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    Cool Club 500

    Asalam U Alikum,

    Friends Club 500 thread is for all those who love Bikes, Safety Gadget, Modifications etc.. Being a owner of GS 500 I tried to put all info that i have in my mind & experience that i have wth 500..

    My Traveling Experience with GS 500:

    Well Worlds Best bike in 90s as it was the king & Road Master of its time no dough long as well as short trip give u really comfort at 1st place. My 1st Long tour on 500 is to AJK for 3 days. Really its fun for me & enjoyed a lot on Highway as well as on narrow roads, Sharp turn, Mud, Water, Rocky road etc

    Plus Points:

    No Problem On long run ( even u ride continuous 8 hr)
    Good Grip
    Easy Break
    No Heat Up ( As it is Air Cooled)

    Neg Points:

    Change Handel If u wanna go Long rides its sport edition so have to bear it...
    Don't be smart in MUD..other wise

    Fuel Consumption :

    I am getting 25 @ long & at local 22

    GS500 Manual :

    You can print it really informative.....

    http://www.motorkari.cz/upload/files...ser-manual.pdf

    OIL CHANGE:

    http://gstwin.com/oil_change.htm

    Genuine Suzuki Parts Prices : (Est.)

    Oil Filter = 470/-
    Air Filter = 2400/-
    Disk Pad = 4119/-(Rear) 5671/- (Front)
    Chain Sprocket Set = 17140/-
    Clutch Lever = 750/-
    Break Lever = 750/-
    Tyre Rear + Front Dunlop = 34500/-
    Clutch Cable = 1850/-
    Excelerator Cable = 2440/-
    Battery 11amp Liquid = 3800/- Dry = 1800/-



    Maintenance Schedule

    Club 500 -1186256


    • Initial Service
      • Tighten cylinder nuts and exhaust bolts
      • Inspect valve clearance, adjust if necessary
      • Inspect all fuel lines for leakage
      • (California models) Inspect evaporation canister and vapor lines
      • Change engine oil and replace filter
      • Check engine idle speed; adjust to 1200 rpm if necessary
      • Check clutch adjustment; adjust if necessary
      • Check drive chain tension; adjust if necessary
      • Inspect all brake hoses for leakage
      • Check brake fluid levels in both master cylinders; add fluid if necessary
      • Check brake pad wear
      • Inspect tire condition and air pressure
      • Check steering operation; adjust if necessary
      • Check operation of front forks
      • Check rear suspension operation
      • Check all chassis bolts and nuts for tightness; tighten if necessary

    • Every 600 miles (1000km)
      • Clean & Lube Chain
      • Check Oil level. The distance from Low to Full on the Dipstick is approximately 1 pint (0.6 litres)
      • Check Tire Pressure (33psi Front & 36psi Rear)

    • Every 2000 miles (3000km)
      • Clean & inspect air filter

    • Every 4000 miles (6000km)
      • Check battery electrolyte level and condition
      • Inspect spark plugs; regap or replace if necessary
      • Tighten cylinder head nuts and exhaust pipe bolts
      • Inspect valve clearance; adjust if necessary
      • Inspect all fuel lines for deterioration and leakage
      • (California models) Inspect evaporation canister and vapor lines
      • Change engine oil and replace filter
      • Check engine idle speed; adjust to 1200 rpm if necessary
      • Check clutch adjustment; adjust if necessary
      • Check drive chain tension; adjust if necessary
      • Inspect all brake hoses for chaffing, cracks or leakage
      • Check brake fluid levels in both master cylinders; add fluid if necessary
      • Check brake pad wear
      • Inspect tire condition and air pressure
      • Check steering operation; adjust if necessary
      • Check operation of front forks
      • Check rear suspension operation
      • Check all chassis bolts and nuts for tightness; tighten if necessary
      • Check all cable adjustments; adjust if necessary
      • Check throttle grip operation, play and adjustment
      • Check headlight aim, adjust if necessary
      • Check front and rear brake light switch operation
      • Lubricate rear suspension linkage and swing arm bearings

    • Every 7500 miles (12000km)
      • Replace spark plugs
      • Replace Air Filter element
      • Synchronize carburetors
      • Check operation of front brake
      • Check front fork seals for leakage
      • Check rear suspension operation
      • Check rear shock absorber for leakage, looseness or damage. From forum post: "Push on the tail of the bike, and listen to hear if it sounds like the shock is sucking in air. Pay attention to how fast the shock compresses, and how it rebounds - if it feels like it shoots back like a spring, you have a failed shock. If it comes back in a somewhat controlled manor, the stock shock is probably okay. If it overshoots and bounces around a bit, definitely bad shock."
      • Check rear suspension linkage for looseness or damage
      • Inspect tires for excessive wear, cuts or other damage
      • Check wheel rims for damage
      • Inspect drive chain guide for wear
      • Check break pedal height
      • Check center stand for looseness or damage
      • Check side stand for looseness or damage

    • Every 2 years
      • Change Brake Fluid

    • Every 4 years
      • Replace all brake hoses
      • Replace all fuel lines



    FOR PARTS

    Suzuki Gs500 F (usa) parts list partsmanual partsfiche
    Suzuki GS500 Parts & Accessories - Parts N More - Japanese Vintage Motorcycle Parts[page]=3


  2. #281
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    Quote Originally Posted by mohsinwahhab View Post
    bro plz tell me the name and model of the camera these pics are awsome
    Any DSLR can take such pics. These were taken by a Nikon 5200D.
    Web: http://www.bikepics.com/members/sniperr and http://wanderersbook.blogspot.com

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    500km trip, alongwith RocketScience, Haroon, Vickytulla and co.

    Club 500 -1520168

  4. #283
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    Club 500 -1520169

  5. #284
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    Club 500 -1520170

  6. #285
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    It was a great trip

  7. #286
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    where is the thread?????????
    I dont overtake............. I simply takeover

  8. #287
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    Quote Originally Posted by RocketScience View Post
    It was a great trip
    Sir g apnay to matric wala exhaust lagwaya hua hai. Mazaydar sound hogi

    Sent from my LG-F160K using PW Forums mobile app

  9. #288
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    Quote Originally Posted by ammarzahid View Post
    Sir g apnay to matric wala exhaust lagwaya hua hai. Mazaydar sound hogi

    Sent from my LG-F160K using PW Forums mobile app
    Exactly :-)

  10. #289
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    So my blue GS needed a carb cleaning job and since the bike is far away from Lahore so obviously I did not have the option to take it to my mechanic and get the job done easily, so time for a DIY attempt.

    On my previous bike, the FZR, I had opened up the fuel tank so many times without much problem but the same job with a GS500 is a bit more complex thanks to the fuel key system of the bike which does not come with the "Off" option. To reach the carbs we have to remove the tank first and in fact, getting the tank removed is what gave me a bit of a tough time, so here is how I managed it.

    Step 1. Remove the seat
    Step 2. Remove the tail
    Step 3. Open the tank bolts/nuts located on each side of the main frame
    Step 4. Open the fuel key bolt so the key hangs loose.
    Step 5. Raise the tank rear end a little bit and put some support under it so you can reach the screw under the tank and turn the screw to "off" position to cut the fuel flow from tank to carbs.
    Step 6. Take out the Air Filter box.
    Step 7. Loosen the clamps holding the carbs to the engine and pull out the carbs.
    Step 8. Take out the throttle and choke wires. This will detach carbs from the bike.
    Step 9. Carb cleaning.. Since I did not need to adjust the mixture so simple cleaning is not too much of a task, however when you open the main jets you may need new small O rings so the jets sit back properly so do not open the jets unless you have got a pair of the exact size with you. Clean the jets with fuel, nothing big.
    Step 10. Put back the carbs and repeat the above steps inverse. Job done

    Posting some pics below..

    Here is the fuel key after removing from the bike:
    Club 500 -1537749

    I do not know if some other bikes follow the same technique but Suzuki's old models like GS500, 750 and 1000 have a similar fuel key. Options available on the fuel key are On, Prime and Reserve and no Off option. While removing the pipes make sure you memorize well which pipe goes where else there will be problems
    Web: http://www.bikepics.com/members/sniperr and http://wanderersbook.blogspot.com

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    The black pipe shown in the above pic goes into the carbs top slot. This pipe provides extra fuel to the carbs when you have pulled the choke:
    Club 500 -1537758
    Web: http://www.bikepics.com/members/sniperr and http://wanderersbook.blogspot.com

  12. #291
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    The pic below shows the throttle cable. To remove it, loosen the screw indicated be red arrow so you can reach the screw indicated by yellow arrow. Now open the yellow arrow all the way and take out the wire end clip to get the wire free from carbs.
    Club 500 -1537761
    Web: http://www.bikepics.com/members/sniperr and http://wanderersbook.blogspot.com

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    Push the choke cable holder in the direction of the green arrow and remove the clip encircled in red to remove the choke cable. The carb is now free from both the wires:
    Club 500 -1537762
    Web: http://www.bikepics.com/members/sniperr and http://wanderersbook.blogspot.com

  14. #293
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    The air filter box removed:
    Club 500 -1537763
    Web: http://www.bikepics.com/members/sniperr and http://wanderersbook.blogspot.com

  15. #294
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    While putting the carbs back, make sure to check the choke wire and throttle wire that they are working properly. Since it was my first time with the job so I had to open up the fuel tank once again to get the throttle wire in proper functioning, I realized I had tightened the holder nut all the way which resulted in too much free play of the throttle so i opened up the tank and everything again to give the wire proper tension

    Putting back the tank and turning the fuel screw back to On position may require help from another person if there is too much fuel in the tank. While putting back the fuel pipes, it is must to inspect the pipes if they are hard or the ends look worn out then its time to get a new fuel pipe, as once the old pipe is opened it will not fit back as before. If yo can find a good quality heat resistant pipe then you may not need to replace the fuel pipes too often. I found the required heat resistant pipe from Shafiq Autos at Montgomery road, Lahore. With everything in place, time to start the bike. Since the carbs will be empty turn the fuel key to Prime, hit the self and there you go.. Time to ride
    Club 500 -1537765
    Web: http://www.bikepics.com/members/sniperr and http://wanderersbook.blogspot.com

  16. #295
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    Job Nicely done... @7thgear
    https://www.pakwheels.com/forums/motorcycle-travel-diaries/277725-sober-riders-visit-khunjerab-adventurous-way-via-nori-pass

  17. #296
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    Quote Originally Posted by 7thgear View Post
    While putting the carbs back, make sure to check the choke wire and throttle wire that they are working properly. Since it was my first time with the job so I had to open up the fuel tank once again to get the throttle wire in proper functioning, I realized I had tightened the holder nut all the way which resulted in too much free play of the throttle so i opened up the tank and everything again to give the wire proper tension

    Putting back the tank and turning the fuel screw back to On position may require help from another person if there is too much fuel in the tank. While putting back the fuel pipes, it is must to inspect the pipes if they are hard or the ends look worn out then its time to get a new fuel pipe, as once the old pipe is opened it will not fit back as before. If yo can find a good quality heat resistant pipe then you may not need to replace the fuel pipes too often. I found the required heat resistant pipe from Shafiq Autos at Montgomery road, Lahore. With everything in place, time to start the bike. Since the carbs will be empty turn the fuel key to Prime, hit the self and there you go.. Time to ride
    Club 500 -1537765
    Goood Work

  18. #297
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    Trying new things
    Club 500 -1587996
    Web: http://www.bikepics.com/members/sniperr and http://wanderersbook.blogspot.com

  19. #298
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    Club 500 -1588005
    Web: http://www.bikepics.com/members/sniperr and http://wanderersbook.blogspot.com

  20. #299
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    Two black beauties..

    Club 500 -1593923
    Web: http://www.bikepics.com/members/sniperr and http://wanderersbook.blogspot.com

  21. #300
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    Quote Originally Posted by 7thgear View Post
    Two black beauties..

    Club 500 -1593923
    Silent monster....

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