gs-500 k6 part 1
TRANSCRIPT
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2006-2 4TH EDITION
G S 5 0 0 / F (BK111/BK211/BK221/BK232/ BK242/BK311/BK411/BK422)
GS500 (U/H/HU)K3GS500 (U/F/FU)K4GS500(U/F/FU)K5GS500(U/F/FU)K6
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12
45
3
INFORMATION ILLUSTRATION INDEX
ENGINETRANSMISSION
ELECTRICAL
BODY
PARTS NUMBER INDEX
Model of catalogue
GS500 9900BCOBE00H030
Parts Catalogue No.
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PHOTO K4
GS500K3 GS500UK3 GS500HK3 GS500HUK3 GS500K4/K5 GS500UK4
GS500FK4 GS500FUK4
PHOTO K4
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PHOTO K6 PHOTO K5
GS500FK5/FK6 GS500FUK5/FUK6
GS500K6 GS500UK6
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12 x 34 x 5.6 ...................... Los nmeros en la columna de "Observaciones" muestran las T T T dimensiones de las piezas.ID OD T (or W, L)
PREFACIO
INSTRUCCIONES SOBRE EL USO DEL CATALOGO
1. DIMENSIONES
2. ABREVIATURAS
Las referencias cuya estructura es la sigu iente: 12345C56781H000
Las letras C y H indican que la fabricacin de la pieza es origen Colombia.
3. PIEZAS INTERNAS DEL CONJUNTO
4. NOTICIA DE MODIFICACIN
5. NOTA
6. CODIGO DE ESPECIFICACION
7. NUMERO DE SERIE DE MARCO O CHASIS
1
-1-GS500K6 P2
Este catlogo contiene las piezas de los modelos diseados para las siguientes especificaciones:Cdigo de especificacin: P2, P19, P24, P54.
GS500K3 (P2) : 9FSGM51A03C001685~GS500K4 (P2) : GS500K5 (P2) : GS500K6 (P2) :
5-1.Hay ciertas diferencias entre las piezas de produccin en serie y las de recambio por razones administrativas y por su uso comn en otros modelos.
5-2.En cuanto a las mangueras de goma y los tubos de vinilo, srvase usarlos cortando segn la longitud mencionada en el catlogo o segn la realmente requerida por el vehculo.
5-3. Debe observarse que las ilustraciones son para una rpida referencia del nmero de pieza y no para usarse como un manual de montaje: para ello emplee siempre el "MANUAL DE SERVICIO DE SUZUKI".
Se remitir un boletn en el caso de modificacin de piezas, que incluye modificaciones de intercambiabilidad entre piezas nuevas y viejas.
Las piezas marcadas con un punto (.) antes de la denominacin, forman parte de un conjunto.
Las abreviaturas usadas son las siguientes:A : Suzuki Motor Espaa NT : Nmero de dientesAR : Lo necesario OPT : OpcionalASSY : Conjunto OS : SobremedidaE.No. : Nmero de motor S : Suzuki Motor CorporationF.No. : Nmero de bastidor STD : NormalizadoD : Dimetro del material T : EspesorID : Dimetro interno US : SubmedidaOD : Dimetro externo W : AnchoL : LongitudLH : Lado izquierdoRH : Lado derecho
~100045: Hasta F. No. 100045100046- : From F. No. 100046
Cuando sea necesario reemplazar piezas en las MOTOCICLETAS de SUZUKI, srvase usar Siempre las PIEZAS GENUINAS DE SUZUKI que han pasado una estricta inspeccin de calidad y rendimiento.Este catlogo contiene todas las piezas de recambio para las SUZUKI GS500K3, GS500UK3, GS500HK3, GS500HUK3, GS500K4/K5/K6, GS500UK4/K5/K6, GS500FK4/K5/K6, GS500FUK4/K5/K6.
12345-56781 (No. de pieza): indica que el nmero de pieza fue modificado a 12345-56781 y que las nuevas piezas son intercambiables con las anteriores, pero no viceversa.
12345-56781 (No. de pieza): indica que el nmero de pieza fue modificado a 12345-56781 y que las nuevas piezas son intercambiables con las anteriores, pero no viceversa.
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CODIGO DESCRIPCION COLOR No. PARTE DESCRIPCION001 BICAPA NEGRO 99999CPINTUH001 KIT PINTURA-BICAPA NEGRO002 NEGRO DIAMANTE 99999CPINTUH002 KIT PINTURA-NEGRO DIAMANTE041 GRIS CORSA 99999CPINTUH041 KIT PINTURA-GRIS CORSA042 GRIS HUMO 99999CPINTUH042 KIT PINTURA-GRIS HUMO043 GRIS METALIZADO 99999CPINTUH043 KIT PINTURA-GRIS METALIZADO044 GRIS HOUSTON 99999CPINTUH044 KIT PINTURA-GRIS HOUSTON121 VERDE CRISTAL 99999CPINTUH121 KIT PINTURA-VERDE CRISTAL123 VERDE OBDULIA 99999CPINTUH123 KIT PINTURA-VERDE OBDULIA124 VERDE ARRECIFE 99999CPINTUH124 KIT PINTURA-VERDE ARRECIFE221 AZUL AMORTIGUADOR 99999CPINTUH221 KIT PINTURA-AZUL AMORTIGUADOR223 AZUL LUNA 99999CPINTUH223 KIT PINTURA-AZUL LUNA224 AZUL PETROLEO 99999CPINTUH224 KIT PINTURA-AZUL PETROLEO225 AZUL TRADICIONAL 99999CPINTUH225 KIT PINTURA-AZUL TRADICIONAL226 AZUL DEEP 99999CPINTUH226 KIT PINTURA-AZUL DEEP331 ROJO TRADICIONAL 99999CPINTUH331 KIT PINTURA-ROJO TRADICIONAL332 ROJO FIESTA 99999CPINTUH332 KIT PINTURA-ROJO FIESTA334 ROJO RUB 99999CPINTUH334 KIT PINTURA-ROJO RUB336 ROJO LASER 99999CPINTUH336 KIT PINTURA-ROJO LASER337 ROJO LASER N 2 99999CPINTUH337 KIT PINTURA-ROJO LASER N 2340 NARANJA ZODIACAL 99999CPINTUH340 KIT PINTURA NARANJA ZODIACAL411 BLANCO NIEVE 99999CPINTUH411 KIT PINTURA-BLANCO NIEVEAFE AMARILLO FERRARI 99999CPINTUHAFE KIT PINTURA-AMARILLO FERRARINAZ NARANJA AZTECA 99999CPINTUHNAZ KIT PINTURA-NARANJA AZTECA
CODIGO ESPECIFICACION COLORES MOTOCICLETAS COLOMBIA
-2-
Nota: En la columna Remarks (Observaciones) del catlogo encontrar indicaciones de piezas las cuales son aplicadas a un color espefico de un modelo particular, a travs de un cdigo cuya equivalencia se encuentra en esta tabla.
1
-
1
-1-
GS500K6 P02_001GASKET SET
FIG.1
GS500K6 P02_002CYLINDER HEAD COVER GS500K6 P02_003CYLINDER HEAD
9
2322
21
20
19
18
17
16
15
14
14
13
12
11
10
9
9
9
8
65
7
2
4
3
27
1
6A 6B
GS500K6 P02_004CYLINDER
31
23
252
27
292927
26
1819
303 22
2826
1
21
20
11
24
4
26
416
125
6
12126 17
9
151315
11
10
775
512
14
168916
28
GS500K6 P02_005CRANKCASE GS500K6 P02_006
CRANKCASE COVER
21
20 1918
17
161615
14
13
12
11
10 98
7
6
5
4
3
2
1
GS500K6 P02_007OIL FILTER/OIL PUMP
GS500K6 P02_008CRANKSHAFT
4
6
6
7
7
8
5
10
9
12
1
11
2
3
3
1615
13
14
17
12
FIG.2 FIG.3 FIG.4
FIG.5 FIG.6 FIG.7 FIG.8
-
-2-
FIG.15A
FIG.15
FIG.10 FIG.11 FIG.12 FIG.9
FIG.13 FIG.14
1
2
10
10
10
10
1
3
4
78
9 6
56
GS500K6 P02_ 009CRANK BALANCER GS500K6 P02_010
STARTER CLUTCHGS500K6 P02_011CAM SHAFT/VALVE
22
21
20
1918
17
15
13
65
4
3
2
1
22
2120
1918
17
16
14
1211
10
9
7
2B2A
2B
8B8A
8B
8
GS500K6 P02_012CAM CHAIN
GS500K6 P02_013CARBURETOR
GS500K6 P02_014CARBURETOR
GS500K6 P02_015AIR CLEANER
1312
11
12
14
7
5
4
1010 6
15
11
8
9 11
1010
1
216
3
13
GS500K6 P02_015A2ND AIR
-
-3-
FIG.16 FIG.17 FIG.18
FIG.22 FIG.21 FIG.20 FIG.19
FIG.15B 1
GS500K6 P02_015BOIL COOLER
9 14
11
9
15
16
138
12
10
10
3
2
14
4 56
1
7
4A
A
GS500K6 P02_016MUFFLER GS500K6 P02_017CLUTCH
2625
28
27
24
GS500K6 P02_018TRANSMISSION
40
GS500K6 P02_019GEAR SHIFTING
3031
32
GS500K6 P02_020STARTING MOTOR
515
2
119
16
14
12
13
5
1
3
4
4
8
10
6
7 7
GS500K6 P02_021GENERATOR
1
2
3
6
7
5
4
GS500K6 P02_022SIGNAL GENERATOR
-
-4-
FIG. 24 FIG.25 FIG.25A
FIG.26B FIG.26A FIG.26 FIG.25B
FIG.23 1
GS500K6 P02_023BATTERY
7
5
4
1
68
2
3
A
GS500K6 P02_024ELECTRICAL
1514
13
12
11
9
10
16
5
8
6
7
4
3
2
1
GS500K6 P02_025SPEEDOMETER
123
4
5
5
6
789
10
11
13
13
12A
14 15
17161819
20
2122
23
25
26
24
12
GS500K6 P02_025ASPEEDOMETER
123
4
5
5
6
789
10
11
13
13
12A
14 15
17161819
20
2122
23
25
26
24
12
GS500K6 P02_025BSPEEDOMETER
123
4
5
5
6
789
10
11
13
13
12
14 15
17161819
20
2122
23 24
25
12A
GS500K6 P02_026HEAD LAMP
16
11
1310
9
87
6
4
3
2
1
3
2
14
5
12
15
GS500K6 P02_026AHEADLAMP
1
67
5
4
12
10
14
15 8
9
2
13
11
3
GS500K6 P02_026BHEADLAMP
1 2
3
5
4
6
7
8
-
-5-
FIG.28 FIG.27B FIG.27A FIG.27
FIG.30 FIG.29B FIG.29A FIG.29
1
GS500K6 P02_027HEADLAMP
14
5
1012
9
87
6
4
3
2
1
13
11
GS500K6 P02_027AHEADLAMP
1
67
5
4
1013 8
2
12
11
9
3
15
14
16
GS500K6 P02_027BHEADLAMP
1 2
3
5
4
6
7
8
9
1011
GS500K6 P02_028TURSIGNAL LAMP
2
4
5
6
7 89
11
1213
14
15
3
10
1
GS500K6 P02_029TURSIGNAL LAMP
2
4
5
6
7 89
11
1213
14
15
3
10
1
GS500K6 P02_029ATURNSIGNAL LAMP
4
5
7
6
8
1 2
3
9
11
10
12
1314
15
GS500K6 P02_029BTURNSIGNAL LAMP
4
5
1 2
3
11
10
12
13
14
15
8 .9
16
76
GS500K6 P02_030REAR COMBINATION LAMP
-
-6-
FIG.31 FIG.31A
FIG.31B
FIG.32
FIG.30A 1
GS500K6 P02_030AREAR COMBINATION LAMP
22
21
20
19
2
4
5
6
91011
13
14
15
16
17
18
312
17
8
GS500K6 P02_031WIRING HARNESS
21
2
4
5
6
7
8
9
11
12
13
1415
19
18
17
16
3
10
1
20
GS500K6 P02_031AWIRING HARNESS
21
2
4
5
6
7
8
9
11
12
13
1415
19
18
17
16
3
10
1
20
GS500K6 P02_031BWIRING HARNESS
216
15
14
13
12
71
21
20 3 4 5 6
19
18
17
8 9
10
11
GS500K6 P02_032HANDLE SWITCH
2
4
6
3
7
1
5
FIG.32A FIG33 FIG.33A
2
4
6
8
3
9
7
1
5
GS500K6 P02_032AHANDLE SWITCH GS500K6 P02_033
FRAMEGS500K6 P02_033AFRAME
-6-
FIG.31 FIG.31A
FIG.31B
FIG.32
FIG.30A 1
GS500K6 P02_030AREAR COMBINATION LAMP
22
21
20
19
2
4
5
6
91011
13
14
15
16
17
18
312
17
8
GS500K6 P02_031WIRING HARNESS
21
2
4
5
6
7
8
9
11
12
13
1415
19
18
17
16
3
10
1
20
GS500K6 P02_031AWIRING HARNESS
21
2
4
5
6
7
8
9
11
12
13
1415
19
18
17
16
3
10
1
20
GS500K6 P02_031BWIRING HARNESS
216
15
14
13
12
71
21
20 3 4 5 6
19
18
17
8 9
10
11
GS500K6 P02_032HANDLE SWITCH
2
4
6
3
7
1
5
FIG.32A FIG33 FIG.33A
2
4
6
8
3
9
7
1
5
GS500K6 P02_032AHANDLE SWITCH GS500K6 P02_033
FRAMEGS500K6 P02_033AFRAME
-
-5-
FIG.36 FIG.35 FIG.34A FIG.34
FIG.37 FIG.36C FIG.36B FIG.36A
1
GS500K6 P02_034STAND/REAR BRAKE GS500K6 P02_034A
STAND
2
4
5
6
7
8
9
11
12 13
14
15
16
3
10
1
GS500K6 P02_035FOOTREST
GS500K6 P02_036FUEL TANK
GS500K6 P02_036AFUEL TANK
2
4
5
6
78
9
11
12
1314
15
16
3
10
1
GS500K6 P02_036BFUEL TANK
2
4
5
6
78
9
11
12
1314
15
16
3
10
1
GS500K6 P02_036CFUEL TANK
2
4
5
6
78
9
11
12
1314
15
16
3
10
1
GS500K6 P02_037FUEL COCK
56
11
12
13
3
10
1
4
8
7.97.9
7.8
7.8
22A
-
-6-
FIG.38A FIG.38B
FIG.38C
FIG.38D
FIG.38 1
FIG.38E FIG38F FIG.39
GS500K6 P02_038FRAME COVER
GS500K6 P02_038AFRAME COVER
1
8
12
11
10
9
76
543
2
GS500K6 P02_038BFRAME COVER
25
4 67
89
11
12
13
14
3
10
1
GS500K6 P02_038CFRAME COVER
1
8
12
11
10
9
76
43
2
5
5A
GS500K6 P02_038DFRAME COVER
2
3 4
67
9
10
11
12
8
1
5
5A
GS500K6 P02_038EFRAME COVER
2
3 45
67
9
10
11
12
8
1
5A
GS500K6 P02_038FFRAME COVER
2
3 45
67
9
10
11
12
8
1
5A
GS500K6 P02_039HEAD LAMP HOUSING
-
-5-
FIG.40C FIG.40B FIG.40A FIG.40
FIG.43 FIG.42 FIG.41A FIG.41
1
GS500K6 P02_040FRONT FENDER
47
3
8
265
1
GS500K6 P02_040AFRONT FENDER
47
3
8
265
1
GS500K6 P02_040BFRONT FENDER
47
3
8
265
1
GS500K6 P02_040CFRONT FENDER
10
16
17
1819
20
21
15
141312
11
98
7
6
5
3
4
2
1
5
22
23
GS500K6 P02_041HANDLE BAR
GS500K6 P02_041AHANDLE BAR
27
26
2524
2322
21
28
29
2
4
5
6
7
89
11
121314
15
20
19
1817
16
3
10
1
22
21
20
23
5
GS500K6 P02_042HANDLE LEVER
15
9
7
1
65
3
2
4
11
1410
1312
8
GS500K6 P02_043REAR FENDER
-
-6-
FIG.43B FIG.43C
FIG.43D
FIG.43E
FIG.43A 1
FIG.43F FIG.43G FIG.43H
GS500K6 P02_043ACOWLING BODY
2
4
5
6
7
8
3
16
5
GS500K6 P02_043BCOWLING BODY
2
4
5
6
7
8
3
16
5
4
5
6
7
8
3
16
5
2
GS500K6 P02_043CCOWLING BODY
GS500K6 P02_043DBODY COWL INSTALLATION PARTS
2
4
5
67
8
9
1112
13
14
3
10
1
5
GS500K6 P02_043EUNDER COWLING
2
4
6
7
3
1
GS500K6 P02_043FUNDER COWLING
1
9
3.4
3.4
5.6
5.6
7
2
8
2
9
10
1
87
43 65
GS500K6 P02_043GUNDER COWLING
GS500K6 P02_043HUNDER COWL INSTALLATION PARTS
2
4 5
67
8
911
12
10
1
3
10
-
-5-
FIG.46 FIG.45 FIG.44A FIG.44
FIG.47B FIG.47A FIG.47 FIG.46A
1
GS500K6 P02_044LABEL GS500K6 P02_044ALABEL
2
4
3
1
GS500K6 P02_045SEAT
19
42
1
12
13
11
3
8
7
6 5
109
17
18
3
16
1514
1 214
13
15
23
2422
21
20
19
10
25
9
87
6
5
12
3
4
17
161811
GS500K6 P02_046FRONT DAMPER
GS500K6 P02_046AFRONT DAMPER
1 2
24
9
8
7
6
5
12
14
15
13
10
11
19
20
21
23
22
3
4
171618
GS500K6 P02_047STEERING STEM
5
1
2
4
55
7
8
119
312
5
10
15
1412
13
6
GS500K6 P02_047ASTEERING STEM
3
1
2
4
5
6
98
7
12
1110
9
GS500K6 P02_047BSTEERING STEM
-
-6-
FIG.49 FIG.49A
FIG.50
FIG.50A
FIG.48 1
FIG.50B FIG.51 FIG.51A
GS500K6 P02_048FRONT WHEEL
14
1
4
11
10
9
8
3
3
2
6
5
7
12 13
GS500K6 P02_049FRONT CALIPER
11
5
4
2
1
8
6
7
10
9
GS500K6 P02_049AFRONT CALIPER
3
3
14
12
13
1
1314
14
11
1617
17
15
12
14
14
9 6
7
84
10
3
2
5
GS500K6 P02_050FRONT MASTER CYLINDER
1
1314
14
11
1617
17
15
12
14
14
9 6
7
84
10
3
2
5
GS500K6 P02_050AFRONT MASTER CYLINDER
1
1314
14
11
1617
12
14
14
9 6
7
84
10
3
2
5
17
15
GS500K6 P02_050BFRONT MASTER CYLINDER GS500K6 P02_051
REAR SWINGING ARM
11
8
76
5
4
123
21
23
567
91011
1415
1319
17
1618
19
GS500K6 P02_051AREAR SWINGING ARM
-
-5-
FIG.54 FIG.53 FIG. FIG.52
FIG.56 FIG.55A FIG.55 FIG.54A
152A
GS500K6 P02_052REAR CUSHION LEVER
GS500K6 P02_052AREAR CUSHION LEVER
GS500K6 P02_053REAR WHEEL
1
8
6
77
6
5
5
2
3
3
10
9
3
11
13
12
14
4
GS500K6 P02_054REAR CALIPER
1
108
9
77
2
3
43
12
11
5
6
GS500K6 P02_054AREAR CALIPER
13 14
3
5
6
GS500K6 P02_055REAR MASTER CYLINDER
GS500K6 P02_055AREAR MASTER CYLINDER
GS500K6 P02_056OPTIONAL
-
REF.NO PART.NO DESCRIPTION QTY REMARKS
GS500K P2
2
FIG.1 (B-2) GASKET
1-1 11400-01862 GASKET SET 1 GS5001-1 OPT1-2 11400-01881 GASKET SET 1 GS500F1-2 OPT2 11141-01D10 .GASKET, CYLINDER HEAD 1 NOT SHOWN3 11143-06B00 .O RING, HEAD GASKET 4 NOT SHOWN4 11173-15502 .GASKET, CYLINDER HEAD COVER 1 NOT SHOWN5 11177-15510-H17 .GASKET, BREATHER COVER 1 NOT SHOWN6 11241-01D00 .GASKET, CYLINDER 1 NOT SHOWN7 11482-44110 .GASKET, CLUTCH COVER 1 NOT SHOWN8 11483-44110 .GASKET, MAGNETO COVER 1 NOT SHOWN
9-1 11489-44110 .GASKET, OIL PAN 1 NOT SHOWN MODEL K3 GS5009-2 11489-01D00 .GASKET, OIL PAN 1 NOT SHOWN GS500F10 12837-24A10 .GASKET, EXHAUST PIPE 2 NOT SHOWN11 14181-01D00 .GASKET, EXHAUST PIPE 2 NOT SHOWN12 16518-45000 .O RING, OIL FILTER CAP 1 NOT SHOWN13 09168-06023 .GASKET (5.8X13X1.2) 4 NOT SHOWN14 09168-08016 .GASKET (8.2X14X1) 1 NOT SHOWN15 09168-10031 .GASKET (10.2X20X2.3) 2 NOT SHOWN16 09168-14004 .GASKET (14.1X18X1.5) 2 NOT SHOWN17 09280-03003 .O RING (D:1.05, ID:3.1) 2 NOT SHOWN18 09280-13004 .O RING (D:1.9, ID:13) 2 NOT SHOWN19 09280-15006 .O RING (D:1.9, ID:14.5) 4 NOT SHOWN20 09280-26006 .O RING (D:3.1, ID:26.4) 1 NOT SHOWN21 09280-40010 .O RING (D:2.4, ID:39.7) 2 NOT SHOWN
-
REF.NO PART.NO DESCRIPTION QTY REMARSK
GN125H
2
FIG.2 (B-3) CYLINDER HEAD COVER
GS500K P2
GS500K6 P02_002CYLINDER HEAD COVER
1 11171-01D02 COVER, CYLINDER HEAD 12 11173-15502 GASKET, HEAD COVER 13 09106-07010 BOLT (L:19) 24 09106-07009 BOLT (L:5.5) 45 09280-15006 O RING (D:1.9, ID:14.5) 46 11176-33201 COVER, BREATHER 17 11186-15501 SEPARATOR, OIL BREATHER 18 11177-15510-H17 GASKET, BREATHER COVER 19 01550-06253 BOLT 4
-
FIG.3 (B-4) CYLINDER HEAD
1-1 11100-01D40 HEAD ASSY, CYLINDER 1 MODEL K31-2 11100-01D60 HEAD ASSY, CYLINDER 1 MODEL K4/K5/K62 09381-10003 .RING, VALVE GUIDE 43 09103-06026 .BOLT (6X39) 84 09206-08001 .PIN 85 01550-06123 .BOLT, OIL GALLERY 26 09168-06023 .GASKET 2
6A 09106-06075 PLUG, OIL GALLERY 4 MODEL K4/K5/K66B 09248-10010 PLUG, OIL GALLERY 4 MODEL K4/K5/K67 11115-45740 .GUIDE, VALVE (OS:0.3) 4 OPT8 11141-01D10 GASKET, CYLINDER HEAD 19 11143-06B00 O RING, CYLINDER HEAD 410 01550-06303 BOLT 111 04211-11169 PIN 212 09159-10069 NUT 413 09159-10026 NUT 414 09168-10031 GASKET 8
15-1 09482-00334 SPARK PLUG (NGK, DPR8EA-9) 215-2 09482-00335 SPARK PLUG (ND, X24EPR-U9) 216 26442-45000 CAP, TACHOMETER GEAR SLEEVE 1 MODEL K317 26449-33000 PLATE, TACHOMETER DRIVEN GEAR 1 MODEL K318 26451-45000 SEAL BAND 1 MODEL K319 09128-05101 SCREW (5X12) 1 MODEL K320 13101-01D40 PIPE, INTAKE 221 09280-40010 .O RING (D:2.4, ID:39.7) 222 02112-16163 SCREW 423 09402-54208 CLAMP 2
REF.NO PART.NO DESCRIPTION QTY REMARSK
GN125H
2
GS500K P2
FIG.3
GS500K6 P02_003CYLINDER HEAD
9
2322
21
20
19
18
17
16
15
14
14
13
12
11
10
9
9
9
8
65
7
2
4
3
27
1
6A 6B
-
FIG.4 (B-5) CYLINDER
GN125H
2
GS500K P2
REF.NO PART.NO DESCRIPTION QTY REMARSK
GS500K6 P02_004CYLINDER
1-1 11210-01D20-0F0 CYLINDER 1 MODEL K31-1 MODEL K4/K5/K6 P241-2 11210-01D30-0F0 CYLINDER 1 MODEL K4/K5/K6 P2, P19, P542 09108-10112 STUD BOLT (L:168) 43 09108-10041 STUD BOLT (L:178) 44 04211-11169 PIN 25 11241-01D00 GASKET, CYLINDER 1
-
FIG.5 (B-6) CRANKCASE
2
31
23
252
27
292927
26
1819
303 22
2826
1
21
20
11
24
4
26
416
125
6
12126 17
9
151315
11
10
775
512
14
168916
28
FIG.5
GS500K6 P02_005CRANKCASE GS500K P2
1-1 11301-44890 CRANKCASE SET 1 GS500/U1-2 11301-01810 CRANKCASE SET 1 GS500F/FU2 09206-13004 .PIN 23 09206-11007 .PIN 24 07130-08703 .BOLT (8X70) 25 09103-08182 .BOLT (8X125) 36 09103-08134 .BOLT (8X110) 27 09103-08230 .BOLT (8X100) 28 01550-08653 .BOLT (8X65) 19 01550-08453 .BOLT (8X45) 210 09103-06033 .BOLT (6X125) 111 09103-06067 .BOLT (6X105) 212 01550-06903 .BOLT (6X90) 413 01550-06703 .BOLT (6X70) 114 01550-06653 .BOLT (6X65) 115 01550-06507 .BOLT (6X50) 216 01550-06453 .BOLT (6X45) 317 09168-08016 .GASKET 118 09493-22010 .JET, OIL GALLERY MISSION 119 09493-32002 .JET, OIL GALLERY BAL SHAFT 220 09493-24008 .JET, OIL GALLERY CYLINDER 221 09280-03003 .O RING (D:1.1, ID:3.1) 222 09103-10137 BOLT (10X255) 123 09103-10154 BOLT (10X245) 124 09103-10127 BOLT (10X170) 125 09103-10278 BOLT (10X160) 126 09159-10078 NUT 427 11611-01D10 SPACER (L:16.8) 228 11610-45410 SPACER (L:65) 229 11521-44100 PLATE, OIL SEPARATOR 230 09125-06110 SCREW 431 11532-46E00 JET, OIL GALLERY 1 GS500F/FU
REF.NO PART.NO DESCRIPTION QTY REMARSK
-
FIG.6 (B-7) CRANKCASE COVER
GN125H
2
GS500K P2
REF.NO PART.NO DESCRIPTION QTY REMARSK
GS500K6 P02_006CRANKCASE COVER
1 11341-01D10 COVER, CLUTCH 12 11482-44110 GASKET, CLUTCH COVER 13 04211-13189 PIN 24 09103-06216 BOLT 25 09103-06214 BOLT 26 09103-06212 BOLT 17 11970-44110 GAUGE, OIL LEVEL 18 09280-26006 O RING (D:3.1, ID:26.4) 19 09247-14012 PLUG, OIL CHECK 110 09168-14002 GASKET 111 11381-01D10 COVER, CONTACT BREAKER 112 09103-05016 BOLT 3
13-1 68233-01D00 EMBLEM 1 MODEL K313-2 68233-01D10 EMBLEM 1 MODEL K4/K5/K614 11351-01D10 COVER, MAGNETO 115 11483-44110 GASKET, GENERATOR COVER 116 04211-13189 PIN 117 09103-06214 BOLT 0
18-1 68233-01D00 EMBLEM 1 MODEL K318-2 68233-01D10 EMBLEM 1 MODEL K4/K5/K619 11361-01D10 COVER, ENGINE SPROCKET 120 04211-09129 PIN 121 09103-06239 BOLT 222 09103-06238 BOLT 123 09103-06215 BOLT 224 11387-01D10 CAP, CLUTCH RELEASE 125 02122-05127 SCREW 226 11382-01D00 COVER, STARTER MOTOR 127 01547-05083 BOLT 228 37820-33D10 SWITCH ASSY, OIL PRESSURE 129 37822-33D00 .BOLT 1
-
FIG.7 (B-8) OIL FILTER-OIL PUMP
2
GN125HGS500K P2
21
20 1918
17
161615
14
13
12
11
10 98
7
6
5
4
3
2
1
FIG.7
GS500K6 P02_007OIL FILTER/OIL PUMP
1-1 11511-44100 PAN, OIL 1 GS500/U1-2 11511-01D00 PAN, OIL 1 GS500F/FU2-1 11489-44110 GASKET, OIL PAN 1 GS500/U2-2 11489-01D00 GASKET, OIL PAN 1 GS500F/FU3 01550-06303 BOLT 1 24 09247-14026 PLUG, OIL DRAIN 15 09168-14002 GASKET 16 16440-11D00 VALVE ASSY, OIL RELIEF 17 16510-45040 FILTER, ENGINE OIL 18 16518-45000 O RING 19 09440-32004 SPRING 110 16512-45D00 CAP, ENGINE OIL FILTER 111 01421-06208 STUD BOLT 312 08313-20063 NUT 313 16520-01D01 STRAINER, ENGINE OIL 114 01570-06123 SCREW 315 16400-44100 PUMP ASSY, ENGINE OIL 116 09280-13004 O RING (D:1.9, ID:13) 217 02112-06253 SCREW 318 16331-01D10 GEAR, DRIVEN (NT:27) 119 09181-10158 WASHER 120 09261-04009 PIN 121 08331-31106 CIRCLIP 1
REF.NO PART.NO DESCRIPTION QTY REMARSK
-
FIG.8 (B-9) CRANKSHAFT
GN125H
2
GS500K P2
FIG.8
GS500K6 P02_008CRANKSHAFT
4
6
6
7
7
8
5
10
9
12
1
11
2
3
3
1615
13
14
17
12
1 12160-44100 ROD ASSY, CONNECTING 22 09159-08033 .NUT 4
3-1 12164-01D01-0A0 BEARING, CRANK PIN (GREEN) 43-2 12164-01D01-0B0 BEARING, CRANK PIN (BLACK) 43-3 12164-01D01-0C0 BEARING, CRANK PIN (BROWN) 43-4 12164-01D01-0D0 BEARING, CRANK PIN (YELLOW) 44 12220-01D02 CRANKSHAFT 15 09202-03016 .PIN 1
6-1 12229-01D01-0A0 BEARING, CRANKSHAFT (GREEN) 86-2 12229-01D01-0B0 BEARING, CRANKSHAFT (BLACK) 86-3 12229-01D01-0C0 BEARING, CRANKSHAFT (BROWN) 86-4 12229-01D01-0D0 BEARING, CRANKSHAFT (YELLOW) 87 12228-44106 BEARING, THRUST 28 09283-22015 OIL SEAL, RH (22X40X8) 19 12111-01D01-0F0 PISTON 210 12140-01D20 RING SET, PISTON 211 12151-45501 PIN, PISTON 212 09381-18002 CIRCLIP 413 12100-01D00-050 PISTON SET (OS:0.5) 2 OPT14 21111-44100 GEAR, PRIMARY DRIVE (NT:28) 115 09140-24007 NUT 116 09164-25001 WASHER 117 08341-31059 KEY 1
REF.NO PART.NO DESCRIPTION QTY REMARSK
-
FIG.9 (B-10) CRANKSHAFT BALANCER
2
GS500K P2
2
10
10
10
10
1
3
4
78
9 6
56
GS500K6 P02_ 009CRANK BALANCER
1 12650-01D01 BALANCER, CRANKSHAFT 12 09420-04008 .KEY 13 12666-44001 GEAR, DRIVEN (NT:46) 14 09160-24026 WASHER 15 09440-15007 SPRING 36 09201-08001 PIN 67 09180-24009 SPACER 18 09160-12039 WASHER 19 01500-12203 BOLT 1
10-1 12229-01D01-0A0 BEARING (GREEN) 410-2 12229-01D01-0B0 BEARING (BLACK) 410-3 12229-01D01-0C0 BEARING (BROWN) 410-4 12229-01D01-0D0 BEARING (YELLOW) 4
REF.NO PART.NO DESCRIPTION QTY REMARSK
-
FIG.10 (B-11) STARTER CLUTCH
2
GS500K P2
1 12611-01D00 GEAR, STARTER IDLE (NT:55/19) 12 09206-13003 PIN 13 12600-44835 CLUTCH SET, STARTER 14 09261-15001 .ROLLER 35 09440-04015 .SPRING 36 12633-31000 .PIECE, PUSH 37 07130-08163 BOLT 38 12649-45000 SHIM 1
REF.NO PART.NO DESCRIPTION QTY REMARSK
GS500K6 P02_010STARTER CLUTCH
-
FIG.11 (C-2) CAMSHAFT-VALVE
2
GS500K P2GS500K6 P02_011CAM SHAFT/VALVE
22
21
20
1918
17
15
13
65
4
3
2
1
22
2120
1918
17
16
14
1211
10
9
7
2B2A
2B
8B8A
8B
8
REF.NO PART.NO DESCRIPTION QTY REMARSK 1 12710-01831 CAMSHAFT SET, INTAKE 1
2-1 09181-22167 .WASHER (T:1.0) 12-2 09160-22074 .WASHER (T:1.1) 1 OPT2-3 09160-22075 .WASHER (T:1.2) 1 OPT2-4 09160-22076 .WASHER (T:1.3) 1 OPT2A 09164-22012 .WASHER, WAVE 12B 09181-22132 .WASHER (T: 0.7) 23 12740-45042 SPROCKET, INTAKE (NT:30) 14 12748-44000 PIN 15 09111-06027 BOLT (6X12.5) 26 12747-44000 WASHER 1
7-1 12720-01820 CAMSHAFT SET, EXHAUST 1 MODEL K37-2 12720-01841 CAMSHAFT SET, EXHAUST 1 MODEL K4/K5/K68-1 09181-22167 .WASHER (T:1.0) 18-2 09160-22074 .WASHER (T:1.1) 1 OPT8-3 09160-22075 .WASHER (T:1.2) 1 OPT8-4 09160-22076 .WASHER (T:1.3) 1 OPT8A 09164-22012 .WASHER, WAVE 18B 09181-22132 .WASHER (T: 0.7) 29 12750-45041 SPROCKET, EXHAUST (NT:30) 110 12748-44000 PIN 111 09111-06027 BOLT (6X12.5) 212 12747-44000 WASHER 113 12891-15501 TAPPET, INTAKE 214 12891-45001 TAPPET, EXHAUST 215 12911-01D00 VALVE, INTAKE 216 12912-01D00 VALVE, EXHAUST 217 12920-44110 SPRING SET, VALVE 418 12931-45000 RETAINER, SPRING 419 12932-45010 COTTER, VALVE 820 12933-45001 SEAT, SPRING 421 09289-07002 OIL SEAL (7X14.4X9) 4
-
FIG.11 (C-3) CAMSHAFT-VALVE
2
GS500K P2
22-1 12892-45000-215 SHIM, TAPPET (T:2.15) 422-2 12892-45000-220 SHIM, TAPPET (T:2.20) 422-3 12892-45000-225 SHIM, TAPPET (T:2.25) 422-4 12892-45000-230 SHIM, TAPPET (T:2.30) 422-5 12892-45000-235 SHIM, TAPPET (T:2.35) 422-6 12892-45000-240 SHIM, TAPPET (T:2.40) 422-7 12892-45000-245 SHIM, TAPPET (T:2.45) 422-8 12892-45000-250 SHIM, TAPPET (T:2.50) 422-9 12892-45000-255 SHIM, TAPPET (T:2.55) 422-10 12892-45000-260 SHIM, TAPPET (T:2.60) 422-11 12892-45000-265 SHIM, TAPPET (T:2.65) 422-12 12892-45000-270 SHIM, TAPPET (T:2.70) 422-13 12892-45000-275 SHIM, TAPPET (T:2.75) 422-14 12892-45000-280 SHIM, TAPPET (T:2.80) 422-15 12892-45000-285 SHIM, TAPPET (T:2.85) 422-16 12892-45000-290 SHIM, TAPPET (T:2.90) 422-17 12892-45000-295 SHIM, TAPPET (T:2.95) 422-18 12892-45000-300 SHIM, TAPPET (T:3.00) 422-19 12892-45000-305 SHIM, TAPPET (T:3.05) 422-20 12892-45000-310 SHIM, TAPPET (T:3.10) 4
REF.NO PART.NO DESCRIPTION QTY REMARSK
GS500K6 P02_01 1CAM SHAFT/V ALVE
22
21
20
1918
17
15
13
65
4
3
2
1
22
2120
1918
17
16
14
1211
10
9
7
2B2A
2B
8B8A
8B
8
-
FIG.12 (C-4) CAM CHAIN
2
GS500K P2
GS500K6 P02_012CAM CHAIN
1 12760-45040 CHAIN, CAM SHAFT DRIVE (120L) 12 12771-45052 GUIDE, CAM CHAIN NO.1 13 12782-49200 GUIDE, CAM CHAIN NO.2 14 02112-05103 SCREW 25 12791-45040 GUIDE, CAM CHAIN NO.3 16 01550-06123 BOLT 27 09168-06023 WASHER 28 12810-01D00 TENSIONER, CAM CHAIN 19 12814-44101 CUSHION 210 12830-01D12 ADJUSTER ASSY, TENSIONER 111 12838-38200-H17 .GASKET 112 12839-38200 PLUG 113 12837-24A10 GASKET, ADJUSTER 114 07130-06253 BOLT 2
REF.NO PART.NO DESCRIPTION QTY REMARSK
-
FIG.13 (C-5) CARBURETOR (GS500K3/UK3)
2
GS500K P2
GS500K6 P02_013CARBURETOR
REF.NO PART.NO DESCRIPTION QTY REMARSK 1-1 13201-01DE0 CARBURETOR ASSY, LH 1 GS500K3 P2, P19, P24,P54 1-2 13201-01DG0 CARBURETOR ASSY, LH 1 GS500UK3 P192-1 13202-01DE0 CARBURETOR ASSY, RH 1 GS500K3 P2, P19, P24,P542-2 13202-01DG0 CARBURETOR ASSY, RH 1 GS500UK3 P193 13573-19E00 .SPRING 24 13418-33E00 .HOLDER 25 09280-05004 .O RING (D:1.9, ID:4.8) 26 13481-13F00 .SPRING 27 13382-19E00 .WASHER 28 13387-13F00 .E RING 29 13383-01DE0 .NEEDLE, JET (5DH41-4) 210 13502-07F00 .COVER, DIAPHRAGM 2
11-1 13501-29FA0 .VALVE, PISTON 2 GS500K3 P2, P19, P24,P5411-2 13501-01DG0 .VALVE, PISTON 2 GS500UK3 P1912 13507-17C01 .DIAPHRAGM 213 13247-02340 .SCREW, DRAIN 214 09492-17016 .JET, PILOT 215 13247-33E00 .SCREW 416 13258-44B00 .GASKET, FLOAT CHAMBER 217 13250-04F00 .FLOAT ASSY 218 13254-01010 .PIN, FLOAT 219 02112-04083 .SCREW 220 13602-05A10 .SCREW 221 13370-33E80 .VALVE ASSY, NEEDLE 222 09491-23012 .JET, MAIN (115) 223 09491-60010 .JET, MAIN (60) 224 13385-07F00 .HOLDER, JET 225 13246-43010 .O RING 226 09494-00949 .JET, NEEDLE (P-5M) 227 13279-33E00 .SCREW, PILOT (2 3/4) 228 13268-47070 .SPRING 229 13291-29900 .WASHER 230 13295-29900 .O RING 231 13267-13F00 .ADJUSTER RH 132 13271-33C00 .SPRING RH 133 13411-05300 .PLUNGER ASSY 234 13682-31210 .CAP 235 13418-44080 .HOLDER, GUIDE 236 13417-26D00 .SPRING 237 13278-47090 .O RING 238 13247-33E00 .SCREW 439 09493-33002 .JET, AIR (165) 240 13274-84000 .CAP 1
-
FIG.13 (C-6) CARBURETOR (GS500K3/UK3)
2
GS500K P2
REF.NO PART.NO DESCRIPTION QTY REMARSK
GS500K6 P02_013CARBURETOR
41 09401-06101 .CLIP 142 13295-33010 .O RING 243 13268-96111 SPRING 144 13271-44B00 SPRING 145 13267-44B00 SCREW 146 13683-01DF0 HOSE 147 13413-01DE0 PLATE 148 13602-04F00 SCREW 249 13557-33E00 PACKING 250 13683-01DE0 HOSE 151 13683-01DB0 HOSE 152 13673-44B00 SEAL 253 13685-33EQ0 NIPPLE 154 13565-01DE0 BRACKET 155 02122-05103 SCREW 156 13685-01DB0 PIPE 2
REFERTO FIG. 14 (C-8) FOR GS500HK3/HUK3REFERTO FIG. 14A (C-11) FOR MODEL K4/K5/K6
-
FIG.14 (C-8) CARBURETOR (GS500HK3/HUK3)
GS500K P2
3
1-1 13201-01DF1 CARBURETOR ASSY, LH 1 GS500HK3 P191-2 13201-01DK0 CARBURETOR ASSY, LH 1 GS500HUK3 P192-1 13202-01DF1 CARBURETOR ASSY, RH 1 GS500HK3 P192-2 13202-01DK0 CARBURETOR ASSY, RH 1 GS500HUK3 P193 13573-01DB0 .SPRING 24 13507-17C01 .DIAPHRAGM 2
5-1 13501-29FA0 .VALVE, PISTON 2 GS500HK3 P195-2 13501-01DK0 .VALVE, PISTON 2 GS500HUK3 P196 13418-33E00 .HOLDER 27 09280-05004 .O RING (D:1.9,ID:4.8) 28 13481-13F00 .SPRING 29 13382-44030 .WASHER 210 13394-17E60 .E RING 211 13387-13F00 .RING 2
12-1 13383-01DF0 .NEEDLE, JET (5DH41-3) 2 GS500HK312-2 13383-01DE0 .NEEDLE, JET (5DH41-3) 2 GS500HUK313 09494-00949 .JET, NEEDLE (P-5M) 214 13246-43010 .O RING 215 13385-07F00 .HOLDER, JET 2
16-1 09491-26016 .JET, MAIN (130) 2 GS500HK316-2 09491-27008 .JET, MAIN (135) 2 GS500HUK317 13295-29900 .O RING 218 13291-29900 .WASHER 219 13268-48700 .SPRING 220 13279-33E00 .ADJUSTER (2 5/8) 221 13370-33E80 .VALVE ASSY, NEEDLE 222 02112-04083 .SCREW 223 13602-05A10 .SCREW 224 13250-04F00 .FLOAT ASSY 225 13254-01010 .PIN, FLOAT 226 09492-17016 .JET, PILOT (17.5) 227 09491-60005 .JET, MAIN (60) 228 09493-34003 .JET, PILOT AIR (170) 229 13258-04F00 .GASKET 230 02112-04107 .SCREW 231 13247-02340 .PLUG, DRAIN 2
32-1 13502-01DB0 .COVER ASSY, DIAPHRAGM LH 132-2 13502-01DC0 .COVER ASSY, DIAPHRAGM RH 133 13411-05300 .PLUNGER ASSY 234 13417-26D00 .SPRING 235 13278-47090 .O RING 236 13418-44080 .HOLDER, GUIDE 237 13682-31210 .CAP 238 02112-05127 .SCREW 439 13274-84000 .CAP 140 09401-06101 .CLIP 1
REF.NO PART.NO DESCRIPTION QTY REMARSK
GS500K6 P02_014CARBURETOR
-
FIG.14 (C-9) CARBURETOR (GS500HK3/HUK3)
3
GS500K P2
3
REF.NO PART.NO DESCRIPTION QTY REMARSK 41 13267-13F00 .ADJUSTER 142 13271-33C00 .SPRING 143 09355-35755-600 HOSE 1 L:600 --> 17544 13683-10F60 HOSE 245 13685-04F10 NIPPLE 146 95569-78040 CHECK VALVE ASSY 147 18115-70G10 SOLENOID ASSY 148 13683-01DB0 HOSE 149 13683-01DE0 HOSE 150 13683-46D10 3 WAY 151 13683-01DC1 HOSE 152 09401-16401 CLIP 153 09408-00033 CLIP 254 13413-01DE0 LEVER 155 02142-04083 SCREW 256 13557-33E00 PACKING 257 13550-13D60 SENSOR ASSY 158 13605-20C00 SCREW 259 09355-35755-600 HOSE 1 L:600 --> 16560 09355-35755-600 HOSE 1 L:600 --> 4061 09355-35755-600 HOSE 1 L:600 --> 3562 09367-04007 NIPPLE 163 09355-35755-600 HOSE 1 L:600 --> 5564 13685-01DC0 ROD 265 13685-01DB0 PIPE 266 13268-96111 SPRING 167 13271-44B00 SPRING 168 13267-44B00 SCREW 169 13673-44B00 SEAL 270 13685-33EQ0 NIPPLE 171 18780-32E00 FILTER, AIR CLEANER NO.2 172 09355-35755-600 HOSE, CONTROL AIR 1 L:600 --> 36073 09355-50105-600 HOSE, FUEL COCK VACUUM 1 L:600 --> 48074 13715-04F00 CHAMBER, VACUUM 175 D1557-06205 BOLT 1
GS500K6 P02_014CARBURETOR
-
1-1 13201-01DN0 CARBURETOR ASSY, LH 1 GS500/F P2, P19, P24,P541-2 13201-01DP0 CARBURETOR ASSY, LH 1 GS500U/FU P192-1 13202-01DN0 CARBURETOR ASSY, RH 1 GS500/F P2, P19, P24,P542-2 13202-01DP0 CARBURETOR ASSY, RH 1 GS500U/FU P193 13573-19E00 .SPRING 24 13507-17C01 .DIAPHRAGM 2
5-1 13501-29FA0 .VALVE, PISTON 2 GS500/F P2, P19, P24,P545-2 13501-01DK0 .VALVE, PISTON 2 GS500U/FU P196 13418-44080 .HOLDER 27 09280-05004 .O RING (D:1.9, ID:4.8) 28 13481-13F00 .SPRING 29 13382-19E00 .WASHER 210 13394-17E60 .E RING 211 13387-13F00 .RING 212 13383-01DN0 .NEEDLE, JET (5DH57-3) 213 13341-01DN0 .JET, NEEDLE (P-5M) 214 13246-43010 .O RING 215 13385-07F00 .HOLDER, JET 2
16-1 09491-26016 .JET, MAIN (130) 2 GS500/F P2, P19, P24,P54 16-2 09491-27008 .JET, MAIN (135) 2 GS500U/FU P1917 13295-29900 .O RING 218 13291-29900 .WASHER 219 13268-48700 .SPRING 220 13279-01DN0 .ADJUSTER (2 5/8) 221 13370-04F00 .VALVE ASSY, NEEDLE 222 02112-04083 .SCREW 223 13602-05A10 .SCREW 224 13250-04F00 .FLOAT ASSY 225 13254-01010 .PIN, FLOAT 226 09492-17016 .JET, PILOT (17.5) 227 09491-60010 .JET, MAIN (60) 228 09493-34003 .JET, PILOT AIR (170) 229 13258-04F00 .GASKET 230 02112-04107 .SCREW 231 13247-13A00 .PLUG, DRAIN 2
32-1 13502-01DB0 .COVER ASSY, DIAPHRAGM LH 132-2 13502-01DC0 .COVER ASSY, DIAPHRAGM RH 133 13411-05300 .PLUNGER ASSY 234 13417-26D00 .SPRING 235 13278-47090 .O RING 236 13418-44080 .HOLDER, GUIDE 237 13682-31210 .CAP 238 02112-05127 .SCREW 439 13274-84000 .CAP 140 09401-06101 .CLIP 1
FIG.14A (C-10) CARBURETOR (GS500HK3/HUK3)
3
GS500K P2
REF.NO PART.NO DESCRIPTION QTY REMARSK
FIG.14A
GS500K6 P02_014ACARBURET OR
57
3940
66
6768
65
41
42
2
53
60
62
61
283334
35
23 21
373617181920
1
545655
47
64
69 70
69
5
4
4948
50
4362
63
58
4644
45
51
59
44
52
31
29 27
26
2422
1314
25
1615
30
71
72
73
12
11109876
3
3238
7677 74
75
3
-
FIG.14A (C-11) CARBURETOR (GS500HK3/HUK3)
GS500K P2
3
REF.NO PART.NO DESCRIPTION QTY REMARSK
32
3
FIG.14A
GS500K6 P02_014ACARBURETOR
57
3940
66
6768
65
41
42
2
53
60
62
61
283334
35
23 21
373617181920
1
545655
47
64
69 70
69
5
4
4948
50
4362
63
58
4644
45
51
59
44
52
31
29 27
26
2422
1314
25
1615
30
71
72
73
12
11109876
3
3876
77 7475
41 13267-13F00 .ADJUSTER 142 13271-33C00 .SPRING 143 09355-35755-600 HOSE 1 L:600 --> 17544 09355-35755-600 HOSE 2 L:600 --> 6045 13685-04F10 NIPPLE 146 95569-01DN0 CHECK VALVE ASSY 147 18115-70G10 SOLENOID ASSY 148 13683-01DB0 HOSE 149 13683-01DN0 HOSE 150 13683-01DP0 3 WAY 151 13683-01DC1 HOSE 152 09401-16401 CLIP 153 09408-00200 CLIP 254 13413-01DE0 LEVER 155 13602-04F00 SCREW 256 13557-33E00 PACKING 257 13550-13D60 SENSOR ASSY 158 13605-20C00 SCREW 259 09355-35755-600 HOSE 1 L:600 --> 16560 09355-35755-600 HOSE 1 L:600 --> 4061 09355-35755-600 HOSE 1 L:600 --> 3562 09367-04007 NIPPLE 163 09355-35755-600 HOSE 1 L:600 --> 5564 13685-01DC0 ROD 265 13685-01DB0 PIPE 266 13268-96111 SPRING 167 13271-44B00 SPRING 168 13267-44B00 SCREW 169 13673-44B00 SEAL 270 13685-33EQ0 NIPPLE 171 18780-32E00 FILTER, AIR CLEANER NO.2 172 09355-35755-600 HOSE, CONTROL AIR 1 L:600 --> 360
73-1 09355-50105-600 HOSE, FUEL COCK VACUUM NO. 1 1 L:600 --> 100 P2, P19, P5473-2 09355-50105-600 HOSE, FUEL COCK VACUUM NO. 1 1 L:600 --> 480 P2474 09355-50105-600 HOSE, FUEL COCK VACUUM NO. 2 1 L:600 --> 380 P2, P19, P5475 09367-06002 JOINT 1 P2, P19, P5476 13715-04F00 CHAMBER, VACUUM 177 D1557-06205 BOLT 1
-
FIG.15 (C-14) AIR CLEANERFIG.15
GS500K P2
4
1-1 13700-01D71 CLEANER ASSY, AIR 1 GS500K3 P2, P19, P24,P541-1 GS500UK3 P191-2 13700-01D61 CLEANER ASSY, AIR 1 GS500HK3 P191-2 GS500HUK3 P191-2 GS500K4/K5/K6 P241-2 GS500FK4/K5/K6 P241-3 13700-01D90 CLEANER ASSY, AIR 1 GS500K4/K5/K6 P2, P19, P541-3 GS500UK4/K5/K6 P191-3 GS500FK4/K5/K6 P2, P19, P541-3 GS500FUK4/K5/K6 P192-1 13780-01D51 .FILTER ASSY 1 GS500K3 P2, P19, P24,P542-1 GS500UK3 P192-2 13780-01D00 .FILTER ASSY 1 GS500HK3 P192-2 GS500HUK3 P192-2 MODEL K4/K5/K63 02142-05087 .SCREW 44 13881-01D60 .TUBE, OUTLET 25 09402-64203 .CLAMP 26 09352-11153-600 .TUBE, BREATHER 1 L:600 --> 2007 09401-14301 .CLIP 28 13870-21458 .TUBE, DRAIN 19 09401-13409 .CLIP 110 09404-06432 .CLAMP 211 13859-41B10 .PLUG 1 MODEL K311 MODEL K4/K5/K6 P2412 09401-14301 .CLIP 1 MODEL K312 MODEL K4/K5/K6 P2413 D1557-06165 BOLT 214 D8321-51065 WASHER 215 09404-06433 CLAMP 1
REF.NO PART.NO DESCRIPTION QTY REMARSK
GS500K6 P02_015AIR CLEANER
1312
11
-
FIG.15A (C-16) 2ND AIR (MODEL K4/K5/R (MODEL K4/K5/K6 P2, P19, P54)FIG.15A
GS500K P2
4
12
14
7
5
4
1010 6
15
11
8
9 11
1010
1
216
3
13
GS500K6 P02_015A2ND AIR
1 18420-01D01 PIPE, 2ND AIR RH 12 18430-01D01 PIPE, 2ND AIR LH 13 18441-12D10 GASKET 24 18445-01D20 HOSE , 2ND AIR REED VALVE RH 15 18446-01D20 HOSE , 2ND AIR REED VALVE LH 16 18450-10F03 VALVE ASSY, 2ND AIR REED 17 18610-01D20-E0Z BRACKET, 2ND AIR VALVE 18 18711-01D20 HOSE, 2ND AIR CLEANER 29 09359-40701-600 HOSE 1 L:600 --> 27010 09401-13409 CLIP 411 09401-15101 CLIP 212 09404-06429 CLAMP 113 01421-06163 BOLT 414 D1557-06125 BOLT 215 D7107-06165 BOLT 216 D8320-10065 NUT 41 16600-01D01 COOLER ASSY, OIL 12 16621-0BE00-E0N BRACKET, OIL COOLER 13 16628C27A00J000 CUSHION 14 D1507-06205 BOLT 2
4A D8322-91065 WASHER 25 09180C06310J000 SPACER (6.5X10X10) 26 09320-10501 CUSHION 27 16460-01D00 HOSE, OIL COOLER RH 18 16470-01D00 HOSE, OIL COOLER LH 19 09168-14015 GASKET (16X22X2) 410 09280-12005 O RING (D:2.4, ID:11.8) 211 09360-14012 BOLT (16X32) 212 D7107-06165 BOLT 413 16480-01D00-E0N CLAMP, OIL HOSE RH 114 D1557-06125 BOLT 415 16492-01D00-E0N GUIDE, OIL HOSE 216 16490-01D00-E0N CLAMP, OIL HOSE LH 1
REF.NO PART.NO DESCRIPTION QTY REMARSK
-
FIG.15B (C-16) OIL COOLER (GS500FK4/K5/K6/FUK4/K5/K6)FIG.15B
GS500K P2
4
GS500K6 P02_015BOIL COOLER
9 14
11
9
15
16
138
12
10
10
3
2
14
4 56
1
7
4A
1 16600-01D01 COOLER ASSY, OIL 12 16621-0BE00-E0N BRACKET, OIL COOLER 13 16628C27A00J000 CUSHION 14 D1507-06205 BOLT 2
4A D8322-91065 WASHER 25 09180C06310J000 SPACER (6.5X10X10) 26 09320-10501 CUSHION 27 16460-01D00 HOSE, OIL COOLER RH 18 16470-01D00 HOSE, OIL COOLER LH 19 09168-14015 GASKET (16X22X2) 410 09280-12005 O RING (D:2.4, ID:11.8) 211 09360-14012 BOLT (16X32) 212 D7107-06165 BOLT 413 16480-01D00-E0N CLAMP, OIL HOSE RH 114 D1557-06125 BOLT 415 16492-01D00-E0N GUIDE, OIL HOSE 216 16490-01D00-E0N CLAMP, OIL HOSE LH 1
REF.NO PART.NO DESCRIPTION QTY REMARSK
-
FIG.16 (D-2) MUFFLERFIG.16
GS500K P2
4A
GS500K6 P02_016MUFFLER
1 14181-01D00 GASKET, EXHAUST PIPE 22 D7109-08405 BOLT 4
2A D8322-01085 WASHER 43-1 14301-01DB1-E02 MUFFLER ASSY 1 GS500K3 P2, P19, P24,P543-1 GS500UK3 P193-2 14301-01DA1-E02 MUFFLER ASSY 1 GS500HK3 P193-2 GS500HUK3 P193-3 14301-01DE0-E02 MUFFLER ASSY 1 GS500K4/K5/K6 P2, P19, P543-3 GS500UK4/K5/K6 P193-3 GS500FK4/K5/K6 P2, P19, P543-3 GS500FUK4/K5/K6 P193-4 14301-01DF0-E02 MUFFLER ASSY 1 GS500K4/K5/K6 P243-4 GS500FK4/K5/K6 P244-1 09103-08256 BOLT (8X40) 1 MODEL K34-2 09103-08392 BOLT 1 MODEL K4/K5/K65 09160-08136 WASHER (8.5X28X1.6) 16 09180-08152 SPACER (8.6X12X20.1) 17 09320-12048 CUSHION 18 08316-10083 NUT 1
REF.NO PART.NO DESCRIPTION QTY REMARSK
-
FIG.17 (D-3) CLUTCHFIG.17
GS500K P2
4
1 21200-44102 GEAR, PRIMARY DRIVEN (NT:76) 12 09181-25223 WASHER (25X38X1.0) 13 21411-44101 HUB, SLEEVE 14 09140-20001 NUT 15 09167-20006 WASHER (20.5X38X0.8) 16 09160-20015 WASHER (20X44X3) 17 21441-37400 PLATE, DRIVE 78 21451-28C31 PLATE, DRIVEN 69 21462-14301 DISK, PRESSURE 110 09440-20019 SPRING 611 09100-06145 BOLT (6X40) 612 21414-01D00 SPACER 613 23121-44100 PIECE, PUSH 114 09263-15003 BEARING (15X28X2) 115 09160-15045 WASHER (15.5X28X1) 116 16321-01D10 GEAR, OIL PUMP DRIVE (NT:39) 117 09261-06002 PIN 118 08331-31383 CIRCLIP 119 23110-44111 ROD, PUSH RH 120 23111-24A01 ROD, PUSH LH 121 09285-06011 OIL SEAL (6X34X10) 122 23117-44102 HOLDER, OIL SEAL 123 01500-06123 BOLT 224 23200-01D00 SCREW ASSY, RELEASE 125 09134-06010 .SCREW 126 08310-00067 .NUT 127 03141-06163 SCREW 228 09443-08001 SPRING 1
REF.NO PART.NO DESCRIPTION QTY REMARSK
GS500K6 P02_017CLUTCH
2625
28
27
24
-
FIG.18 (D-4) TRANSMISSIONFIG.18
GS500K P2
4
1 24121-01D01 COUNTERSHAFT (NT:13) 12 24221-44001 GEAR, 2ND DRIVE (NT:18) 13 24231-20F03 GEAR, 3/4 DRIVE (NT:21/24) 14 24251-20F02 GEAR, 5TH DRIVE (NT:26) 15 24252-19F00 BUSH 16 24260-01D01 GEAR, 6TH DRIVE (NT:27) 17 09181-25167 WASHER (25X34X1.0) 18 09380-25010 CIRCLIP 19 09262-25051 BEARING, RH (25X62X17) 110 09390-62012 C RING 111 09263-20025 BEARING, LH (20X34X20) 112 04221-07129 PIN 113 24741-44102 HOLDER, BEARING 114 09126-06014 SCREW (6X16) 315 24131-01D00 DRIVESHAFT 116 24310-44001 GEAR, 1ST DRIVEN (NT:32) 117 09181-20251 WASHER (20X34X1) 118 24321-20F00 GEAR, 2ND DRIVEN (NT:32) 119 24322-19F00 BUSH 120 09380-25010 CIRCLIP 121 24331-44003 GEAR, 3RD DRIVEN (NT:29) 122 09167-25012 WASHER (25.1X31X1.0) 123 09167-25013 LOCK WASHER 124 09380-25010 CIRCLIP 125 24341-44003 GEAR, 4TH DRIVEN (NT:27) 126 09167-25012 WASHER (25.1X31X1.0) 127 09169-25001 LOCK WASHER 128 09380-25010 CIRCLIP 129 24351-44001 GEAR, 5TH DRIVEN (NT:25) 130 24361-44010 GEAR, 6TH DRIVEN (NT:23) 131 09390-62012 C RING 132 09283-32015 OIL SEAL (32X62X7) 133 09263-20027 BEARING, RH (20X34X17) 134 09262-25065 BEARING, LH (25X62X17) 135 09282-32002 OIL SEAL 136 27511-01D01 SPROCKET, ENGINE (NT:16) 137 27531-01D10 SPACER (L:32.7) 138 08331-31256 CIRCLIP 139 27600C01C10J110 CHAIN, DRIVE (DID520VM,110LE) 140 27620C01C10J000 .JOINT SET, CHAIN 1
GS500K6 P02_018TRANSMISSION
40
REF.NO PART.NO DESCRIPTION QTY REMARSK
-
FIG.19 (D-5) GEAR-SHIFTINGFIG.19
GS500K P2
4
GS500K6 P02_019GEAR SHIFTING
3031
32
REF.NO PART.NO DESCRIPTION QTY REMARSK 1 25211-44001 FORK, GEAR SHIFTING NO.1 12 25221-44001 FORK, GEAR SHIFTING NO.2 13 25231-44000 FORK, GEAR SHIFTING NO.3 14 25411-18900 SHAFT, GEAR SHIFTING FORK 15 09125-06115 SCREW (6X8) 16 08211-06141 WASHER 17 25311-01D00 CAM, GEAR SHIFTING 18 09261-04001 PIN 59 09209-04013 PIN 110 09181-26001 WASHER (26X32.5X0.3) 111 25322-44000 HOLDER, DRIVE PIN 112 02112-06163 SCREW 113 25341-33300 GUIDE, CAM 114 09111-06054 BOLT (6X14.6) 115 09103-06240 BOLT 116 09263-40001 BEARING (40X47X12) 117 25350-44000 STOPPER, CAM NO.1 118 09443-09007 SPRING 119 25351-30010 STOPPER, CAM NO.2 120 25354-30000 HOLDER, SPRING 121 09440-06020 SPRING 122 09168-14002 GASKET (13.8X18.8X0.4) 123 25510-44100 SHAFT, GEAR SHIFTING 124 09448-13008 SPRING 125 08332-11073 E RING 126 09444-26013 SPRING 127 09180-12068 SPACER (12X20X15.3) 128 25671-01011 STOPPER 129 09285-12002 OIL SEAL (12X22X9) 130 25600-01D02 LEVER ASSY, GEAR SHIFTING 131 25652-20C00 .RUBBER 132 D1507-06205 BOLT 133 37720-47D00 BASE ASSY, GEAR SHIFT 1 GS500K3 P2, P19, P24,P5433 GS500UK3 P1934 37720-01D00 BASE ASSY, GEAR SHIFT 1 GS500HK3 P1934 GS500HUK3 P1934 MODEL K4/K5/K635 09280-26007 O RING (D:2.4, ID:25.7) 136 02112-75203 SCREW 237 09209-05011 CONTACT 138 09440-04010 SPRING 1
-
FIG.20 (E-2) STARTING MOTORFIG.20REF.NO PART.NO DESCRIPTION QTY REMARSK
GS500K P2
4
GS500K6 P02_021GENERATOR
1 31100-20C00 MOTOR ASSY, STARTING 12 31310-27A01-H17 .ARMATURE 13 31153-43400 .OIL SEAL 14 31170-43400 .SHIM SET 15 31264-44110 .O RING 26 31132-27A01 .BRUSH HOLDER ASSY 17 31135-65010 ..SPRING 28 31130-38300 .BRUSH 19 31172-38300 .BUSHING (A) 110 31171-38300 .BUSHING (B) 111 31143-38300 .O RING 112 31281-88C00 .BOLT 213 31156-38300 .O RING 214 09280-24003 .O RING (D:3.0, ID:24.5) 115 09128-06024 BOLT (6X25) 116 08361-35068 NUT 1
-
FIG.21 (E-3) GENERATORFIG.21
GS500K P2
4
GS500K6 P02_021GENERATOR
1 31401-01D10 STATOR 12 31402-01D00 ROTOR 13 02112-35303 SCREW 34 09103-12004 BOLT (12X60) 15 31497-45000 CLAMP 26 02112-05083 SCREW 27 31498-45000 CLAMP 18 02112-06103 SCREW 19 09404-06429 CLAMP (L:45) 1
REF.NO PART.NO DESCRIPTION QTY REMARSK
-
FIG.22 (E-4) SIGNALGENERATORFIG.22
GS500K P2
4
1-1 32900-01D40 IGNITOR 1 GS500K3 P2, P19, P24,P541-1 GS500UK3 P191-2 32900-01D50 IGNITOR 1 GS500HK3 P191-2 GS500HUK3 P192 32900-01DA0 IGNITOR 1 MODEL K4/K5/K63 33110-01D00 SIGNAL GENERATOR ASSY 14 33120-01D20 CLAMP (L:45) 15 09103-06064 BOLT (6X60) 16 02112-05103 SCREW 27 09404-06429 CLAMP (L:45) 2
REF.NO PART.NO DESCRIPTION QTY REMARSK
1
2
3
6
7
5
4
GS500K6 P02_022SIGNAL GENERATOR