I got a sweet deal 2004 suzuki gs500f, but the catch was that it did not start. So I went on to find what was wrong. I tried starting the engine but could only hear the starter motor turning.![Suzuki Suzuki](/uploads/1/1/9/7/119710941/107944423.jpg)
![2015 2015](/uploads/1/1/9/7/119710941/150189551.jpg)
Suzuki Motorcycles. Suzuki is a Japanese manufacturer of both automobiles and motorcycles. Suzuki motorcycles are known to be among the most reliable in the industry. The company started its cycle history by producing motorized bicycles in 1952. In those early years and until the 1970s, Suzuki made only cycles with two-stroke engines. Suzuki GS500F (2008) 1271 x 872: Suzuki GS500F (2008) 1368 x 1759: Suzuki GS550 Katana (1982) 961 x 578. Suzuki GSX-S 1000 (2015) 996 x 1231: Suzuki GSX1100 (1979). SUZUKI GS500F This is the most complete Service Repair Manual for your SUZUKI vehicle. Service Repair Manual can come in handy especially when you have to do immediate repair to your vehicle. Repair Manual comes with comprehensive details regarding technical data, Diagrams and a complete list of parts and pictures.This is a must for the Do-It. Suzuki GSX1250 GSX 1250 F Workshop Service Repair Manual 2010 - 2015. Suzuki GSX1300 R Hayabusa GSX 1300 Exploded View Parts List Diagram Schematics. Suzuki GSX1300 Hayabusa GSX 1300 Owners Maintenance Instruction Manual 1999 - 2003.
![Suzuki Suzuki](/uploads/1/1/9/7/119710941/107944423.jpg)
![2015 2015](/uploads/1/1/9/7/119710941/150189551.jpg)
Suzuki GS500, GS500E, GS500F Twin 487cc 1989 - 2008 Workshop Manual Rating Required Select Rating 1 star (worst) 2 stars 3 stars (average) 4 stars 5 stars (best) Name.
I pinpointed the problem to the starter clutch bolts. I will list the process of fixing the starter clutch below.Inspect the old starter clutch components. The springs,rollers, and the pins. If any of them are damaged replace them.
Oil resistant locktite
7/8 thin wrench
Clutch fly wheel extraction bolt 1.50 thread atleast 1.5inch in length
Allen wrench keys
Disassemble the fairings using allen keys. Take off the shift lever (10mm) bolt. Remove all of the 8mm bolts on the chain and magneto cover. Remove both covers.
Use the 7/8 wrench on the shaft and 22mm wrench on the flywheel bolt. We shaved off the wrench ending so it would be thinner and fit. Also hear up the end of the wrench and bend it.
Remove the stator(magneto) and remove the allen bolts.
Inspect the rollers,springs, and pins. Replace if nessesary.
Drill new holes in the stator housing.
Cut new threads.
Suzuki Gs500f 2004
Use oil risistant locktite on the three bolts tighten to torque spec. We decided to weld the bolts aswell so they wont come loose.
2015 Suzuki Gs500f Manual Yamaha
Use oil risistant locktite on all main clutch bolt and tighten to torque spec(87lbs-ft). Reassemble and top off engine oil.