GS500 01-02 PM

Suzuki Worldwide Motorcycle-ATV Page: 1 of 61GS500K1 (GS500K1 E2)Catalogue Title:

FIG1 GASKET SETBlock No. Block Title.

Copyright © 2006 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.

Ref No

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Part No

11400-0186111141-01D1011143-06B0011173-1550211177-15510-H1711241-01D0011482-4411011483-4411011489-4411012837-24A1014181-01D0016518-4500009168-0602309168-0800809168-1003109168-1400409280-0300309280-1300409280-1500609280-2600609280-40010

Description

Gasket Set• . Gasket, Cylinder Head• . O Ring, Head Gasket• . Gasket, Cylinder Head Cover• . Gasket, Breather Cover• . Gasket, Cylinder• . Gasket, Clutch Cover• . Gasket, Magneto Cover• . Gasket, Oil Pan• . Gasket, Exhaust Pipe• . Gasket, Exhaust Pipe• . O Ring, Oil Filter Cap• . Gasket (5.8x13x1.2)• . Gasket (8.2x14x1)• . Gasket (10.2x20x2.3)• . Gasket (14.1x18x1.5)• . O Ring (d:1.05,id:3.1)• . O Ring (d:1.9,id:13)• . O Ring (d:1.9,id:14.5)• . O Ring (d:3.1,id:26.4)• . O Ring (d:2.4,id:39.7)


FIG2 CYLINDER HEAD COVERBlock No. Block Title.


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12345678910

Part No

11171-01D0211173-1550209106-0701009106-0700909280-1500611176-3320111186-1550111177-15510-H1701550-0625309404-06432

Description

Cover, Cylinder HeadGasket, Head CoverBolt (l:19)Bolt (l:5.5)O Ring (d:1.9,id:14.5)Cover, BreatherSeparator, Oil BreatherGasket, Breather CoverBoltClamp


FIG3 CYLINDER HEADBlock No. Block Title.


Ref No

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Part No

11100-01D2011115-4574009381-1000309103-0607109206-0800107120-0612309168-0602311141-01D1011143-06B0001550-0630304211-1118909159-1006909159-1002609168-1003109482-0033409482-0033526431-4500226441-4900026451-4500009289-0500209128-0510113101-01D4009280-4001002112-1616309402-54208

Description

Head Assy, Cylinder• . Guide, Valve (os:0.3)• . Ring, Valve Guide• . Bolt (6x39)• . Pin• . Bolt, Oil Gallery• . GasketGasket, Cylinder HeadO Ring, Cylinder HeadBoltPinNutNutGasketSpark Plug (ngk,dpr8ea-9)Spark Plug (nd,x24epr-u9)Gear, Tacho. Driven (nt:10)SleeveSeal BandOil Seal (5x12x8)Screw (5x12)Pipe, Intake• . O Ring (d:2.4,id:39.7)ScrewClamp


FIG4 CYLINDERBlock No. Block Title.


Ref No

12345

Part No

11210-01D20-0F009108-1011209108-1004104211-1118911241-01D00

Description

CylinderStud Bolt (l:168)Stud Bolt (l:178)PinGasket, Cylinder


FIG5 CRANKCASEBlock No. Block Title.


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Part No

11301-4489009206-1300409206-1101707130-0870309103-0818209103-0813409103-0823001550-0865301550-0845309103-0603309103-0606701550-0690301550-0670301550-0665301550-0650701550-0645309168-0800809493-2201009493-3200209493-2400809280-0300309103-1013709103-1015409103-1012709103-1027809159-1007811611-01D1011610-4541011521-4410002112-06123

Description

Crankcase Set• . Pin• . Pin• . Bolt (8x70)• . Bolt (8x125)• . Bolt (8x110)• . Bolt (8x100)• . Bolt (8x65)• . Bolt (8x45)• . Bolt (6x125)• . Bolt (6x105)• . Bolt (6x90)• . Bolt (6x70)• . Bolt (6x65)• . Bolt (6x50)• . Bolt (6x45)• . Gasket• . Jet, Oil Gallery Mission• . Jet, Oil Galy. Bal. Shaft• . Jet, Oil Gallery Cylinder• . O Ring (d:1.1,id:3.1)Bolt (10x255)Bolt (10x245)Bolt (10x170)Bolt (10x160)NutSpacer (l:16.8)Spacer (l:65)Plate, Oil SeparatorScrew


FIG6 CRANKCASE COVERBlock No. Block Title.


Ref No

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Part No

11341-01D1011482-4411004211-1318909103-0621609103-0621409103-0621611970-4411009280-2600609247-1401209168-1400211381-01D1009103-0501668233-01D0011351-01D1011483-4411004211-1318909103-0621468233-01D0011361-01D1004211-0912909103-0623909103-0623809103-0621511382-4411101547-0508311387-01D1002122-0512737820-33D10

Description

Cover, ClutchGasket, Clutch CoverPinBoltBoltBoltGauge, Oil LevelO Ring (d:3.1,id:26.4)Plug, Oil CheckGasketCover, Contact BreakerBoltEmblemCover, GeneratorGasket, Generator CoverPinBoltEmblemCover, Engine SprocketPinBoltBoltBoltCover, Starter MotorBoltCap, Clutch ReleaseScrewSwitch, Oil Pressure


FIG7 OIL FILTER - OIL PUMPBlock No. Block Title.


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Part No

11511-4410011489-4411001550-0630309247-1402609168-1400216440-11D0016510-4504016518-4500009440-3200416512-45D0001421-0620808313-2006316520-01D0101570-0612316400-4410009280-1300402112-0625316331-01D1009181-1015809261-0400908331-31106

Description

Pan, OilGasket, Oil PanBoltPlug, Oil DrainGasketValve Assy, Oil ReliefFilter, Engine OilO RingSpringCap, Engine Oil FilterStud BoltNutStrainer, Engine OilScrewPump Assy, Engine OilO Ring (d:1.9,id:13)ScrewGear, Driven (nt:27)WasherPinCirclip


FIG8 CRANKSHAFTBlock No. Block Title.


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123333456666789101112131415161717

Part No

12160-4410009159-0803312164-01D01-0A012164-01D01-0B012164-01D01-0C012164-01D01-0D012220-01D0209202-0301612229-01D01-0A012229-01D01-0B012229-01D01-0C012229-01D01-0D012228-4410621111-4410009140-2400709164-2500108341-3105909283-2201512111-01D01-0F012140-01D2012151-4550109381-1800212100-01D00-05012100-01D00-100

Description

Rod Assy, Connecting• . NutBearing, Crank Pin (green)Bearing, Crank Pin (black)Bearing, Crank Pin (brown)Bearing, Crank Pin (yellow)Crankshaft• . PinBearing, Crankshaft (green)Bearing, Crankshaft (black)Bearing, Crankshaft (brown)Bearing, Crankshaft (yellow)Bearing, ThrustGear, Primary Drive (nt:28)NutWasherKeyOil Seal, Rh (22x40x8)PistonRing Set, PistonPin, PistonCirclipPiston Set (os:0.5)Piston Set (os:1.0)


FIG9 CRANKSHAFT BALANCERBlock No. Block Title.


Ref No

123456789999

Part No

12650-01D0112666-4400109160-2402609440-1500709201-0800109180-2400909160-1203901500-1220312229-01D01-0A012229-01D01-0B012229-01D01-0C012229-01D01-0D0

Description

Balancer, CrankshaftGear, Driven (nt:46)WasherSpringPinSpacerWasherBoltBearing (green)Bearing (black)Bearing (brown)Bearing (yellow)


FIG10 STARTER CLUTCHBlock No. Block Title.


Ref No

12345678

Part No

12611-01D0009206-1300312600-4483409261-1500109440-0401512633-3100007130-0816312649-45000

Description

Gear, Starter Idle (nt:55/19)PinClutch Set, Starter• . Roller• . Spring• . Piece, PushBoltShim


FIG11 CAM SHAFT - VALVEBlock No. Block Title.


Ref No

12222345678888910111213141516171819202122222222222222222222222222222222222222222324

Part No

12710-0183009181-2216709160-2207409160-2207509160-2207612740-4504212748-4400009111-0602712747-4400012720-0182009181-2216709160-2207409160-2207509160-2207612750-4504112748-4400009111-0602712747-4400012891-1550012891-1550012911-01D0012912-01D0012920-4411012931-4500012932-4501012933-4500109289-0700212892-45000-21512892-45000-22012892-45000-22512892-45000-23012892-45000-23512892-45000-24012892-45000-24512892-45000-25012892-45000-25512892-45000-26012892-45000-26512892-45000-27012892-45000-27512892-45000-28012892-45000-28512892-45000-29012892-45000-29512892-45000-30012892-45000-30512892-45000-31012800-4581199000-69521

Description

Camshaft Set, Intake• . Washer (t:1.0)• . Washer (t:1.1)• . Washer (t:1.2)• . Washer (t:1.3)Sprocket, Intake (nt:30)PinBolt (6x12.5)WasherCamshaft Set, Exhaust• . Washer (t:1.0)• . Washer (t:1.1)• . Washer (t:1.2)• . Washer (t:1.3)Sprocket, Exhaust (nt:30)PinBolt (6x12.5)WasherTappet, IntakeTappet, ExhaustValve, IntakeValve, ExhaustSpring Set, ValveRetainer, SpringCotter, ValveSeat, SpringOil Seal (7x14.4x9)Shim, Tappet (t:2.15)Shim, Tappet (t:2.20)Shim, Tappet (t:2.25)Shim, Tappet (t:2.30)Shim, Tappet (t:2.35)Shim, Tappet (t:2.40)Shim, Tappet (t:2.45)Shim, Tappet (t:2.50)Shim, Tappet (t:2.55)Shim, Tappet (t:2.60)Shim, Tappet (t:2.65)Shim, Tappet (t:2.70)Shim, Tappet (t:2.75)Shim, Tappet (t:2.80)Shim, Tappet (t:2.85)Shim, Tappet (t:2.90)Shim, Tappet (t:2.95)Shim, Tappet (t:3.00)Shim, Tappet (t:3.05)Shim, Tappet (t:3.10)Shim Set Inc.no.22-1~22-20(3pcs.each)• . Case


FIG12 CAM CHAINBlock No. Block Title.


Ref No

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Part No

12760-4504012771-4505212782-4920002112-0510312791-4504001550-0612309168-0602312810-01D0012814-4410112830-01D1212838-38200-H1712839-3820012837-24A1007130-06253

Description

Chain, Cam Shaft Drive (120l)Guide, Cam Chain No.1Guide, Cam Chain No.2ScrewGuide, Cam Chain No.3BoltWasherTensioner, Cam ChainCushionAdjuster Assy, Tensioner• . GasketPlugGasket, AdjusterBolt


FIG13 CARBURETOR (GS500K1/K2/UK1/UK2/P37)Block No. Block Title.


Ref No

11223456789101111121314141516171819202122222323242526272728293031323334353637383940414243444546

Part No

13201-01DE013201-01DL013202-01DE013202-01DL013573-19E0013418-33E0009280-0500413481-13F0013382-19E0013387-13F0013383-01DE013502-07F0013501-29FA013501-29FA013507-17C0113247-0234009492-1701609492-2002413247-33E0013258-44B0013250-04F0013254-0101002112-0408313602-05A1013370-33E8009491-2301209491-2402609491-6001009491-6200413385-07F0013246-4301009494-0094913279-33E0013279-19F1013268-4707013291-2990013295-2990013267-13F0013271-33C0013411-0530013682-3121013418-4408013417-26D0013278-4709013247-33E0009493-3300213274-8400009401-0610113295-3301013268-9611113271-44B0013267-44B0013683-01DF0

Description

Carburetor Assy, LhCarburetor Assy, LhCarburetor Assy, RhCarburetor Assy, Rh• . Spring• . Holder• . O Ring (d:1.9,id:4.8)• . Spring• . Washer• . E Ring• . Needle, Jet (5dh41-4)• . Cover, Diaphragm• . Valve, Piston• . Valve, Piston• . Diaphragm• . Screw, Drain• . Jet, Pilot• . Jet, Pilot (20)• . Screw• . Gasket, Float Chamber• . Float Assy• . Pin, Float• . Screw• . Screw• . Valve Assy, Needle• . Jet, Main (115)• . Jet, Main (120)• . Jet, Main (60)• . Jet, Main (62.5)• . Holder, Jet• . O Ring• . Jet, Needle (p-5m)• . Screw, Pilot (2 3/4)• . Screw, Pilot (2.0)• . Spring• . Washer• . O Ring• . Adjuster• . Spring• . Plunger Assy• . Cap• . Holder, Guide• . Spring• . O Ring• . Screw• . Jet, Air (165)• . Cap• . Clip• . O RingSpringSpringScrewHose


FIG13 CARBURETOR (GS500K1/K2/UK1/UK2/P37)Block No. Block Title.


Ref No

47484950515253545556

Part No

13413-01DE013602-04F0013557-33E0013683-01DE013683-01DB013673-44B0013685-33EQ013565-01DE002122-0510313685-01DB0

Description

PlateScrewPackingHoseHoseSealNippleBracketScrewPipe


FIG13A CARBURETOR (GS500HK1/HK2/HUK1/HUK2)Block No. Block Title.


Ref No

3467891011121314151718192021222324252627282930313232333435363738394041424344454647484950515253545556

Part No

13573-01DB013507-17C0113418-33E0009280-0500413481-13F0013382-4403013394-17E6013387-13F0013383-01DE009494-0094913246-4301013385-07F0013295-2990013291-2990013268-4870013279-33E0013370-33E8002112-0408313602-05A1013250-04F0013254-0101009492-1701609491-6001009493-3400313258-04F0002112-0410713247-0234013502-01DB013502-01DC013411-0530013417-26D0013278-4709013418-4408013682-3121002112-0512713274-8400009401-0610113267-13F0013271-33C0009355-35755-60013683-10F6013685-04F1095569-7804018115-70G1013683-01DB013683-01DE013683-46D1013683-01DC109401-1640109408-0003313413-01DE002142-0408313557-33E00

Description

• . Spring• . Diaphragm• . Holder• . O Ring (d:1.9,id:4.8)• . Spring• . Washer• . E Ring• . Ring• . Needle, Jet (5dh41-3)• . Jet, Needle (p-5m)• . O Ring• . Holder, Jet• . O Ring• . Washer• . Spring• . Adjuster (2 5/8)• . Valve Assy, Needle• . Screw• . Screw• . Float Assy• . Pin, Float• . Jet, Pilot (17.5)• . Jet, Mian (60)• . Jet, Pilot Air (170)• . Gasket• . Screw• . Plug, Drain• . Cover Assy, Diaphragm Lh• . Cover Assy, Diaphragm Rh• . Plunger Assy• . Spring• . O Ring• . Holder, Guide• . Cap• . Screw• . Cap• . ClipAdjusterSpringHoseHoseNippleCheck Valve AssySolenoid AssyHoseHoseHoseHoseClipClipLeverScrewPacking


FIG13A CARBURETOR (GS500HK1/HK2/HUK1/HUK2)Block No. Block Title.


Ref No

575859606162636465666768697071

Part No

13602-13D6013602-55A0009355-35755-60009355-35755-60009355-35755-60009367-0400709355-35755-60013685-01DC013685-01DB013268-9611013271-44B0013267-44B0013673-44B0013685-33EQ018780-32E00

Description

Sensor AssyScrewHoseHoseHoseNippleHoseRodPipeSpringSpringScrewSealNippleFilter, Air Cleaner No.2


FIG14 AIR CLEANERBlock No. Block Title.


Ref No

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Part No

13700-01D7013780-01D5102142-0508713881-01D6009402-6420309352-11153-60009401-1430113870-2145809401-1340909404-0641301580-0616309404-06434

Description

Cleaner Assy, Air• . Filter Assy• . Screw• . Tube, Outlet• . Clamp• . Tube, Breather• . Clip• . Tube, Drain• . Clip• . ClampBoltClamp


FIG15 MUFFLERBlock No. Block Title.


Ref No

12345678

Part No

14181-01D0007120-0840314301-01DB009103-0825609160-0813609180-0815209320-1204808316-10083

Description

Gasket, Exhaust PipeBoltMuffler AssyBolt (8x40)Washer (8.5x28x1.6)Spacer (8.6x12x20.1)CushionNut


FIG16 CLUTCHBlock No. Block Title.


Ref No

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Part No

21200-4410209181-2522321411-4410109140-2000109167-2000609160-2001521441-3740021451-28C3121462-1430109440-2001909100-0614521414-01D0023121-4410009263-1500309160-1504516321-01D1009261-0600208331-3138323110-4411123111-24A0109285-0601123117-4410201500-0612323200-01D0009134-0601008310-0006703141-0616309443-08001

Description

Gear, Primary Driven (nt:76)Washer (25x38x1.0)Hub, SleeveNutWasher (20.5x38x0.8)Washer (20x44x3)Plate, DrivePlate, DrivenDisk, PressureSpringBolt (6x40)SpacerPiece, PushBearing (15x28x2)Washer (15.5x28x1)Gear, Oil Pump Drive (nt:39)PinCirclipRod, Push RhRod, Push LhOil Seal (6x34x10)Holder, Oil SealBoltScrew Assy, Release• . Screw• . NutScrewSpring


FIG17 TRANSMISSIONBlock No. Block Title.


Ref No

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Part No

24121-01D0124221-4400124231-01D1124251-01D0024252-19F0024260-01D0109181-2516709380-2501009262-2505109390-6201209263-2002504221-0712924741-4410209126-0601424131-01D0024310-4400109181-2025124321-4400509301-2500109380-2501024331-4400309167-2501209167-2501309380-2501024341-4400309167-2501209169-2500109380-2501024351-4400124361-4401009390-6201209283-3201509263-2002709262-2510509282-3200227511-01D0127531-01D1008331-3125627600-01C10-110

Description

Countershaft (nt:13)Gear, 2nd Drive (nt:18)Gear, 3/4 Drive (nt:21/24)Gear, 5th Drive (nt:26)BushGear, 6th Drive (nt:27)Washer (25x34x1.0)CirclipBearing, Rh (25x62x17)C RingBearing, Lh (20x34x20)PinHolder, BearingScrew (6x16)DriveshaftGear, 1st Driven (nt:32)Washer (20x34x1)Gear, 2nd Driven (nt:32)BushCirclipGear, 3rd Driven (nt:29)Washer (25.1x31x1.0)Lock WasherCirclipGear, 4th Driven (nt:27)Washer (25.1x31x1.0)Lock WasherCirclipGear, 5th Driven (nt:25)Gear, 6th Driven (nt:23)C RingOil Seal (32x62x7)Bearing, Rh (20x34x17)Bearing, Lh (25x62x17)Oil SealSprocket, Engine (nt:16)Spacer (l:32.7)CirclipChain, Drive (did520vm,110le)


FIG18 GEAR SHIFTINGBlock No. Block Title.


Ref No

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Part No

25211-4400125221-4400125231-4400025411-1890002142-0608308211-0614125311-01D0009261-0400109209-0401309181-2600125322-4400002112-0616325341-3330009111-0605401500-0616309263-4000125350-4400009443-0900725351-3001025354-3000009440-0602009168-1400225510-4410009448-1300808332-1107309444-2601309180-1206825671-0101109285-1200225600-01D0225652-20C0001500-0620337720-47D0037720-01D0009280-2600502112-7520309209-0501109440-04010

Description

Fork, Gear Shifting No.1Fork, Gear Shifting No.2Fork, Gear Shifting No.3Shaft, Gear Shifting ForkScrewWasherCam, Gear ShiftingPinPinWasher (26x32.5x0.3)Holder, Drive PinScrewGuide, CamBolt (6x14.6)BoltBearing (40x47x12)Stopper, Cam No.1SpringStopper, Cam No.2Holder, SpringSpringGasket (13.8x18.8x0.4)Shaft, Gear ShiftingSpringE RingSpringSpacer (12x20x15.3)StopperOil Seal (12x22x9)Lever Assy, Gear Shifting• . RubberBoltBase Assy, Gear Shift Base Assy, Gear ShiftO Ring (d:2.4,id:26.2)ScrewContactSpring


FIG19 STARTING MOTORBlock No. Block Title.


Ref No

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Part No

31100-20C0031310-27A01-H1731153-4340031170-4340031264-4411031132-27A0131135-6501031130-3830031172-3830031171-3830031143-3830031281-88C0031156-3830009280-2400309128-0602408361-35068

Description

Motor Assy, Starting• . Armature• . Oil Seal• . Shim Set• . O Ring• . Brush Holder Assy•• .. Spring• . Brush• . Bushing (a)• . Bushing (b)• . O Ring• . Bolt• . O Ring• . O Ring (d:3.0,id:24.5)Bolt (6x25)Nut


FIG20 GENERATORBlock No. Block Title.


Ref No

123456789

Part No

31401-01D1031402-01D0002112-3530309103-1200431497-4500002112-0508331498-4500002112-0610309404-06432

Description

Stator RotorScrewBolt (12x60)ClampScrewClampScrewClamp (l:65)


FIG21 SIGNAL GENERATORBlock No. Block Title.


Ref No

12356789

Part No

32900-01D2002142-0616333110-4442033120-01D0033120-01D2009103-0606402112-0510309404-06432

Description

Ignitor ScrewSignal Generator Assy Rotor, Signal Rotor, SignalBolt (6x60)ScrewClamp (l:80)


FIG22 BATTERYBlock No. Block Title.


Ref No

12345678

Part No

33610-01D0033652-19B0033651-3700033680-16A1033860-01D1033870-01D0033624-01D0033624-43500

Description

Battery (fb10l-b2,12v 11ah)Cushion (30x130x3) Protector (170x95x3) Hose, ExhaustLead Wire, (-)Lead Wire, Battery (+)• . Cap, Starter Relay Terminal• . Cap, Battery (+)


FIG23 ELECTRICALBlock No. Block Title.


Ref No

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Part No

31800-01D0031841-01D0031892-07D0009481-2010108361-3506833810-01DA031861-48B1033624-01D1032800-33C0002162-0620333410-01D0001500-0640309180-0619833510-2201033541-2451033542-38B00

Description

Relay Assy, Starting Motor• . Terminal, Relay• . Holder, Relay• . Fuse, (20a)NutWire, Starter Motor Lead• . Cap, Starter Motor• . Cap, Battery PlusRectifier AssyScrewCoil Assy, IgnitionBoltSpacer (6.2x12x16)Cap Assy, Spark PlugSeal, Spark PlugSeal, High Tension Cord


FIG24 SPEEDOMETER - TACHOMETERBlock No. Block Title.


Ref No

112345678910111212131415161718192021222324252627

Part No

34110-01D7034110-01D6034124-21E1009139-0200334210-01D6034288-01D2034193-01D6034189-01D2009160-0501308313-1005702112-3408334950-01D6034170-01D2134170-01D2109471-1202809471-1216509107-0600309180-0629434956-3100109160-0613608316-1006334910-01D0234938-4510001550-0616334938-01D0134938-01D1001550-0612302112-0516334940-01D02

Description

Speedometer (mile/kilo)Speedometer (kilo)KnobScrewTachometerDamperCoverCushionWasher (5.2x16x1)NutScrewBracket, MeterSocketSocketBulb (12v,3.4w)Bulb (12v,1.7w)Bolt (6x30)Spacer (6.5x10x15.7)CushionWasher (6.5x28x1.6)NutCable, SpeedometerGuide, Cable No.1BoltGuide, Cable No.2Guide, Cable No.3BoltScrewCable, Tachometer


FIG25 HEADLAMPBlock No. Block Title.


Ref No

11233456789101112131415

Part No

35100-26D60-99935100-26D52-99935111-01D2035121-26D6035121-26D5235127-10D2035173-20A0135181-1561108321-0105708310-0005335151-4590035152-1561135154-3190036118-26D5009471-1206009471-1206309126-05003

Description

Headlamp AssyHeadlamp Assy• . Rim• . Lamp Unit• . Lamp Unit• . Ring• . Cover, Socket• . Screw• . Lock Washer• . Nut• . Screw, Adjusting• . Nut• . Spring• . SocketBulb (12v60/55w)Bulb (12v,4w)Screw (l:12)


FIG26 HEADLAMP (E24)Block No. Block Title.


Ref No

12345678910111213

Part No

35100-10D70-99935111-01D2035121-10D3035127-10D2035173-20A0135181-1561108321-0105708310-0005335151-4590035152-1561135154-3190009471-1206009126-05003

Description

Headlamp Assy• . Rim• . Lamp Unit• . Ring• . Cover, Socket• . Screw• . Lock Washer• . Nut• . Screw, Adjusting• . Nut• . SpringBulb (12v60/55w)Screw (l:12)


FIG27 TURNSIGNAL LAMPBlock No. Block Title.


Ref No

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Part No

35604-33E3035603-33E3035610-33E0003242-0412309471-1204508316-1010335603-33E3035604-33E3035610-33E0003242-0412309471-1204508310-0010309160-1050135695-17C0038610-26E00

Description

Lamp Assy, Front TurnsignalLamp Assy, Front Turnsignal• . Lamp Unit• . Screw• . Bulb (12v,21w)NutLamp Assy, Rear RhLamp Assy, Rear Lh• . Lamp Unit• . Screw• . Bulb (12v,21w)NutWasher (10.5x30x2.30)SpacerRelay Assy, Turnsignal


FIG28 TURNSIGNAL LAMP (E24)Block No. Block Title.


Ref No

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Part No

35601-03FC035602-03FC035610-33E0003242-0412309471-1204508316-1010335603-33E3035604-33E3035610-33E0003242-0412309471-1204508310-0010309160-1050135695-17C0038610-26E00

Description

Lamp Assy, Front RhLamp Assy, Front Lh• . Lamp Unit• . Screw• . Bulb (12v,21w)NutLamp Assy, Rear RhLamp Assy, Rear Lh• . Lamp Unit• . Screw• . Bulb (12v,21w)NutWasher (10.5x30x2.30)SpacerRelay Assy, Turnsignal


FIG29 REAR COMBINATION LAMPBlock No. Block Title.


Ref No

1234566a6b7891011121314151617181920

Part No

35710-01D2035712-01D2035713-01D2003511-0440309471-1208333652-01D1033652-01D2033652-06C0009160-0607709320-0900909180-0626202112-0620335927-01D2009321-0602602142-0616309160-0607708310-0006335970-07F0008310-0005335974-01D0002142-0612308310-00063

Description

Lamp Assy, Rear Combination• . Lens• . Gasket, Lens• . Screw• . Bulb (12v,21/5w)Cushion (80x20x10)Cushion, Upper (40x40x38)Cushion, Lower (40x120x6) Washer (6.5x20x1.2)CushionSpacer (6.5x9x8.5)ScrewBracket, License PlateCushionScrewWasherNutReflex Reflector Assy, RearNutBracket, Rear Reflex ReflectorScrewNut


FIG30 WIRING HARNESSBlock No. Block Title.


Ref No

1234555666789101111121314151617181920

Part No

36610-01DB036611-38A0036611-01D0036611-01D1009404-0643209404-0643409404-0820709407-1440309407-1840209407-1940109403-0631001550-0616337000-2689037100-2686037100-26D0337100-26D1109139-0602637740-24A0009443-0604237840-26X5001550-0630338740-24X5038500-01D1001550-0612337146-26D10

Description

Harness, Wiring • . DiodeProtector, Wiring HarnessProtector, Wiring HarnessClamp (l:80)Clamp (l:95)Clamp (l:97)Clamp (l:125)Clamp (l:165)Clamp (l:190)ClampBolt, Wiring Harness GuideLock SetLock Set• . Lock Assy, Steering• . Lock Assy, SteeringBoltSwitch Assy, Stop LampSpringSwitch Assy, Side StandBoltRelay Assy, Side StandHorn AssyBoltKey, Blank


FIG31 HANDLE SWITCHBlock No. Block Title.


Ref No

11345678910

Part No

37200-27E1137200-27E3102112-0550502112-0530502112-0510337400-23E1002112-0545509125-0506637560-38A0037564-26E00

Description

Switch Assy, Handle RhSwitch Assy, Handle Rh• . Screw• . ScrewScrew, Throttle CableSwitch Assy, Handle Lh• . Screw• . Screw (5x25)Switch Assy, ClutchScrew, Clutch Switch


FIG32 FRAMEBlock No. Block Title.


Ref No

123456789101112

Part No

41102-01880-13L09103-1033408319-3110743585-01D0041540-01D3109116-0616709116-0616809180-0603809320-0802108313-2006347410-01D1001550-06163

Description

Frame Set (silver)• . Bolt• . NutCapHolder, BatteryBolt, LowerBolt, UpperSpacer (6.2x9x7.5)CushionNutHolder, Electric PartsBolt


FIG33 STAND - REAR BRAKEBlock No. Block Title.


Ref No

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Part No

42100-01D0001580-1060309180-1004009443-1405909443-2201309321-1001742310-01D10-01909111-1002708319-2110309443-1504609443-2201743110-01D1225652-4930043121-01D0043212-04A0001550-0625309443-13028

Description

Stand, CenterBoltSpacerSpring, InnerSpring, OuterCushionStand, Prop (black)BoltNutSpring, InnerSpring, OuterPedal, BrakeRubberArm, Brake RodWasherBoltSpring, Return


FIG34 FOOTRESTBlock No. Block Title.


Ref No

12345678910111213141516

Part No

43550-01D0043560-01D0043631-34A0109208-0600508332-1104343510-01D00-13L43520-01D00-13L09106-0809443586-01D1043596-01D1009139-0606243600-12B0043700-12B0043631-34A0109208-0600508332-11043

Description

Rubber Assy, Front RhRubber Assy, Front LhWasher, RubberPinE RingBracket, Front Rh (silver)Bracket, Front Lh (silver)Bolt, BracketGuard, Front Footrest RhGuard, Front Footrest LhBolt, GuardFootrest Assy, Pillion RhFootrest Assy, Pillion LhWasher, RubberPinE Ring


FIG35 FUEL TANK (MODEL K1)Block No. Block Title.


Ref No

11122233345678910111213141516

Part No

44100-01DJ0-YC244100-01DJ0-Y9H44100-01DJ0-YM768110-01D70-FT568110-01D70-FT668110-01D70-FT768111-42E00-YD868111-42E00-20G68111-42E00-1ZY44201-3382009106-0501744511-27E0002142-0510309169-0501244541-01D0044550-01D0101550-0840309320-1401709320-1003809180-0627109116-0617244423-01D00

Description

Tank Assy, Fuel (blue)Tank Assy, Fuel (yellow)Tank Assy, Fuel (blue)• . Tape Set, Fuel Tank• . Tape Set, Fuel Tank• . Tape Set, Fuel Tank• . Emblem, Fuel Tank (silver)• . Emblem, Fuel Tank (gray)• . Emblem, Fuel Tank (gray)Cap Set, Fuel TankBoltCushion, FrontScrew, FrontWasherCushion, SideBracket, RearBolt, BracketCushion, Rear UpperCushion, Rear LowerSpacerBoltHose, Water Drain


FIG35A FUEL TANK (MODEL K2)Block No. Block Title.


Ref No

1122345678910111213141516

Part No

44100-01DD0-Y7L44100-01DD0-YC268110-01DA0-FP268110-01DA0-GZ868111-42E20-0JW44201-3382009106-0501744511-27E0002142-0510309169-0501244541-01D0044550-01D0101551-0840309320-1401709320-1003809180-0627109116-0617244423-01D00

Description

Tank Assy, Fuel (black)Tank Assy, Fuel (blue)• . Tape Set• . Tape Set• . EmblemCap Set, Fuel TankBoltCushion, FrontScrewWasherCushion, SideBracket, RearBolt, BracketCushion, Rear UpperCushion, Rear LowerSpacerBoltHose, Drain


FIG36 FUEL COCKBlock No. Block Title.


Ref No

1234567891011

Part No

44300-01D3007120-0610344443-01D1009401-1140744442-01D2044441-01D2009401-1040944300-01D1044348-2807034826-03F0009168-06026

Description

Cock Assy, FuelBoltHose, FuelClipHose, Fuel "res"Hose, Fuel "on"ClipFilter Unit, Fuel• . O RingBolt, UnitGasket


FIG37 FRAME COVER (MODEL K1)Block No. Block Title.


Ref No

11122234445556789101010111111121314

Part No

47110-01DJ0-YC247110-01DJ0-Y9H47110-01DJ0-YM768135-01D50-FT568135-01D50-FT668135-01D50-FT768131-01D40-FN347210-01DJ0-YC247210-01DJ0-Y9H47210-01DJ0-YM768145-01D50-FT568145-01D50-FT668145-01D50-FT768131-01D40-FN309116-0601009180-0626309320-0901647310-01D50-YC247310-01D50-Y9H47310-01D50-YM768165-01D00-YD868165-01D00-20G68165-01D00-1ZY47321-01DA003541-0410309320-08018

Description

Cover, Frame Rh (blue)Cover, Frame Rh (yellow)Cover, Frame Rh (blue)• . Tape, Rh• . Tape, Rh• . Tape, Rh• . EmblemCover, Frame Lh (blue)Cover, Frame Lh (yellow)Cover, Frame Lh (blue)• . Tape, Lh• . Tape, Lh• . Tape, Lh• . EmblemBoltSpacerCushionCover, Center (blue)Cover, Center (yellow)Cover, Center (blue)• . Emblem, "suzuki" (silver)• . Emblem, "suzuki" (gray)• . Emblem, "suzuki" (gray)Cover, Frame LowerScrewCushion


FIG37A FRAME COVER (MODEL K2)Block No. Block Title.


Ref No

11223445567891011121314

Part No

47110-01DK0-YD847110-01DK0-YUX68130-01D90-FP268130-01D90-GZ868135-01D40-HJ547210-01DK0-YD847210-01DK0-YUX68140-01D90-FP268140-01D90-GZ868145-01D40-HJ509116-0601009180-0626309320-0901647310-01D50-YD868165-01D00-Y7L47321-01DA003541-0410309320-08018

Description

Cover, Frame Rh (silver)Cover, Frame Rh (silver)• . Tape Set, Rh• . Tape Set, Rh• . Tape, RhCover, Frame Lh (silver)Cover, Frame Lh (silver)• . Tape Set, Lh• . Tape Set, Lh• . Tape, LhBoltSpacerCushionCover, Center (silver)• . EmblemCover, Frame LowerScrewCushion


FIG38 HEADLAMP HOUSINGBlock No. Block Title.


Ref No

1234567891011

Part No

51810-01D1151817-01D0101550-0830708316-1008351851-01D1151861-01D1101550-0612709118-0600709180-0700409320-1001551815-06C00

Description

Housing, Headlamp• . GrommetBoltNutStay, Headlamp Housing RhStay, Headlamp Housing LhBoltBolt, StopperSpacerCushionPlate


FIG39 FRONT FENDERBlock No. Block Title.


Ref No

1112345678

Part No

53111-01D40-YC253111-01D40-Y9H53111-01D40-YM753145-30B0053114-01D0009139-0503209169-0501009159-0504309139-0602758621-21203

Description

Fender, Front (blue)Fender, Front (yellow)Fender, Front (blue)CushionBrace, Front Fender (silver)ScrewWasherNutScrewGuide, Cable


FIG40 HANDLEBARBlock No. Block Title.


Ref No

1234567891011121314151617181920212223

Part No

56111-01DA056211-31F00-0FP56221-01D50-0FP07130-0830756241-01D0009250-0601107130-1065309160-1009408319-3110756200-0184002122-0685356272-4450008316-1008309159-0602456500-0809056500-01D1156600-01D1158200-01DA058300-01DA058300-01DB058410-01D7094474-22D0072895-78A30

Description

HandlebarClamp, Upper (silver)Clamp, Lower (silver)BoltCushion, HolderCapBoltWasherNutBalcncer Set, Handlebar• . Screw• . Expander• . Nut• . NutMirror Assy, Rear ViewMirror Assy, Rear View RhMirror Assy, Rear View LhCable Assy, ClutchCable Assy, Throttle No.1Cable Assy, Throttle No.2Cable, StarterProtector, CableProtector, Cable


FIG41 HANDLE LEVERBlock No. Block Title.


Ref No

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Part No

57110-22D0257300-33E0157431-17C0008316-1006357460-17C0057465-17C0057211-22D0157500-01D0157620-01D0057531-14A0008319-2106357441-1101057442-1101001547-0620357661-33400

Description

Grip, ThrottleLever Assy, Brake• . Bolt, Pivot• . NutSwitch Assy, Stop• . ScrewGrip, LhLever Assy, Clutch• . Lever, Clutch• . Bolt• . Nut• . Adjuster• . Nut• . BoltCover, Clutch Lever


FIG42 REAR FENDERBlock No. Block Title.


Ref No

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Part No

63111-01D3109113-0600101550-0616309169-0603763210-01DA063220-01DA001550-0812301550-0820347425-01D0009800-2101709822-0000509462-0004695720-01D0001550-0616363411-42A0009169-0601002142-0616363115-06C00

Description

Body, Rear FenderBoltBolt, SideWasherBrace, Rear Fender RhBrace, Rear Fender LhBolt, Brace RearBolt, Brace FrontPlate, Tool HolderTool AssyClamp, WrenchBandHolder, HelmetBoltMud Guard, Rear UnitWasherScrewTape, Fender


FIG43 LABELBlock No. Block Title.


Ref No

11111111111112234444

Part No

68319-29F0068319-29F2068319-29F3068319-29F4068319-29F5068319-29F7068319-29F8068319-29F9068319-29FA068319-29FB068319-29FC068319-30F4068319-30F9068623-17D0086932-7306068332-01D3099011-01D62-28B99011-01D62-04299011-01D62-05799011-01D63-042

Description

Label, Warning (english)Label, Warning (german)Label, Warning (french)Label, Warning (italian)Label, Warning (spanish)Label, Warning (dutch)Label, Warning (potuguese)Label, Warning (swedish)Label, Warning (finnish)Label, Warning (norwegian)Label, Warning (danish)Label, Warning (italian)Label, Warning (swedish)Label, Fuel CautionLabel, Fuel CautionLabel, TireManual, Owner'sManual, Owner'sManual, Owner'sManual, Owner's


FIG44 COWLING (OPTIONAL)Block No. Block Title.


Ref No

111234567891011111112131415

Part No

94402-01D60-YC294402-01D60-Y9H94402-01D60-YM794432-01D6002142-0412308322-0104308321-0104308310-0004394741-01D6094511-01D6001570-0616708310-0006394401-01810-YC294401-01810-Y9H94401-01810-YM794580-01D5094582-01D5002112-3645709160-06084

Description

Cowling Assy, Upper (blue)Cowling Assy, Upper (yellow)Cowling Assy, Upper (blue)• . Screen, Wind• . Screw• . Washer• . Lock Wahser• . Nut• . Bolt, Headlamp• . Brace, Cowling• . Bolt• . NutCowling Set, Under (blue)Cowling Set, Under (yellow)Cowling Set, Under (blue)• . Bracket, Outer• . Bracket, Inner• . Screw• . Washer


FIG45 SEATBlock No. Block Title.


Ref No

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Part No

45100-01D20-FH409321-1001245149-3130094982-2940045215-22A0045213-1360145126-41B0045127-41B0008316-2006345220-20A0102122-0630345280-3840045288-14F0045289-11F0095700-1481046211-01D00-13L01550-0825309407-18402

Description

Seat Assy (black)• . Cushion, Front Lower• . Cushion, Center & Rear• . Cushion, Battery Stopper• . Striker, Seat Lock• . Cushion, Boss• . Cushion, Striker Upper• . Cushion, Striker Lower• . NutBracket, Seat SupportScrewCable, Seat LockGuide, Seat Lock CablePlate, Seat Lock AssyLock Set, SeatHandle, Pillion Rider (silver)BoltClamp, Seat Lock Cable


FIG46 FRONT DAMPERBlock No. Block Title.


Ref No

123456789101112131415161718192021222324

Part No

51103-01DB051104-01DB051103-01DC051104-01DB051130-01DA051140-01DA051167-01D0051158-4950051153-26F0051156-4030151173-26F0051110-01D6051121-01D0051195-01D0051146-01D0051196-13A1051177-01D0051147-1651051148-4131001550-0840751171-01D6051172-01D0051176-01DB051192-01D6051351-24D0051117-3826051201-01DA051166-01D80

Description

Damper Assy, Front Fork RhDamper Assy, Front Fork LhDamper Assy, Front Fork RhDamper Assy, Front Fork Lh• . Tube, Outer Rh• . Tube, Outer Lh• . Metal, Slide• . Washer• . Seal, Oil• . Ring, Snap• . Seal, Dust• . Tube, Inner•• .. Piston• . Piece, Oil Lock• . Cylinder•• .. Ring, Piston•• .. Spring, Rebound• . Bolt• . Gasket• . Bolt, Rh• . Spring, Main• . Washer, Spring• . Spacer• . Washer, Upper• . Bolt, Fork• . O Ring• . ProtectorBolt, Rh


FIG47 STEERING STEMBlock No. Block Title.


Ref No

112345678910111112131415

Part No

51410-01D9151410-01D8009265-3000951530-01D0151540-01D0151553-3430051352-01D0009265-2501951643-4900251631-2800051311-01D0007130-0830351328-01D8056240-01D0056243-01D0051353-05C0051356-22012

Description

Stem, SteeringStem, Steering• . Bearing (30x55x17)Bracket, Headlamp RhBracket, Headlamp LhCushion, BracketBolt, Steering StemBearing (25x47x15)Dust SealNutHead, Steering StemBolt, Stem HeadBolt, Stem HeadCushion, Stem HeadSpacer, Stem HeadBolt, UpperWasher


FIG48 FRONT WHEELBlock No. Block Title.


Ref No

12345678910111213141515

Part No

54111-34C00-Y6G09180-1501108123-6302754711-01D0054740-3341054741-01D0009159-1205809160-1209454600-01D0154871-38C00-0SR59210-01D2109106-0812555110-01D0043130-24A0055411-00A0055412-00A01

Description

Wheel, Front (mt3.00x17) (silver)Spacer (15.3x21.7x63)BearingAxle, FrontSpacer, Front Axle RhSpacer, Front Axle RhNutWasherBox Assy, Speedometer GearCover, Front Hub Lh (gray)Disc, Front Brake RhBolt (8x33)Tire, Front,110/70-17 54h BridgestoneValve Assy, Wheel Rim (tr412)Balancer, Wheel (10g)Balancer, Wheel (20g)


FIG49 FRONT CALIPERBlock No. Block Title.


Ref No

12345678910111213

Part No

59100-33D9059300-3383059300-3384059102-3381059171-33D0059115-33D0059112-44B0059313-3650059116-33D0059121-1841055156-6631059141-44B0169142-4500001550-10253

Description

Caliper Assy, Front Rh• . Piston Set•• .. Seal Set, Piston• . Pad SetShim, Pad• . Spring• . Boot• . Insulator• . Guide• . Bleeder• . Cap• . Pin• . ClipBolt


FIG50 FRONT MASTER CYLINDERBlock No. Block Title.


Ref No

1234567891011121314151617

Part No

59600-45C1059600-0481059667-4946059669-41C0069689-4930059671-4430059675-19C0059675-19C1059664-48B0059668-41C0059480-01D7009360-1004109360-1004209161-1000959268-01D0159268-45D0001550-06123

Description

Cylinder Assy, Front Master• . Piston/cup Set• . Diaphragm• . Cap• . Screw• . Holder• . Bolt• . Bolt, Upper• . Protector• . PlateHose, Front BrakeBolt (10x1.00x22)Bolt, Lower (10x1.25x22)WasherClamp, HoseClamp, HoseBolt


FIG51 REAR SWINGING ARMBlock No. Block Title.


Ref No

12345678910111213141516171819

Part No

61000-01D10-13L09263-2201709263-1703761282-01D0061251-4500109160-1402061262-4500261211-30B0009160-1400909159-1401961222-48B0061273-01D0061310-01D0002142-0612309169-0602664310-01D0209111-1005209100-1018708319-31103

Description

Swinging Arm Assy, Rear (silver)• . Bearing, Pivot (22x29x30)• . Bearing, Rod (17x24x25)Spacer, CenterSpacer, Pivot BearingWasherDust Seal, Pivot ShaftShaft, Swinging Arm PivotWasherNutCap, Swinging Arm PivotBuffer, Chain Touch DefenseCase, ChainScrewWasherTorque Link, Rear (black)Bolt, Front (10x41)Bolt, Rear (10x34)Nut


FIG52 CUSHION LEVERBlock No. Block Title.


Ref No

123456789101112131415

Part No

62601-0182109263-2006409263-1703709263-1703462684-01D0009103-1204208319-3112809180-1212562684-40A1062641-01D0209103-1204108319-3112862100-01D2009103-1021308319-31107

Description

Lever Set, Rear Cushion• . Bearing, Front (20x27x26)• . Bearing (17x24x25)• . Bearing, Rear (17x24x26)Spacer, Front (12x20x30)Bolt, Front (12x57)NutSpacer, Center (12x17x89)Spacer, Rear (10x17x30)Rod, Rear CushionBolt, Center (12x118)NutAbsorber Assy, Rear ShockBolt (10x52)Nut


FIG53 REAR WHEELBlock No. Block Title.


Ref No

1234567891011121314151617181920212223242526272728

Part No

64111-34C00-Y6G69211-01D0009106-0813169721-4340064740-19C0064611-01D0064651-27A0164711-01D3064733-01D0064751-19C0009160-1704708319-2116809180-1706708143-6303709262-2507309285-3500164511-01D0409119-1005908319-3110761410-01D0061421-01D0008319-3108764712-19C0164712-01D0065110-01D0043130-24A0055411-00A0055412-00A0161442-33300

Description

Wheel, Rear (mt3.50x17) (silver)Disc, Rear Brake (gold)Bolt (8x30)Bracket, Caliper (black)Spacer, Rear Axle,rhDrum, Rear SprocketAbsorber, Rear Hub ShockAxle, RearRetainer, DrumSpacer, Rear Axle,lhWasherNutSpacer, Bearing (17.5x25x88)BearingBearing (25x62x17)Oil Seal (35x62x8)Sprocket, Rear (nt:39)Bolt (10x38)NutAdjuster, ChainPlate, GuideNutWasher, Chain Adjuster RhWasher, Chain Adjuster LhTire, Rear (130/70-17 62h) BridgestoneValve Assy, Wheel Rim (tr412)Balancer (10g)Balancer (20g)Cap


FIG54 REAR CALIPERBlock No. Block Title.


Ref No

12345678910111213

Part No

69100-01D2069100-3284069100-0584069100-0182059145-1670059143-1670069141-4500069142-4500059151-1670159121-1841055156-6631059371-20C0059381-20C0001550-08303

Description

Caliper Assy, Rear• . Piston Set•• .. Seal Set, Piston• . Pad Set• . Bolt• . Spring• . Pin• . Clip• . Cover• . Bleeder• . Cap• . Shim, Inner• . Shim, OuterBolt


FIG55 REAR MASTER CYLINDERBlock No. Block Title.


Ref No

12345678910111213141516171819202122232425

Part No

69600-01D0069600-0482069691-00A0069692-19A0069670-01D0069693-05A0069672-00A0069686-3420002112-7412309139-0605769740-01D0259667-0470059669-05D0069689-04A0001550-0616308316-1006369731-01D0209401-1341769480-01D2009360-1004109161-1000969243-01D1009200-0603708322-0106304111-20158

Description

Cylinder Assy, Rear Master• . Piston / Cap Set•• .. Boot• . Yoke• . Rod, Push• . Nut• . Connector• . O Ring• . ScrewScrew (6x25)Tank Assy, Rear Reservoir• . Diaphragm• . Cap• . ScrewBoltNutHose, ReservoirClampHose, Rear BrakeBolt (10x1.00x22)Washer (10x15x1.5)Guide, Brake HosePinWasherPin, Cotter


FIG56 OPTIONALBlock No. Block Title.


Ref No

12222234456777777777777

Part No

99000-2511099000-3202099000-3203099000-3205099000-3210099000-3213099000-3204099000-3114099000-3111099000-2503099000-2514099000-10209-33J99000-10209-0FP99000-10209-13L99000-10209-19A99000-10209-1LF99000-10209-Y0V99000-10109-01999000-10209-Z9499000-10209-Y0W99000-10209-Y9899000-10209-16399000-10209-Y7E

Description

Suzuki Pbc GreaseThread Lock Super (1333b)Thread Lock Super (1303b)Thread Lock Super (1342)Thread Lock Super (1305)Thread Lock Super (1360)Thread Lock CementSuzuki Bond (1207b) BlackSuzuki Bond (1215)Suzuki Super GreaseSuzuki Moly PastePaint (pearl Novelty Black)Paint (traditional Silver Metallic)Paint (bright Silver Metallic)Paint (candy Antares Red)Paint (pearl Suzuki Deep Blue)Paint (candy Marine Blueish Green)Paint (black)Paint (mable Azteca Orange)Paint (candy Koran Orange)Paint (candy Forest Green)Paint (mable Phlolina Yellow)Paint (candy Koran Orange)

GS500 01-02 PM

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Transcript of GS500 01-02 PM