needle jet (WJ) X68 Throttle valve #135 Pilot jet Pd #0 By pass (e.P.) 1.0, 0.8, 0.8 Pilot outlet P.O.) 07 Valve seat v.s) 2.0 Starter jet (G.S.) #35 Pilot screw (P.S.) PRE-SET Pilot air jet (P. A. J.) #120 Throttle cable play 05-10 (002-004 ) Choke cable play 05-10 {002-004 )GS500X/550X(E-O1) 441 ELECTRICAL Unit:_mm (in) ITEM ‘SPECIFICATION Ignition timing 15° B.T.D.C. Below 1500 + 100 r/min and 40° B.T.D.C. Above 2360 + 100 r/min Firing order 1,2,4,3 Spark plug Type NGK BES or N.D.W24ES—U 06-08 |_ Se ( 0.024-0.031_) Type NGK BR8ES or N.D. W24ESR ee 06-08 aR (_ 0.024—0.031_) ‘Spark performance Over 8 (0.3) at 1 atm Signal coil resistanee Approx. 60-80 2 Ignition coil resistance Pri O/W — Wor B/Y rimary Approx. 3-5 © Plug cap — Plug cap Se id ee Approx. 30-35 ke Generator no-load voltage More than 80 V (AC) at 5000 r/min. Regulated voltage: 14.0-15.5 Vat 5000 r/min. Starter motor Brush length] _N. D. Limit 6 ( 0.24 ) Commutator under cut Limit 0.2 ( 0.008 } Starter relay resistance Approx. 3-4 & Battery Type designation | YB10L -A2 Capacity 12V 43.2kC (12An)/10HR Standard eg electrolyte S. G. 1.28 at 20°C (68°F) Fuse size Main 15 A | Headlight 10 A [Turn signat 10 A | Ignition 1A 10 A |__ Power source442 GS500X/550X(E-01) BRAKE + WHEEL Unit: mm (in) ITEM ‘STANDARD LIMIT Rear brake pedal free travel (Drum brake model) ( 20 — 30 og—12 ) Rear brake pedal height 20 (08 ) Brake drum |.D. Rear 180.7 (741) Brake lining thickness 15 (0.06 ) Brake disc thickness 5-28 6.0402 (0.24 + 0,008 | 55 (022 ) Front 5.00.2 (_0.20+0.008 45 (0.18) Rear 6.7+0.2 (__ 0.26 + 0.008 6.0 (0.24 ) Brake disc runout 0.30 (0.012 } Master cylinder bore 14,000 — 14.043 (0.5512 — 0.5529 L Front 15.870 — 15.913 { 0.6248 - 0.6265 Rear 14.000 — 14.043 (0.5512 — 0.5529 Master cylinder piston diam] _og 13.941 — 13.968 (0.5489 --0.5499 Front 15.827 — 15.854 (0.6231 -0.6242 Rear 13.957 — 13.984 {0.5495 — 0.5506 Brake caliper cylinder bore 42.860 — 42.899 (1.6874 — 1.6889 Front 38.180 — 38.256 (1.5031 — 1.5061 Rear 38.180 — 38.256 (1.5031 — 1.5061 Brake caliper piston diam. | ¢_9g 42.785 — 42.810 (1.6844 — 1.6854 Front 38.098 — 38.148 {1.4999 - 1.5019 Rear 38.098 — 38.148 (1.4999 — 1.5019GS500X/SSOX(E-01) 443 Unit:_mm [in) ITEM STANDARD LIMIT Wheel rim runout 2.0 Axial = ee ; 20 —_ Radial — tie Wheel axle runout 0.25 Front (0.010 } | 0.25 Rear {0.010 ) | Front 3.25H19 4PR —_ | 375H18 4PR — Rear £22 4.00H18 4PR — Tire tread depth 16 Front ae i 2.0 Rear (008) SUSPENSION Unit:_mm (in) ITEM ‘STANDARD MIT Front fork stroke 150 (59) Front fork spring free length| Short | 929 e-28 (366) = ___ 396.4 (15.61) 549 Stet (2.16 ) 4344 tora (17.10) Front fork oil level 201 eat (791) 1748 (688 ) Rear wheel travel 100 (394 ) ‘Swing arm pivot shaft runout 03 (0.012 )444 GS500X/SS50X(E-01) FUEL + OIL ITEM SPECIFICATION SELIRS Use gasoline with an octane number of 85 =95 (Research Method), Preferably unleaded or low-lead type Fuel tank including reserve 16 L (42/35 _US/mp sal) reserve 40. OL (42/35 _Us/imp at) | Engine oil type SAE 100/40 Engine oil capacity 2400 mi Change (25/21 _US/Impat) _ i Filter 26000 mi change (27/23 _US/Imp at) 2700 mil Overhaul (28/24 _US/impat) Front fork oil type Fork oil #15 or SAE 100/30 : A.T.F.= 1:1 Front fork oil capacity £28 190 mn (eech tea) (642/669 _US/Imp oz) 204 smi ( 690/7.18 _US/Imp oz) Brake fluid type SAE J1703, DOTS or DOTS TIRE PRESSURE NORMAL RIDING CONTINUOUS HIGH SPEED RIDING Sine prescune, | soLorionc | UALRIDING | soLoRiDING | DUAL RIDING kPa |kavem?] psi | kPa |kaiem?] psi | KPa |ka/em®] pei | kee |k/em’] psi FRONT 175 | 1.75| 26 | 175 | 1.78| 25 | 200|200| 28 | 200 | 2.00| 28 REAR 200 | 2.00] 28 | 250| 2.50] 36 | 225|2.25| a2 | 280 | 280| 40GS500X/S550X(E-O1) 445 WATTAGE (w) item SPECIFICATION E01, 06, 24, 28 and 30 The others Headlight HI 60 —_ Lo 55 — Parking or city light _ 4 Tail/Brake light 8/23 _ 5/21 Turn signal light a 23 at Speedometer light 34 asm Tachometer light 34 — Turn signal indicator light 34 — High beam indicator light 34 — Neutral indicator light 3.4 — Oil pressure indicator light 34 — Gear position indicator light 14 —4S GS500X/550X(E-01) GS550L Model: GS55OL VALVE + GUIDE Unit:_mm (in) ITEM STANDARD LIMIT Valve diam. 32.0 ie (126) 270 ed (406) Valve lift 72 __ me (0.283) 7 = 7.0 Ee (0276 ) Tappet clearance 0.03 — 0.08 (when cold) IN REX, (0.001 0.003 ) Valve guide to valve stem clearance | Wy, 0.020 —0.050 036 (0.0008 — 0.0020 ) (0014 ) ex 0,030 — 0.060 0.35 J (00012-00024) | (0014) Valve guide |.D. 7,000 —7.015 | IN&EX:| (02756 -0.2762 ) Valve stem 0.0. iN. 6.965 — 6.980 kh (0.2742 ~0.2748 ) zm 6.955 —6.970 : (02738 -0.2744 ) Valve stem runout WeeK, oS Valve head thickness AEX a Valve stem end length iNcwER. ¢ eo Valve seat width 09-11 INEEX: ( 0.035 -0.043_) Valve head radial runout IN. & EX. ’ can f Valve spring free length INNER, — 33.9 (IN, & EX.) (133) 413 OUTER (1.63) Valve spring tension 89-125 kg (IN, & EX.) INNER ( 19.6-27.6 Ibs) — atlength 31 mm (_ 1.2 in) 22.1-27.1 kg ouTer ( 40.7-89.7 tbs) + at length 35 mm (_1.4 in)GS500X/550X(E-01) 447 CAMSHAFT + CYLINDER HEAD Unit:_mm fin) ITEM STANDARD. LIMIT Cam height 1 35.485 — 35.516 35.190 i (4.3970 ~ 1.3982 ) (1.3854) x 35.285 — 96.316 34.880 * ( 1.3892 — 1.3904 ) (1.3776 ) Camshaft journal oil clearance: IN. & EX. 0.020 — 0.054 0.150, - m { 0.0008 — 0.0021 ) { 0.0059 ) Camshaft journal holder 1.D. Wad 22.000 — 22.013 &EX.| (08661 — 08667 ) ‘Camshaft journal O.D. 21.959 — 21.980 IN &EX. | (0.8645 0.8654 ) Camshaft runout 0.10 INES (0.004 } Cam chain 20 pitch length 157.8 (6.213 ) Cam chain pin (at arrow 20 thpin Cylinder head distortion — 02 (0.008 ) CYLINDER + PISTON + PISTON RING Unit:_mm (in) ITEM STANDARD LIMIT Compression pressure 90-130 Kglem* 7.0 kglem* ( 128 — 185 psi) (100 _ psi) Compression pressure difference 2 kg/cm? (28 psi) Piston to cylinder clearance 0.045 — 0.086 0.120 { 0.0018 — 0.0022 ) {0.0047 ) Cylinder bore 56.000 — 56.015, 56.085 ( 2.2047 — 2.2053 ) (2.2081 ) Pieton: diam: 55.950 — 55.965 2.2028 — 2: poses ‘ ass) ( 2.2000 ) Measure at the 15 ( 0.59 ) from skirt end. Cylinder distortion 0.26 (0.008 }448 GS500X/550X(E-01) Unit:_mm (in) 1TEM ‘STANDARD LIMIT Piston ring free end gap 65 52 ° ia NAPOOR (028 (0.20 ) 65 5.2 T) Approx, i oa i 65 52 ona PO (0.28 (0.20 ) 65 82 7 Approx (0.26 (0.20 ) Pree Pane te | ( ooo zoor (0028 ) ta 01-03 0.70 m (_ 0.004 ~ 0.012 ( 0.028 ) Piston ring to groove clearance -” co 0.150 ane | ( 0.0059 ) Piston ring groove width 1 121-123 | (0.0476 ~ 0.0484 aa 1.21 1.23 (0.0476 - 0.0484 on 251-253 : (0.0988 - 0.0996 - Piston ring thickness iz oe, 1.170 — 1.190 aed (0.0461 - 0.0469 Piston pin bore 16.002 — 16.008 76.030 { 0.6300 ~ 0.6302 ) (0.6311 ) Piston pin 0.0. 15.995 — 16.000 15.980 (0.6297 — 0.6300 ) (0.6291) CONROD + CRANKSHAFT Unit:_mm (in) 1TEM STANDARD Limit Conrod small end |.D. 16.006 — 16.014 16.040 ( 0.6302 ~ 0.6305 ) (0.6315) Conrod deflection 30 (012 ) ‘Conrod big end side cl 0.10 — 0.65 1.0 mrodibsa end) site clearance (0.004 ~ 0.026 _) (0.039 } ‘Crankshaft runout ( Oy )GS500X/S550X(E-01) 449 OIL PUMP ITEM STANDARD LIMIT. Oil pump reduction ratio 1.821 ( 87/44 x 35/38 d Oil pressure (at 60°C, 140°F) 0.1 kg/cm? Above ( 1.42 psi) 0.3 kg/cm? ee Below (4.27 psi at 3000 r/min. CLUTCH Unit:_mm [in) TEM STANDARD LIMIT Clutch cable play 2-3 (0.08 - 0.12) Clutch release screw GB TGR back Drive plate thickness. 29-31 26 (0114-0122) (010) Drive plate claw width 11.8 —12.0 11.0 (0465-0472) (0.433 ) Driven plate thickness 1.6 +006 ( 0.063+0.002 ) Driven plate distortion ot (0.004 ) Clutch spring free length 36.5 (144)450 GS500X/550X(E-01) TRANSMISSION + DRIVE CHAIN Unit:_mm (in) ITEM ‘STANDARD LIMIT Primary reduction ratio 1977 (87/44) — Final reduction 1 3.400 ( 51/15 ) = E-28 3.266 ( 49/18 ) ae Gear ratios Low 2666 ( 32/12 ) — 2nd 1777 (32/18) — 3rd 1380 (29/21 ) = 4th 1473 (27/23) — Sth 1.045 (23/22) — Top oss ( 22/23 ) -—— Shift fork to groove clearance 0.1-0.3 0.5 (_ 0.004 ~0,012_) (0.020 ) Shift fork groove width 55-56 (0217-0220 } Shift fork thickness 53-64 (0.195 0.199) —_ Drive chain Di.D.: SOHDL Type | TAKASAGO: RKBOSHO Links 110 — £23 | Links 108 ; 320.0 20 pitch length —— a Drive chain slack 20-30 (08-12) —GS500X/550X(E-01) 451 CARBURETOR mm (in) ITEM ‘SPECIFICATION Carburetor type MIKUNIBS32SS, Four Bore size 32 1. D. No. 47090 Idle r/min. 1100 # 50 r/min, Fuel level 50210 (0.202004) Float height 22.4210 (_ 088+0.04 } Main jet (M.J.) #925 Main airjet (M.A. J.) 1.6 Jet needle a) 5F42-3rd Needle jet (NJ) se Throttle valve #135 Pilot jet (P.J.) #40 By pass (B.P.) 1.0, 0.8, 0.8 Pilot outlet _(P. ©.) 07 Valveseat_ —_(V.S.) 2.0 Starter jet (G.S.) #35 Pilotscrew —_(P.S.) PRE-SET Pilot airjet (PA. J.) #120 Throttle cable play 05-10 (_ 002-004 ) Choke cable play os 10 (002-004)452 GS500X/550X(E-O1) ELECTRICAL Unit:_mm {in) ITEM ‘SPECIFICATION Ignition timing 15* B.T.D.C. Below 1600 100 r/min and 40° B.T.D.C. Above 2350 + 100 r/min. Firing order 1,2,4,3 Spark plug Type NGK BES or N.D. W24ES—U 06-08 i (0024-0031) Type NGK BR8ES or N.D, W24ESR aoe 0.6 —08 Se (_0.024~0.031_} Spark performance ‘Over 8 (0.3) at 1 atm ‘Signal coil resistence Ignition coil resistance Prit | mary Approx. 3-5 9 ‘Shcondary Plug cap — Plug cap Approx. 30-35 ka Generator no-load voltage More than 80 V (AC) at 5000 r/min. Regulated voltage 140-155 Vat 5000 r/min, Starter motor [Brush length] —_N.D. Limit 6 ( 0.24 ) ‘Commutator under cut Limit 0.2 ( 0.008 ) Starter relay resistance Approx. 3-4 2 Battery Type designation YB10L -A2 Capacity 12V 43.2kC (12Ah)/10HR Standard electrolyte S. G. 1.28'st 20°C (68°F) Fuse size Main 1B A Headlight 10 A Turn signal 10 A Ignition 10 A Power source 10 AGS500X/SS5OX(E-O1) 453 BRAKE + WHEEL Unit:_mm (in) ITEM STANDARD LIMIT Rear brake pedal height ' = ; Brake disc thickness —_ « fee 9 on 6.0202 55 Ee (_0.24+0008_) (0.22 ) R 6740.2 6.0 im (_0.26+0.008_) (0.24 ) Brake disc runout i oan i [inder bo! 75.870 — 16.913, ___ Martereytingerbom Front: (0.6248 — 06265 ) 14.000 — 14.043 Ee (05512-05529 ) Re 14.000 — 14.043 ial (0.5512 — 05529 ) Master cylinder piston diam, Aon 15.827 — 15.854 - (06231 — 06242 ) 13.941 — 13.968 LE (0.5489 - 05499 ) 13.957 — 13.984 ne (05495 — 0.5506 ) —_ Brake caliper cylinder bore Front : ne ozs ) ___ 42.860 — 42.899 £28 (16874 ~ 1.6889 ) 38.180 — 38.256, Bem (4.5031 — 1.5061) Brake caliper piston diam. Front i noe ot ae j 42.785 — 42.810 ee (1.6844 — 1.6854 ) | 38.098 — 38.148 Rear (1.4999 — 1.5015) Wheel rim runout Axial i 2 ) Radial — ‘bee i Wheel axle runout Front ae, 0.25 | Peer (0.010)454 GS5O0X/550X(E-01) Unit:_mm (in) ITEM STANDARD LIMIT Te size Front 3.25H19 4PR —— £28 90/90-19 52H Rear 450H17 4PR — £28 130/90- 16 67H Tire tread depth 16 Front toma 20 How (008) SUSPENSION Unit:_mm (in) ITEM ‘STANDARD. LIMIT Front fork stroke 160 (63 ) Front fork spring free length 152.4 Short (6.00 373.4 Long (14.70 ) Short —_—_ (6%) E28 z Lo — ‘eT ae (1767 ) Front fork oil level 219.6 (8.65 ) 208 Be (8.19 ) Rear wheel travel 700 (394 ) 95 ES (3.74 ) ‘Swing arm pivot shaft runout 03 {0.012 )FUEL + OIL GS500X/550X(E-O1) 455 ITEM SPECIFICATION Fuel type Use gasoline with an octane number of 85 ~95 (Research Method), preferably unlead- ed or low-lead type. Fuel tank including reserve 12 L (3.22/26 _us/imp gal) reserve 40 u (42/35 _US/imp qt) Engine oil type SAE 100/40 Engine oil capacit 2400 mi sia Change (25 /2.1__us/imp at) Filter 2600 mi change (27/23 _US/Imp at) Overhaul z100 me (2.8/2.4 _ US/Imp at) Front fork oil type Fork oil #15 or SAE 10W/30 : A. Front fork oil capacity (each leg) £-28 196 ml (662/690 _US/Imp oz) 249 mi (__8.42/8.77 __US/Imp oz) Brake fluid type SAE J1703, DOT3 or DOTA486 GS500X/SS5OX(E-01) TIRE PRESSURE NORMAL RIDING CONTINUOUS HIGH SPEED RIDING COLD INFLATION TBE PRESSUNE SOLO RIDING DUAL RIDING ‘SOLO RIDING DUAL RIDING kPa_|kg/en®| psi | kPa |ko/em?) psi | kPa |kg/em?| psi | kPa |kg/em?| psi FRONT 175 | 1.78) 26 | 175 | 1.75] 26 | 200 | 2.00) 28 | 200 | 2.00| 28 REAR 200 | 2.00| 28 | 225 | 2.25| 32 | 225 | 2.25| 32 | 280/280) 40 E-28 NORMAL RIDING CONTINUOUS HIGH SPEED RIDING Tne PHESURS | Soto mins | UAL AIING | soLo RIDING | DUAL RIDING Pa [ka‘em®] psi | uPa [kaiom] psi | uPa |kofema] psi | ua |kgiem?] pe FRONT 200 | 2.00] 28 | 226 | 2.26| 32 | 200|2.00| 28 | 250 | 250| 36 REAR 200 | 2.00] 28 | 225 | 2.25] 32 | 225| 225] 92 | 200 | 280| 40 WATTAGE (w) ITen SPECIFICATION E-01, 06, 24, 28, and 30 The others Headlight HI 60 — Lo 55 — Parking or city light _ — 4 Tall/Brake tight 8/23 5/21 ‘Turn signal light 23 21 Speedometer light | 3.4 — Tachometer light 3.4 — Turn signal indicator light 34 — High beam indicator light 34 = Neutral indicator light 3.4 eo Oil pressure indicator light 34 — Fuel meter lis 34 Paso, Gear position indicator light 14 —GS500X/SSOX(E-O1) 457 GS550T Model: GS5SOT VALVE + GUIDE Unit:_mm (in) 1TEM STANDARD LIMIT Vale diam. 320 WN (126) 27.0 EX. (4.06) Valve | 7.2 aoe uu (073 ) 7.0 Ex (0276) Tappet clearance | 03008 (when cold) IN-&EX| (9.001 0.003) — Valve quide to valvestem clearance | yy, 0.020 — 0.080 036 : (0.0008 — 0.0020 ) (0014 ) EK (0.030 — 0.060 0.35 (0.0012 — 0.0024 ) (0014) Valve guide 1D. 7.000 — 7.015 IN &EX: | (0.2756 — 0.2762 ) Valve stem 0.D. if 6.965 — 6.980 _ (0.2742 — 0.2748 ) m 6.955 — 6.970 _ _ i: ( 0.2738 — 0.2744 ) Valve stem runout 0.05 IN. &EX. — {0.002 } Valve head thickness ieee 05 = 7 ( 002 ) Valve stem end length Weex 4.0 : REX: (016) Valve seat width o9- 11 __ IN-&EX:| (0.035 -0.043_) Valve head radial runout WEEL oe Valve spring free length inca 339 (IN, & EX.) (133) 8 413 UTE (163 ) Valve spring tension a9-125 ko (IN, & EX.) INNER (196-276 tbs) — at length 31. mm (1.2 in) 22.1-27.1 kg OUTER ( 48.7-59.7 ibs) — at length 35 mm (_1.4 in)458 GS500X/550X(E-01) CAMSHAFT + CYLINDER HEAD Unit:_mm (in) ITEM ‘STANDARD Limit ‘Cam height i 35.485 — 35.515 35.190 . (1.3970 ~ 1.3982 ) (1.3854 ) EX. 35.285 — 35.315 34.990 Z ( 1.3892 — 1.3904 ) (1.3776 ) Camshaft journal oil clearance INR EX 0.020 — 0.054 0.150 “as (0.0008 - 0.0021 ) (0.0059 ) Camshaft journal holder 1.D. 22.000 - 22.013 INBEX ( 0.8661 - 0.8667 ) Camshaft journal 0.D. 21.959 — 21.980 ay IN EX! ( 0.8645 ~ 0.8654 ) ‘Camshaft runout | 0.10 IN. & EX. a 1 onoes (Cam chain 20 pitch length sno 1578 (6.213 } Cam chain pin (at arrow 3") 20 thoin —- Cylinder head distortion 0.2 (0.008 ) CYLINDER + PISTON + PISTON RING Unit:_mm (in) ITEM STANDARD LIMIT Compression pressure 90-130 _ kglem* 7.0 kg/om? (128-185 _ psi) | ( 100 _psi) ‘Compression pressure difference 2 kg/em? _ (28 psi) Piston to cylinder clearance 0.045 — 0.055 0.120 (0.0018 ~ 0.0022 ) (0.0047 ) Cylinder bore 56.000 — 66.015 56.085 ( 2.2087 — 2.2053 ) (2.2081) _ Piston diam. 55.950 — 55.965 23028 22033 55.880 (eam } ( 2.2000 ) Measure at the 15 ( 0.59 ) from skirt end. Cylinder distortion 0.26 (0.008 }GS5O0X/550X(E-01) 458 Unit:_mm (in) TEM STANDARD LIMIT Piston ring free end gap 65 52 am Approx. (026 } (020 ) 65 5.2 Approx. (0.26 ) (0.20 ) 65 5.2 2nd Approx, (0.26 } (0.20 ) 65 5.2 Approx. (0.26 ) (0.20 ) Piston ring end gap | a” 0.1-03 0.70 ( 0.004—0.012 ) ( 0.028 ) 01-03 0.70 2nd ( 0.004~0.012_) (0.028 } Piston ring to groove clearance 4st 0.180 (0.0071 ) 0.150 aia (0.0069 } Piston ring groove width 1k 121-123 ( 0.0476 — 0.0484 ) 1.21 - 1.23 2nd (0.0476 — 0.0484 ) oil 2.51 — 2.53 ( 0.0988 — 0.0996 ) Piston ring thickness 4st 1,175 = 1.190 (0.0463 — 0.0469 ) 1.170 — 1.190 ard (0.0461 — 0.0469) Piston pin bore 16.002 — 16.008 16.030 (0.6300 — 0.6302 ) (06311) Piston pin O.D. 15.995 — 16.000 15.980 (0.6297 — 0.6300 ) (0.6291) CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end |.D. 16.006 — 16.014 16.040 ( 0.6302 — 0.6305 ) (06315 ) Conrod deflection 3.0 (012) Conrod big end side clearance 0.10 = 085 1.0 ( 0.004—0.026 ) ( 0.039 ) Crankshaft runout 0.10 (0.004 )480 GS500X/550X(E-01) OIL PUMP ITEM STANDARD LIMIT Oil pump reduction ratio 1.821 ( 87/44 x 35/38 ) L Oil pressure (at 60°C, 140°F) ‘Above 0:1 Ka/em? (1.42. psi) 0.3 ka/em* ms Below (4.27 psi) at_3000 ¢/min. CLUTCH Unit:_mm (in) ITEM. STANDARD LIMIT ‘Clutch eable play 2-3 (0.08 — 0.12) Clutch release serew 4 Turn back Drive plate thickness 29-31 26 (0.114-0.122 ) (0.10 ) Drive plate claw width 11.8 — 12.9 11.0 (| 0.465—0.472_ ) ( 0.433 ) Driven plate thickness 1.6 + 0.06 (0.063 +0.002_} Driven plate distortion ‘cieaesl 01 (0,004 ) Clutch spring free length 365 ( 1.44)GS500X/S550X(E-01) 461 TRANSMISSION + DRIVE CHAIN Unit:_mm (in) ITEM STANDARD LIMIT Primary reduction ratio 1977 (87/44) oe Final reduction ratio 3333 ( 50/15 } — Gear ratios Low 2666 ( 32/12 ) ee 2nd 777 (32/18) a 3rd 1380 ( 29/21 ) —— 4th 1.173 (27/23) —- 5th 1.045 (23/22) —- Top 0956 ( 22/23 ) —— Shift fork to groove clearance 01-03 05 __ (_0,004~ 0.012) (0.020 ) Shift fork groove width 55-56 _ (0.217 0.220) Shift fork thickness 53-54 (0.195 0.199) Drive chain D..D.: SOHDL Tyee | TAKASAGO: RKSOSHO Links 110 — 320.0 20 pitch length — i eee Drive chain slack 20-30 (08-12)482 GS500X/550X(E-01) CARBURETOR Unit:_mm (in) ITEM SPECIFICATION Carburetor type MIKUNI_ BS32SS, Four Bore size 32 1. D. No. | 47090 Idle r/min. | 1100 # 50 r/min, Fuel level ( on : ia ‘ Float height i aa ‘ oo ) Main jet (MJ) #925 Main air jet (M. A.J.) | 16 Jet needle WN) 5F42—3rd Needle jet (NJ) x8 Throttle valve #135 Pilot jet a) #40 By pass (8.P.) | 1.0, 0.8, 08 Pilot outlet (P.0.)_| 07 Valve seat (V.S.) 20 Starterjet (GS) #35 Pilot screw (P.S.) PRE-SET Pilot air jet (P.A. J.) #120 Throttle cable play ( japeana 1 Choke cable play 0.5 -1.0 (002-004 )ELECTRICAL GS500X/S5S50X(E-O1) 463 Unit:_mm (in) ITEM SPECIFICATION Ignition timing 15° B.T.D.C. Below 1500 + 100 r/min and 40° B.T.D.C. Above 2350 + 100 r/min. Firing order 1.2,4,3 Spark plug Type NGK B8ES or N.D.W24ES—U oe (0028-0031) Type NGK BRBES or N.D.W24ESR £06 Gap 06-08 (0.024 ~0.031_) Spark performance Over 8 (0.3) at 1 atm Signal coil resistance Approx. 60-80 a Ignition coil resistance Primary oper: ON Sect pooron. 2095" a Generator no-load voltage More than 80 V (AC) at 6000 r/min. Regulated voltage 140-155 Vat 5000 1/min. Starter motor [Brush length] —_N. D. Limit 6 ( 0.24 ) ‘Commutator under cut Limit 0.2 ( 0.008 ) Starter relay resistance Approx. 3-4 29 Battery ‘Type designation YBI0L -A2 Capacity 12V 43.2kC (12Ah)/10HR @actes € 1.28 at 20°C (68°F) Fuse size Main 15 A Headlight 10A Turn signal 10 A Ignition 10 A Power source 10 A484 GS500X/550X(E-01) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT. Rear brake pedal height A 3 B) Brake dise thickness Front i Sosa ( ah 60202 | 55 said (0.24 + 0.008 (0.22 ) Re 6.7202 6.0 ear {0.26 + 0.008, (0.24 ) Brake disc runout 0.30 (0012 ) Master cylinder bore Front ( 15870-15818 ‘ 6248 — 0. 14,000 — 14.043 E28 (0.5512 - 0.5529 ) Re 14.000 — 14.043 snd (05512 ~ 0.5529 ) —__ Master cylinder piston diem. Fie (27 165 13.941 — 13.968 ea (0.5489 - 0.5499 ) i 13.957 — 13.984 | ear (0.5495 — 0.5506 ) | = Brake caliper eylinder bore Front | eae 42.860 — 42.899 E-2 (1.6874 — 1.6889 ) 38.180 — 38.256 Pew (4.5031 — 1.5061) Brake caliper piston diam. 38.098 — 38.148 | Font (i999 1.5019) 42.785 — 42.810 | fa (16844 ~ 1.6854) 38.098 — 38.148 Boer (1.4999 - 1.5019 ) | Wheel rim runout ae 7 28, ~ TT Radial = (oe) Wheel axle runout Font | 035 (0.01 | a | 0.25 fest | (0.010 )GS5OOX/S550X(E-01) 465 Unit: mm (in) ITEM ‘STANDARD LIMIT Tire size Front 3.25H19 4PR Rear 4.25H17 4PR Tire tread depth i6 Front (0.06 ) 2.0 Rear (0.08 ) SUSPENSION Unit: mm fin) ITEM STANDARD LIMIT Front fork stroke 180 (59 ) Front fork spring free length 929 Short (366) 306.4 Lona (15.61) Front fork oil level 201 (791) Rear wheel travel 00 (394 ) ‘Swing arm pivot shaft runout 03 (0.012 )486 GS500X/550X(E-01) FUEL + OIL ITEM ‘SPECIFICATION Fuel type Use gasoline with an octane number of 85 — 95 (Research Method), Preferably unleaded or low-lead type Fuel tank including reserve 12 u : (32/26 _US/imp ga) reserve 40. OL : (42/38 _Us/imp at) Engine oil type SAE 10W/40 Engine oil capaci m0 ° eee | Change (2.5/2.1 _US/impat) Filter 2600 mi change (2.7/2.3 _US/imp at) Overhaut 2700, il o (28/24 _US/imp at) Front fork oil type Fork oil #16 or SAE 10W/30 : A.T.F = 1:1 Front fork oll capacity (each leq) 190 mi (642/669 _Us/Imp oz) Brake fluid type SAE J1703, DOTS, or DOT4 TIRE PRESSURE NORMAL RIDING CONTINUOUS HIGH SPEED RIDING JCOLD INFLATION TIRE PRESSURE SOLO RIDING DUAL RIDING SOLO RIDING DUAL RIDING kPa |ka/em?] psi | kPa |kgiem?| psi | kPe |kg/om?| psi | kPa |ka/em?] psi FRONT 175 | 1.75 | 25 | 175| 1.75| 25 | 200| 2.00| 28 | 200 | 2.00) 28 REAR 200 | 2.00} 28 | 250} 250| 36 | 225| 2.25] 32 | 280 | 2.80/ 40GS500X/550X(E-O1) 467 WATTAGE (w) ITEM SPECIFICATION E01, 06, 24, 28 and 30 The others Headlight HI 60 — Lo 55 = Parking or city light 4 Tail/Brake light 8/23 5/21 Turn signal light 23 2 Speedometer light 34 + Tachometer light 34 —- Turn signal indicator light 34 — 34 —_ 3.4 — Oil pressure indicator light 3.4 — Gear position indicator light 14 —_—488 GS500X/550X(E-O1) GS550M Model: GS550M VALVE + GUIDE Unit:_mm (in) ITEM ‘STANDARD L_uimir Valve diam. } IN, | tees I a 27.0 me | (106) Valve lift IN. ‘ oma ; os 7.0 BS (0276 ) Tappet clearance 0.03 - 0.08 (when cold) AN BEX. ( 0,001- 0.003) Valve guide to valve stem clearance wd \ en oy | .0008 ~ 0. . Ex. | 0.030 — 0.060 0.35 | (0.0012 - 0.0024 ) (0.014 ) Valve guide 1.0. IW EX | gA0O=7015 a Valve stem 0.D. TN. 6.965 — 6.980 __ (0.2742 ~ 0.2748 ) Tex 6.955 — 6.970 (0.2738 - 0.2744 ) Va | _— 0.05 alve stem runout Tin. wex. on Valve head thickness IN. REX. oes ( a ) i Valve stem end length IN. & EX. —__ i} i 2 i Valve seat width IN REX. tio bes a | Valve head radial runout IN. & EX. _ ] i oe i = —} z Valve spring free length INNER — 33.9 HIN, & EX.) L133) outer —— | @iei Valve spring tension 89-125 ko (IN. & EX.) INNER (196-276 Ibs) — at length 31. mm (_1.2 in) 22.1-27.1 kg | ouTeR ( 48.7-59.7 Ibs) — at length 35 mm (1.4 in) |GS500X/S5S5OX(E-01) 469 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height IN. 35.485 — 35.515 35.190 7 (4.3970 - 1.3982 ) (1.3854 ) EX. 35.285 — 35.315 | 34.990 PS (13992-13004) | (1.3776) ‘Camshaft journal oil clearance | Iw. & EX. | 0.020 — 0.054 | 0.150 : " ({0,0008 — 0.0021 } (0.0059 ) Camshaft journal holder |.D. | 22.000 — 22.013 | IN. & EX, | (0.8661 — 0.8667 ) Camsha‘r journal O.D. 21,959 — 21.980 ING EX. | (0.8645 — 0.8654 ) ‘Camshaft runout _ 0.10 MSDE (0.004 ) Cam chain 20 pitch length 157.8 ( 6.213 ) Cam chain pin (at arrow “3") 20 thpin | — Cylinder head distortion 0.2 |__( 0.008 ) CYLINDER + PISTON + PISTON RING Unit:_mm (in) ITEM STANDARD LIMIT Compression pressure 9.0—13.0 kg/cm? 7.0 kg/cm? (128-185 psi) (100 _ psi) Compression pressure difference 2 kg/cm? _ | ¢ 28 psi Piston to cylinder clearance 0.045 — 0.055 0.120 (0.0018 — 0.0022 ) | (0.0047) Cylinder bore 56,000 — 56.015, | 56.085 _ (2.2047 — 2.2053 ) ( 2.2081 ) \ 55.950 — 55.965 ( 22028 — 2.2033 po ee0 ) ( 2.2000) at the 15 ( 0.59 ) from skirt end. Cylinder distortion 0.26 | (0.008 )410. GS5O00X/550X(E-O1) 1TEM ‘STANDARD LIMIT Piston ring free end gap 65 32 ta Apron. 0.8 (0.20 } 65 52 Approx. (0.26 (0.20 ) ] 65 5.2 na Arora. 0.8 (0.20 } 65 52 Approx (0.26 (020) Piston ring end gap ta 01-03 0.70 (_ 0.004 - 0.012 {0.028 ) 01-03 0.70 a (0.004 - 0.012 (0.028 } Piston ring to groove clearance 7” 0.180 (0.0071 } 0.150 cal (0.0059 } Piston ring groove width a 121-123 (0.0476 — 0.0484 an 1.21 1.23 (0.0476 - 0.0484 on 2.51 ~2.53 (0.0988 ~ 0.0996 —_ Piston ring thickness = 1.175 — 1.190 (0.0463 ~ 0.0469 1.170 - 1.190 ond (0.0461 - 0.0469 Piston pin bore 76.002 — 16.008 76.030 (0.6300 ~ 0.6302 ) (0.6311 ) Piston pin 0.0. 15.995 — 16.000 15.980 {0.6297 ~ 0.6300 ) (0.6291) CONROD + CRANKSHAFT Unit:_mm (in) ITEM STANDARD. LIMIT Conrod small end I.D. 76.006 — 16.014 76.040, {0.6302 — 0.6305 ) (06315) Conrod deflection 30 (0.12) Conrod big end side clearance 0.10 - 0.65 10 (0004-0026 ) (0.039 ) Crankshaft runout 0.10 (0.004 )GSS500X/S5SOX(E-O1) 471 OIL PUMP ITEM ‘STANDARD LIMIT Oil pump reduction ratio 1821 (87/44 35/38) Oil pressure (at 60°C, 140°F) 0.1 kglem* Above (1.42. psi) 0.3. kg/cm? — Below (4.27 psi) at_ 3000 r/min. CLUTCH Unit=_mm in) ITEM I ‘STANDARD LIMIT Clutch cable play | 2-3 | (008-012) Clutch release screw | %—¥% Turn back Drive plate thickness 29-31 26 (0114-0122 ) (0.10 ) Drive plate claw width 118-120 11.0 (0465 -0.472_) (0.433 ) Driven plate thickness 1.6 #006 (_ 0.063 + 0.002) Driven plate distortion on {0.004 ) Clutch spring free length 365 (1.44)412. GS500X/550X(E-01) TRANSMISSION + DRIVE CHAIN Unit: mm (in) ITEM STANDARD LIMIT Primary reduction ratio 1977 (87/44) Final reduction ratio 3.333 ( 60/15 ) — £2 3.400 ( 51/15 ) Gear ratios Low 2666 ( 32/12 ) — 2nd 1777 (32/18) = 3rd (2/21 ) — ath (27/23) — sth 1.045 (23/22) a Top 0956 ( 22/23 } — fork to groove clearance 0.10.3 ] 05 : (_ 0,004—0,012_) (0.020 ) Shift fork groove width | 55-56 | oes | (0217-0220 } | ‘Shift fork thickness 53-54 __ {0.195 0.199) Drive chain ‘D.1.D.: SOHDL . —H Type | TAKASAGO: RK5OSHO | Links 112 ee T T ; 320.0 20 pitch length —= i cae08) Drive chain slack 20-30 (08-12)GS500X/S550X(E-01) 413 CARBURETOR Unit:_mm (in) ITEM SPECIFICATION Carburetor type MIKUNI_ 8328S, Four Bore size 32 1. D.No. 47090 | idle w/min, | ; 1100 50 r/min. - teste! (020004) Float height 22.4210 (0882004) ‘Mainjet (Md) - _ #925 Main air jet (M. A.J.) 16 Jetreedie WN.) 8F42—3d Needle jet (N.J.) x-6 Throttle valve #136 Pilot jet (Ped) #40 By pass (B.P.) 1.0, 08,08 Pilotoutlet —(P.0.). | 0.7 Valve seat (V.S.) 2.0 Starterjet (6.8) #35 Pilot screw _(P.S.) PRE-SET Pilot air jet (P.A.J.) - #120 Throttle cable play _ 08-10 (002-004) Choke cable play 05-10 {_ 002-004)414 GS500X/550X(E-O1) ELECTRICAL Unit:_mm (in) ITEM SPECIFICATION june T5* B.T-D.C. Below 1500 + 100 r/min and 40° B.T.D.C. Above 2350 # 100 r/min. Firing order 1,2,4,3 Spark plug Type | NGK B8ES or N.D. W24ES—U Gap (0024-0031) Spark performance Over & (0.3) at 1 atm Signal coil resistance ‘Approx. 60-80 9 Ignition coil resistence Primary OW = Wor BY Approx. 3-5 Plug cap — Plug cap Serondary Approx. 30-35 ka Generator no-load voltage More than 80 V (AC) at 5000 r/min. Regulated voltage 140-155 Vat 5000_ ¢/min. Starter motor Brush length} N.D. | Limit: 6 (0.24) SS eT Starter relay resistance Approx. 3-4 Battery Type designation YBIOL —A2 Capacity 12V 43.2kC (12Ah)/10HR Standard aaaeye SiG. 1.28 at 20°C (68°F) Fuse size Main 1B A | _ Headlight 10 A Turn signal 10 A Ignition 10 A Power source 10 AGS500X/550X(E-O1) 475 BRAKE + WHEEL Unit:_mm (in) ITEM ‘STANDARD LIMIT Rear brake pedal height i a ) Brake disc thickness 5.002 45 Ereat (0.200008 _) (0.18 ) 6.7202 6.0 few. (0.260008 _) (024 ) Brake disc runout 0:30 (0.012 ) senor ven] aes) | ii 14,000 — 14.043 ear (0.5512 — 05529 } Master cylinder piston diam. Front | OE eee a 13.957 — 13.984 Rear {0.5495 — 0.5506 ) aaa Brake caliper eylinder bore Dont (Bi BE 38.180 — 38.256 foe (45031 - 1.5061) Brake caliper piston diam. Front am 18 ‘ a 38.008 — 98.148 ea (1.4999 — 15019 ) Wheel rim runout a (ey Radial — ‘ on \ Wheel axle runout | Eront _ — : os i 0.25 Rear (0.010 ) re sze Front 3.25H19 4PR as 3.75H18 4PR = Rear +22 4.00H18 4PR Tire tread depth Front __ dey 20 Rear a 1 oj416 GS50OX/550X(E-01) SUSPENSION Unit:_mm (in) ITEM. STANDARD i LIMIT Front fork stroke 150 foes aes (59 ) Front fork spring free length 874 Short || (225) t 423.2 bos (16.66 ) Front fork oil level 194 ( 7.64 ) Rear wheel travel 105 (413) Swing arm pivot shaft runout 03 ( 0.012 ) FUEL + OIL ITEM SPECIFICATION Fuel type Use gasoline with an octane number of 85 —95 (Research Method), Preferably unleaded or low-lead type Fuel tank including reserve ~ 23 C : (6.1/5.1 _US/imp cal) reserve 4.0 L _ (42/35 _Us/imp av) Engine oil type SAE 100/40 Engine oil capacity 2400 mi Grange (25/24 US/Imp at) Filter 2600 mi change (27/23 US/Imp qt) 2700 mi Overhaul (28/24 _US/Imp at) Front fork oil type Fork oil #15 or SAE 10W/30 : A.T. a Front fork oil capacity (each leg) 195, mi (659/687 _US/Iimp oz) Brake fluid type SAE J1703, DOTS, or DOTAGS500X/550X(E-O1) 477 TIRE PRESSURE NORMAL RIDING CONTINUOUS HIGH SPEED RIDING oe iwescune. | sovorioins | ouaLaIDING | soLORIING | DUAL AIDING Pa |kaiom®| psi | kPa |kolm’] psi | kPa |ka/om?| psi | KPa |ka/em?] ps FRONT 175 | 1.75| 25 | 175 | 1.75| 25 | 200|2.00| 28 | 200| 2.00| 23 REAR 200 | 2.00| 20 | 250| 250] 36 | 225| 2.25| 32 | 280|280| 40 WATTAGE (w) eM ‘SPECIFICATION £2, 4,34 E22 £24 Headlight HI 60 — —_ Lo 5 — — Parking or city light | 34 — Tail/Brake light 5/21 — — Tum signal light 2 — — ‘Speedometer light 34 — — Tachometer light 34 — — “Turn signal indicator light 34 — _—_ High beam indicator light 34 —_ — Neutral indicator light 34 —— —s Oil pressure indicator light 34 — — License light 5 10 8 Gear position’ indicator light 14 — —418 GS500X/550X(E-01) "103 X,,0GGS9GS500X/550X(E-01) 473 > seme rome 2 SSE egg Ss see | 2 = 23 .X,INOGSSD “.X,,0GGSD | i | _480 GSSOOX/550X(E-01) 7 «XsINOGGSD ** .X,,0GGSD) #3 X,INOGGSD *..X,,00ES9GS500X/S50X(E-01) 481 2 «X,0GGS9 *“'3 .X,INOOGSD “3 .X,,00GSD482. GS500X/550X(E-01) easoc43oas § a q E u #23 .X,,0GGSD = ..X,,INOGGSD “..X,00GSDGS500X/550X(E-01) 483 sess o un wooo aw ae nn once mao "3 X,INOGGSD ©? .X,,089SD484 GS500X/550X(E-01) ‘wma oa 6 >EBSESSSS5 Eusscodsces oF oe) Bo fad) iho #3 .X,,0GGS9GS500X/550X(E-O1) 485 [bp wean cam nn *3 .X,INOGGSD “.X,0GGSD “.X,00GSD486. GS500X/550X(E-01) 4 se'L's3 X,, 100GSDGS500X/550X(E-01) 487 [eon s'03 .X, 10GGS9488 GS500X/550X(E-01) Bacstsoas ove 3 .X»10GGSD2 GS500X/S50X(E-01) 489 3 Xs, 10GGSD490 GS5SO0X/550X(E-01) “ame eo wo we 2 secre .X,10G9SDGS550X/550X(E-O1) 491 ee B55588 +55 oe #73 .X,,10GSS9492. GS500X/550X(E-01) eascddtoe® ‘000 | . jr win t~BESSS5353 i é asscodtoee GS550X/S55OX(E-01) 493 3X» 10GGS9 i494 GS500X/550X(E-01) Bgoes Bosse #3 .X,LOGGSDees0d45ca8 5 8 5 GS550X/550X(E-01) 435 sormnm GF macnn we BP] 3 .X»LOGSSD498 GSSOOX/550X(E-01) [FD nor ne en pone Dove #23 .X,LOGGSDGS550X/550X(E-01) 497 CABLE ROUTING GS500E, GS500M, GS550, GS550E AND GS550M Throttle cable (For flat handle) Throttle cable (For normal handle) ‘Starter cable498. GS500X/550X(E-01)GS550X/S550X(E-01) 499 BRAKE HOSE ROUTING O©—ciamp the hose after pasing the hose. Pass the hose inside ofthe torque link bracket.500 GS500X/550X(E-01) WIRE HARNESS ROUTING GS500E, GS500M, GS550, GS550E AND GS550M Tail/orake light Clamp — Battery Boggy ground, Starter relay ‘To magnet Ignition coit Ignition switch, meter © Front Clamp i ‘Tur signal relay i Battery holder | Regulator, Rectifier High tension cord GroundGS550X/550X(E-O1) 501 GS500L, GS550T AND GS550LGROUP 18 FOREWORD The SUZUKI GS550-series are new 1981 models and incorporate many refinements and technical changes from the previous models. This new supplementary section has been produced to aid SUZUK] mechanics in propery maintaining and reparing these motorcycles, which incorporate so many new and innovative changes. These technical improvements have further enhanced the comfort, handling and overall performance of these outstanding models This supplementary section covers four models of GS550-series; GS550, GS550E, GS550T, and GS55OL. This supplementary section has been written primarily for the experienced SUZUKI mechanics but will also be very useful even for the do-it-yourself mechanics. Please refer to the entire GS550 Service Manual for all other areas of information not covered in this manual.GS550EX/TX/LX 505 CONTENTS MODEL IDENTIFICATION: “506 SPECIFICATIONS: --- “508 MODIFICATIONS: “511 SERVICE DATA GS550X AND GS550EXx:-- 513 GS550LX- 524 GS550TX “535 ‘WIRING DIAGRAM “546 CABLE ROUTING ---- “549 BRAKE HOSE ROUTING---- 651 ‘WIRE HARNESS ROUTING -- “552506 GSSSOEX/TX/LX MODEL IDENTIFICATION @S550/GS550E GS550TGSS550EX/TX/LX 507 GSS5OL508 GSSSOEX/TX/LX SPECIFICATIONS GS550 AND GS550E DIMENSIONS AND DRY MASS Overall length. 2.180 mm Overall width 850 mm Overall hei 1160 mm. Wheelbase... 2. 1.440 mm, Ground clearance 150. mm Seatheight . 780 mm Dry mass 200 kg ENGINE Type. sees Number of cylinders Bore. . ‘Compression ratio . Carburetor Polyurethane foam element ‘Starter system < | | Electric Lubrication system | Wet sump TRANSMISSION Clutch ‘Wet multi-plate type ‘Transmission <2? speed constant mesh Gearshift pattern’: ‘down, Sup Primary reduction - | 1.977 (67/44) Final reduc IIIT 31333 60/18) Gearratios, Low |. 2.666 (32/12) and 222221 1.777 32/18) 1/380 (29/21) 1.173 (27/23) 41045 (23/22) 0.956 (22/23) Drive chain DAIDO 0.1.0. SOHDL or TAKASAGO RKSOSHO, 110 links CHASSIS Front suspension... Rear suspension Steering angle. Caster . «Telescopic, oil dampened + Swinging arm, oil dampened, spring S-way adjustable 40° (right & left) 2 61°30" Trail. 116 mm Turing 25m Front brake Disc brake Rear brake {Internal expanding...GS550 Disc brake...SB50E Front tire size. 3.2519 4PI Rear tre size 11 3.75H18 4PR Front fork stroke + 150 mm (6.91 in) Rear wheel travel | 1 100 mm (3.94 in) ELECTRICAL Ignition type Ignition timing Spark plug . Battery Generator Fuse. CAPACITIES Transistorized 11 18°B.7.0.C. below, 1.500 r/min and 40° B.T.D.C. above 2 350 r/ . NGK B8ES or NIPPON DENSO W24ES-U = 12V43.2kC (12Ah)/10HR + Three-phase A.C. generator 10/10/10/154 . 16L 2 4.0L 2aL 2 190mGSS550EX/TX/LX 509 GS550T DIMENSIONS AND DRY MASS Overall length. 2.200 mm Overall width . 22" 850 mm. Overall height "| 21180 mm_ Wheelbase . 1435 mm Ground clearance 150 mm. Seat height 2780 mm_ Dry mass. 1 200 kg ENGINE Type... Four-stroke, aircooled, DOHC 4 56.0. mm TIT 658mm Piston displacement’... 640 em? ‘Compression ratio . 5 86:1 Carburetor MIKUNI 8832S, four Air cleaner | Polyurethane foam element Starter system’ < Electric Lubrication system 1 Wet sump ‘TRANSMISSION Clutch % ++ Wet multi-plate type Transmission | 1 G-speed constant mesh Gearshift pattern’ <<... 1-down, 5:up Primary reduction . 1.1 1.977 (87/44) Final reduc DIDI 31333 (60/15) Gear ratios, Low |... 2.666 (32/12) 2nd | 4.777 (32/18) 3rd 222211 17380 (29/21) ath 2202202 1.173 (27/23) Bth 1.21111 11045 (23/22) Top 12.1111 0.986 (22/23) Drive chain. 2 DAIDO D.1.D. SOHDL or TAKASAGO RK5OSHO, 110 links CHASSIS Front suspension . . Rear suspension : ‘arm, automatic dual damping, spring -way adjustable ‘Steering angle. 40" (right & left) Caster. IIT er's0" Trail. 5116 mm Turning radius | hl 25m Front brake 1 ise brake Rear brake Disc brake Front tre size... 2... 3.25H194PR Rear tire size 1 4.25H17 4PR 2 180mm 2 100 mm ELECTRICAL « Transistorized 1 18° B.7.D.C. below, 1.500 r/min and 40° 8.7.0.¢, above 2 350 r/min. lonition type... Ignition timing Spark plug... « NGK B8ES or NIPPON DENSO W24ES-U Battery . + 12V43.2kC (12Ah)/10HR, Generator ‘Three-phase A.C. generator Fuse . 2 1O/10/10/158 CAPACITIES Fuel tank including reserve. 12L resene ..... 4.0L Engine oil Da Front fork, 1 490 'mt510 GS55OEX/TX/LX GS550L DIMENSIONS AND DRY MASS ‘Overall length - 2. 2215 mm ‘Overall width, 870 mm Overall hei 1180 mm Wheelbase. . 1460 mm Ground clearance 140 mm Seatheight 775 mm Dry mass... 208 ka ENGINE Compression ratio . Carburetor Air deaner MIKUNI BS22SS, four Polyurethane foam element Startr syste Electric Lubrication system Wet sump ‘TRANSMISSION Clutch. Wet multi-plate type Transmission | speed constant mesh Gearshift pattern t-down, Sup Primary reduction « 1.977 (67/44) Final reduction 3.266 (49/18) Gear ratios, Low 2.666 (32/12) 2nd 1.777 (32/18) 3rd | 1.280 (20/21) ath 1.173 (27/23) 5th | 11046 (23/22) Top 0.956 (22/23) Drive chain DAIDO D.1.0. S0HDL or TAKASAGO RKSQSHO, 108 links CHASSIS Front suspension .. Telescopic, oil dampened Rearsuspension . -. ‘Swinging arm, oil dampened, spring 5-way adjustable Steering angle .. 40° (right & left) Caster... 60°00" 112 mm 25m Disc brake Disc brake Front brake . Rearbrake © || Front tire size. | ‘90/90-19 52H Rear tire size 130/90-16 67H Front fork stroke 160 mm Rearwheel travel | | 95mm ELECTRICAL Ignition type Ignition timing Spark plug. . Battery - Generator Fure. CAPACITIES Fuel tank including reserve Engine oil Front fork « Trareistorized « 15° B.T.D.C. below, 1.500 r/min and 40° B.T.0.C. above 2 30 r/min = NGK BBES or NIPPON DENSO W24ES-U = 12V43.2kC (12Ah)/10HR 1 Three-phase A.C. generator 1oNIO/EA 12 4.0L Dat + 249 mt