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G S 5 0 0 / F

(BK111/BK211/BK221/BK232/
BK242/BK311/BK411/BK422)

GS500 (U/H/HU)K3
GS500 (U/F/FU)K4
GS500(U/F/FU)K5
GS500(U/F/FU)K6

2006-2 4TH EDITION


INFORMATION
ILLUSTRATION INDEX 1
Model of catalogue Parts Catalogue No.
ENGINE
GS500 9900BCOBE00H030
TRANSMISSION 2
ELECTRICAL 3
BODY 4
PARTS NUMBER INDEX 5
GS500K3 GS500FK4
GS500UK3 GS500FUK4
GS500HK3
GS500HUK3
GS500K4/K5
GS500UK4

PHOTO K4 PHOTO K4
GS500K6 GS500FK5/FK6
GS500UK6 GS500FUK5/FUK6

PHOTO K6 PHOTO K5
PREFACIO
Cuando sea necesario reemplazar piezas en las MOTOCICLETAS de SUZUKI, sírvase usar
Siempre las PIEZAS GENUINAS DE SUZUKI que han pasado una estricta inspección de calidad y 3. PIEZAS INTERNAS DEL CONJUNTO
rendimiento.
Este catálogo 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.
4.
Las piezas marcadas con un punto (.) antes de la
denominación, forman parte de un conjunto.
NOTICIA DE MODIFICACIÓN
1
INSTRUCCIONES SOBRE EL USO DEL CATALOGO
1. DIMENSIONES Se remitirá un boletín en el caso de modificación de piezas, que
incluye modificaciones de intercambiabilidad entre piezas
2. ABREVIATURAS nuevas y viejas.
Las abreviaturas usadas son las siguientes:
A : Suzuki Motor España NT : Número de dientes
AR : Lo necesario OPT : Opcional 5. NOTA
ASSY : Conjunto OS : Sobremedida
E.No. : Número de motor S : Suzuki Motor Corporation 5-1.Hay ciertas diferencias entre las piezas de producción en serie y
F.No. : Número de bastidor STD : Normalizado las de recambio por razones administrativas y por su uso común en
D : Diámetro del material T : Espesor otros modelos.
ID : Diámetro interno US : Submedida
OD : Diámetro externo W : Ancho 5-2.En cuanto a las mangueras de goma y los tubos de vinilo, sírvase
L : Longitud usarlos cortando según la longitud mencionada en el catálogo o según
LH : Lado izquierdo la realmente requerida por el vehículo.
RH : Lado derecho
5-3. Debe observarse que las ilustraciones son para una rápida
~100045: Hasta F. No. 100045 referencia del número de pieza y no para usarse como un manual de
100046- : From F. No. 100046 montaje: para ello emplee siempre el "MANUAL DE SERVICIO DE
SUZUKI".
12 x 34 x 5.6 ...................... Los números en la columna de "Observaciones" muestran las
T T T dimensiones de las piezas.
ID OD T (or W, L)
6. CODIGO DE ESPECIFICACION
Este catálogo contiene las piezas de los modelos diseñados para las
Las referencias cuya estructura es la sigu iente: siguientes especificaciones:
12345C56781H000 Código de especificación: P2, P19, P24, P54.

Las letras C y H indican que la fabricación de la


pieza es origen Colombia.
12345-56781 (No. de pieza): indica que el número de pieza fue modificado
7. NUMERO DE SERIE DE MARCO O CHASIS
a 12345-56781 y que las nuevas piezas son intercambiables con las
anteriores, pero no viceversa. GS500K3 (P2) : 9FSGM51A03C001685~
GS500K4 (P2) :
GS500K5 (P2) :
GS500K6 (P2) :
12345-56781 (No. de pieza): indica que el número de pieza fue modificado
a 12345-56781 y que las nuevas piezas son intercambiables con las
anteriores, pero no viceversa.

-1-
GS500K6 P2
CODIGO ESPECIFICACION COLORES MOTOCICLETAS COLOMBIA

1 CODIGO
001
DESCRIPCION COLOR
BICAPA NEGRO
No. PARTE
99999CPINTUH001
DESCRIPCION
KIT PINTURA-BICAPA NEGRO
002 NEGRO DIAMANTE 99999CPINTUH002 KIT PINTURA-NEGRO DIAMANT E
041 GRIS CORSA 99999CPINTUH041 KIT PINTURA-GRIS CORSA
042 GRIS HUMO 99999CPINTUH042 KIT PINTURA-GRIS HUMO
043 GRIS METALIZADO 99999CPINTUH043 KIT PINTURA-GRIS METALIZADO
044 GRIS HOUSTON 99999CPINTUH044 KIT PINTURA-GRIS HOUSTON
121 VERDE CRISTAL 99999CPINTUH121 KIT PINTURA-VERDE CRISTAL
123 VERDE OBDULIA 99999CPINTUH123 KIT PINTURA-VERDE OBDULIA
124 VERDE ARRECIFE 99999CPINTUH124 KIT PINTURA-VERDE ARRECIFE
221 AZUL AMORTIGUADOR 99999CPINTUH221 KIT PINTURA-AZUL AMORTIG UADOR
223 AZUL LUNA 99999CPINTUH223 KIT PINTURA-AZUL LUNA
224 AZUL PETROLEO 99999CPINTUH224 KIT PINTURA-AZUL PETROLEO
225 AZUL TRADICIONAL 99999CPINTUH225 KIT PINTURA-AZUL TRADICIO NAL
226 AZUL DEEP 99999CPINTUH226 KIT PINTURA-AZUL DEEP
331 ROJO TRADICIONAL 99999CPINTUH331 KIT PINTURA-ROJO TRADICI ONAL
332 ROJO FIESTA 99999CPINTUH332 KIT PINTURA-ROJO FIESTA
334 ROJO RUBÍ 99999CPINTUH334 KIT PINTURA-ROJO RUBÍ
336 ROJO LASER 99999CPINTUH336 KIT PINTURA-ROJO LASER
337 ROJO LASER N° 2 99999CPINTUH337 KIT PINTURA-ROJO LASER N° 2
340 NARANJA ZODIACAL 99999CPINTUH340 KIT PINTURA NARANJA ZODI ACAL
411 BLANCO NIEVE 99999CPINTUH411 KIT PINTURA-BLANCO NIEVE
AFE AMARILLO FERRARI 99999CPINTUHAFE KIT PINTURA-AMARILLO FERRARI
NAZ NARANJA AZTECA 99999CPINTUHNAZ KIT PINTURA-NARANJA AZTECA

Nota: En la columna Remarks (Observaciones) del catálogo encontrará indicaciones de piezas las cuales son
aplicadas a un color espefico de un modelo particular, a través de un código cuya equivalencia se encuentra en
esta tabla.

-2-
FIG.1 FIG.2 FIG.3
3

7
2
20 22
23
FIG.4
1
4 21

2
7
5
12 6

14
1
13

17 14
19
15

18 11
16
9
6A 6B

8 9

10

GS500K6 P02_001
GASKET SET
GS500K6 P02_002
GS500K6 P02_003 GS500K6 P02_004
CYLINDER HEAD COVER
CYLINDER HEAD CYLINDER

FIG.5 FIG.6 FIG.7 FIG.8


10
16 9 8 16

14 16 6
4 4
12 12 13
5 13 9
5
12
5 6 7
7 14
12
7 12
6 17 10 8
10 9
11
11
26 9
11 12
17
15 13 15
20
21 1
21 11 3

18
26 24 19
20
28
12 16 2
15 16
17

1 8
2 15 3
16
30
28
3 22
18 14 5
19 1

29
29
26
27
25 6
2 3 5

4 7

31 27
7 4
23

GS500K6 P02_007
GS500K6 P02_005 OIL FILTER/OIL PUMP
CRANKCASE GS500K6 P02_006 GS500K6 P02_008
CRANKCASE COVER CRANKSHAFT

-1-
1 FIG.9 FIG.10 FIG.11
2B
2A
2B
5
6

3
FIG.12

11
6 8B 12
5 8A 1
8B
2
9
9 6

8
7 4
1 22
4
13
3
19
18
2 10 7

8
22 17
10
10 14
19 21
18
10 20

10 17
15
21
20

16

GS500K6 P02_ 009


CRANK BALANCER GS500K6 P02_010 GS500K6 P02_012
GS500K6 P02_011
STARTER CLUTCH CAM CHAIN
CAM SHAFT/VALVE

FIG.13 FIG.14 FIG.15 FIG.15A


12 8

9 11
14
11

15
7

5
6
10
10

12
11 13

4
10
10

1
13

3
2
16

GS500K6 P02_015 GS500K6 P02_015A


GS500K6 P02_013 GS500K6 P02_014 2ND AIR
AIR CLEANER
CARBURETOR CARBURETOR

-2-
FIG.15B
4
4A
5
6
FIG.16 FIG.17 FIG.18
1
10

14 A
3 1

10

7
12

13
8
16
27
40

9
28

24

9 15 25
14
26
11

GS500K6 P02_016
GS500K6 P02_017
MUFFLER GS500K6 P02_018
GS500K6 P02_015B CLUTCH
TRANSMISSION
OIL COOLER

FIG.19 FIG.20 FIG.21 FIG.22


1

14

12 2

30 13
31

3
32
4

10

8
16 4

2
9
11
4
7 7
5

6
6
15
5
7

GS500K6 P02_021 GS500K6 P02_022


GS500K6 P02_019 GENERATOR SIGNAL GENERATOR
GS500K6 P02_020
GEAR SHIFTING
STARTING MOTOR

-3-
1 FIG.23
6
8
FI G. 24 9

9 8
FIG.25

7
10
6

11
9 8
FIG.25A
10
6

11

7
7 5 5
5
A
12A 12A
10
1

14 15 4
5 14 15 5 4
4
4
2
2 1
3 2 1
16 17 13 3
6 16 17 13
19 18
19 18
3
1
13
13
5

12 20
12 20
8
11
24
23
24
3 23
25
25
2

13 22
21
22
16 21

15
14 12

26
26

GS500K6 P02_024 GS500K6 P02_025


GS500K6 P02_023 ELECTRICAL SPEEDOMETER GS500K6 P02_025A
BATTERY SPEEDOMETER

FIG.25B FIG.26 FIG.26A FIG.26B 5

6 14
10

13
11
9 8
7
5

1
12A 5 1
3 2

4
1
4
15 3
2
14 15 4
5 6
7
2 1 3
16 17 3 5
13 2
19 18
12
11
13 4
12

8 13
10 9
7
12 20
11
16
9
24
23

6 6
10
15 8
22
14
21
7

25
GS500K6 P02_026B
GS500K6 P02_026
HEADLAMP
HEAD LAMP GS500K6 P02_026A
GS500K6 P02_025B
HEADLAMP
SPEEDOMETER

-4-
FIG.27
13
FIG.27A
12
FIG.27B
5
FIG.28
7 8
9
1
11

3 5 1 1
4 2

4 3
14
10
6 13
2 7 12

15
2 5

3
11 6

4
9

8 12
7 10

11
14
3 5
9
10
13 8
6
6 4

16
15 11
7 1 2
10

14 8
9

GS500K6 P02_028
GS500K6 P02_027A TURSIGNAL LAMP
GS500K6 P02_027B
HEADLAMP
GS500K6 P02_027 HEADLAMP
HEADLAMP

FIG.29 FIG.29A FIG.29B FIG.30


7 8
7 8 8 .9
9

11
12
11

9
10

14
10 10
13 11
12 14
14
15 15 13
16 13
12

6 7 15
6 6

3 5

4 5
3 5
3
4 4

1 2

1 2 1 2

GS500K6 P02_029
GS500K6 P02_030
TURSIGNAL LAMP
GS500K6 P02_029A REAR COMBINATION LAMP
GS500K6 P02_029B
TURNSIGNAL LAMP TURNSIGNAL LAMP

-5-
1 FIG.30A
7
1
FIG.31
9 10 20

5
6
FIG.31A
9 10 20
6
FIG. 31B
8 9
20
3 4 5 6

11
11 10

2
17 2
17
2
16
11
5
12
12

21
3
12
7
2 9 7
10 1
11 7
1
4
1

13
6 8
19
16 19
22
20 19
4 4 14
17
3 13 3
21 13
8 8
12
15
18 18 18
16 16
14 14 14
15 15 15
21 21 13

19 17

18

GS500K6 P02_031 GS500K6 P02_031A


GS500K6 P02_031B
GS500K6 P02_030A WIRING HARNESS WIRING HARNESS WIRING HARNESS
REAR COMBINATION LAMP

FIG.32 FIG.32A FIG33 FIG.33A

5
5

7
7
6
6

1
1
3
3

2
2

4 4

GS500K6 P02_032
HANDLE SWITCH GS500K6 P02_032A
HANDLE SWITCH GS500K6 P02_033 GS500K6 P02_033A
FRAME FRAME

-6-
FIG.34 FIG.34A

12
15

13
FIG.35 FIG.36
1
14
16

11
10

GS500K6 P02_036
GS500K6 P02_034
GS500K6 P02_035 FUEL TANK
STAND/REAR BRAKE
GS500K6 P02_034A
FOOTREST
STAND

FIG.36A FIG.36B FIG.36C FIG.37


5
5
5
4
4
11
4
10
1
1
1

13
2A
2
12 7.9 1
7.9

5
6

3
3 12
12 3
12
7
7 7 8 7.8
8 8
10 7.8
10 2
2 2 10

9
9 9
13
13 13
6 6 14
6 14 14 11 11
11 4

15 15
15

16 16
16

GS500K6 P02_037
GS500K6 P02_036B
GS500K6 P02_036C FUEL COCK
GS500K6 P02_036A FUEL TANK
FUEL TANK FUEL TANK

-5-
1 FIG.38 FIG.38A

9
8
FIG.38B
11
10
FIG. 38C
9
8

1
1

5 3 4
4 6
7 5A
3 4
5 8 6
9 7
6
7

14 12
12
12 10
10
3 5
2 2
2
13 11
11

GS500K6 P02_038B
GS500K6 P02_038A FRAME COVER GS500K6 P02_038C
GS500K6 P02_038
FRAME COVER FRAME COVER FRAME COVER

FIG.38D FIG.38E FIG38F FIG.39


8
9
8
9

8
9

1
1

5 3 4
5 3 4
5A 5A
5 6 6
3 4
7 7
5A
6
7

12 12

12 10 10

10

2
2 2 11
11
11

GS500K6 P02_039
GS500K6 P02_038D GS500K6 P02_038F HEAD LAMP HOUSING
FRAME COVER GS500K6 P02_038E FRAME COVER
FRAME COVER

-6-
FIG.40 FIG.40A
4
7
8
FIG.40B

1
4

3
7
8
FIG.40C
4
7
8 1
3 1 3
1

5 2
5 2 2
6 5
6 6

GS500K6 P02_040 GS500K6 P02_040A GS500K6 P02_040B


FRONT FENDER FRONT FENDER FRONT FENDER GS500K6 P02_040C
FRONT FENDER

FIG.41 FIG.41A FIG.42 FIG.43


1
15
16

15

16 2
20
17 19 3
22 23
21

1 6 23
22
4 18 20
14 12 21 17 5
13 10 6
2 11 4
1 6
4
14 12
13 10
7 2 11

20
5
7 8

26
5
3
8 14
10
5 9
3 12 13
8
18 9
22 5
19 7
21 24
25 28 11
23 27

29

15

GS500K6 P02_041 GS500K6 P02_041A GS500K6 P02_042 GS500K6 P02_043


HANDLE BAR HANDLE BAR HANDLE LEVER REAR FENDER

-5-
1 FIG.43A
3
FIG.43B
3
FIG.43C
3
FIG. 43D
9
10

5
5 5 13

7
7 7
4
4 4 2

6 6 11
6 12
5 5
6 6 5
6
1 1 34
1

8
2

6
7

2
2

14

8 8
8

GS500K6 P02_043B GS500K6 P02_043C GS500K6 P02_043D


GS500K6 P02_043A COWLING BODY COWLING BODY
BODY COWL INSTALLATION PARTS
COWLING BODY

FIG.43E FIG.43F FIG.43G FIG.43H


1
1 1

8
10

56 9
3.4 34 11
10
34
5.6 3.4
1

5
7 8
7

9
6

8
5.6

7 6
2 10 2 12
7
2
9 2
4 5

GS500K6 P02_043E
UNDER COWLING GS500K6 P02_043G
GS500K6 P02_043F UNDER COWLING
UNDER COWLING GS500K6 P02_043H
UNDER COWL INSTALLATION PARTS

-6-
FIG.44 FIG.44A
4

2
1
FIG.45
17
FIG.46

23
14 1 2
1
13
18 24
22 15

1
21

25

20
9
8
19
7
3 6

10
12

6 5
3
8
9
3 10
4
2
12

11
17
15 13
11 18
14 16

16

19

GS500K6 P02_044
GS500K6 P02_044A GS500K6 P02_046
LABEL
LABEL FRONT DAMPER
GS500K6 P02_045
SEAT

FIG.46A FIG.47 FIG.47A FIG.47B


13 10
11
1 2 12 14 9

22
5 12
15
23
14

10 7
15

21
13 12
3 9
11 8
24 9
6

20 9 8
5
8
7
7 4
19 5
6 5
5
10
12 4

3 1
2
1

11 17 3

18 16

GS500K6 P02_047B
GS500K6 P02_047 GS500K6 P02_047A STEERING STEM
GS500K6 P02_046A STEERING STEM
STEERING STEM
FRONT DAMPER

-5-
1 FIG.48 FIG.49
14

1
FIG.49A 14
FIG. 50
1

10
5
4
8

4 3

7
5
11 5 9 6

7 10

9 7
8 8 9
3 14
3
4 12
6 2
14

15
3 3
17
12
2 2
17
11 16
11
10

13

14
12 13 13
14

GS500K6 P02_048
FRONT WHEEL GS500K6 P02_049 GS500K6 P02_050
FRONT CALIPER GS500K6 P02_049A FRONT MASTER CYLINDER
FRONT CALIPER

FIG.50A FIG.50B FIG.51 FIG.51A


19
1 5 1 5
4 4
18
8 8
16
10 10 19
13
3 3

7 7

9 6 9 6
17

15
14

14 14

12 12
2 2
14 14
11
10
9
7
6
5

17

3
15 2
15
3 12
17

17 16
17
16
11 1 2
11 5

6
7
14 11
14
13 8
13
14
14

GS500K6 P02_050B
GS500K6 P02_050A
FRONT MASTER CYLINDER GS500K6 P02_051
FRONT MASTER CYLINDER GS500K6 P02_051A
REAR SWINGING ARM REAR SWINGING ARM

-6-
FIG.52 FIG. 52A FIG.53 FIG.54
1
1
10
8
9

6 6

7
3
5 7

3
4

11
12

13 14

GS500K6 P02_053 GS500K6 P02_054


GS500K6 P02_052A
REAR WHEEL REAR CALIPER
REAR CUSHION LEVER
GS500K6 P02_052
REAR CUSHION LEVER

FIG.54A FIG.55 FIG.55A FIG.56


1

10
8
9

6 6

7
3 5 7

3
4

2 3

11

12

13 14

GS500K6 P02_056
GS500K6 P02_055A
GS500K6 P02_054A GS500K6 P02_055 OPTIONAL
REAR MASTER CYLINDER
REAR CALIPER REAR MASTER CYLINDER

-5-
FIG.1 (B-2) GASKET
REF.NO PART.NO DESCRIPTION QTY REMARKS
1-1 11400-01862 GASKET SET 1 GS500
1-1 OPT
1-2 11400-01881 GASKET SET 1 GS500F
1-2 OPT
2 11141-01D10 .GASKET, CYLINDER HEAD 1 NOT SHOWN

2
3 11143-06B00 .O RING, HEAD GASKET 4 NOT SHOWN
4 11173-15502 .GASKET, CYLINDER HEAD COVER 1 NOT SHOWN
5 11177-15510-H17 .GASKET, BREATHER COVER 1 NOT SHOWN
6 11241-01D00 .GASKET, CYLINDER 1 NOT SHOWN
7 11482-44110 .GASKET, CLUTCH COVER 1 NOT SHOWN
8 11483-44110 .GASKET, MAGNETO COVER 1 NOT SHOWN
9-1 11489-44110 .GASKET, OIL PAN 1 NOT SHOWN MODEL K3 GS500
9-2 11489-01D00 .GASKET, OIL PAN 1 NOT SHOWN GS500F
10 12837-24A10 .GASKET, EXHAUST PIPE 2 NOT SHOWN
11 14181-01D00 .GASKET, EXHAUST PIPE 2 NOT SHOWN
12 16518-45000 .O RING, OIL FILTER CAP 1 NOT SHOWN
13 09168-06023 .GASKET (5.8X13X1.2) 4 NOT SHOWN
14 09168-08016 .GASKET (8.2X14X1) 1 NOT SHOWN
15 09168-10031 .GASKET (10.2X20X2.3) 2 NOT SHOWN
16 09168-14004 .GASKET (14.1X18X1.5) 2 NOT SHOWN
17 09280-03003 .O RING (D:1.05, ID:3.1) 2 NOT SHOWN
18 09280-13004 .O RING (D:1.9, ID:13) 2 NOT SHOWN
19 09280-15006 .O RING (D:1.9, ID:14.5) 4 NOT SHOWN
20 09280-26006 .O RING (D:3.1, ID:26.4) 1 NOT SHOWN
21 09280-40010 .O RING (D:2.4, ID:39.7) 2 NOT SHOWN

GS500K P2
FIG.2 (B-3) CYLINDER HEAD COVER
REF.NO PART.NO DESCRIPTION QTY REMARSK
1 11171-01D02 COVER, CYLINDER HEAD 1
2 11173-15502 GASKET, HEAD COVER 1
3 09106-07010 BOLT (L:19) 2
4 09106-07009 BOLT (L:5.5) 4
5 09280-15006 O RING (D:1.9, ID:14.5) 4
6 11176-33201 COVER, BREATHER 1

2 7
8
9
11186-15501
11177-15510-H17
01550-06253
SEPARATOR, OIL BREATHER
GASKET, BREATHER COVER
BOLT
1
1
4

GS500K6 P02_002
CYLINDER HEAD COVER
GN125H P2
GS500K
FIG.3 FIG.3 (B-4) CYLINDER HEAD
REF.NO PART.NO DESCRIPTION QTY REMARSK
1-1 11100-01D40 HEAD ASSY, CYLINDER 1 MODEL K3
1-2 11100-01D60 HEAD ASSY, CYLINDER 1 MODEL K4/K5/K6
2 09381-10003 .RING, VALVE GUIDE 4
3 09103-06026 .BOLT (6X39) 8
3 4 09206-08001 .PIN 8
2 22 5 01550-06123 .BOLT, OIL GALLERY 2
20

4
7

21
23
6
6A
6B
7
09168-06023
09106-06075
09248-10010
11115-45740
.GASKET
PLUG, OIL GALLERY
PLUG, OIL GALLERY
.GUIDE, VALVE (OS:0.3)
2
4
4
4
MODEL K4/K5/K6
MODEL K4/K5/K6
OPT
2
8 11141-01D10 GASKET, CYLINDER HEAD 1
2 9 11143-06B00 O RING, CYLINDER HEAD 4
7
5 10 01550-06303 BOLT 1
12 6 11 04211-11169 PIN 2
12 09159-10069 NUT 4
14 13 09159-10026 NUT 4
1 14 09168-10031 GASKET 8
13 15-1 09482-00334 SPARK PLUG (NGK, DPR8EA-9) 2
17 14 15-2 09482-00335 SPARK PLUG (ND, X24EPR-U9) 2
19 16 26442-45000 CAP, TACHOMETER GEAR SLEEVE 1 MODEL K3
15 17 26449-33000 PLATE, TACHOMETER DRIVEN GEAR 1 MODEL K3
18 26451-45000 SEAL BAND 1 MODEL K3
19 09128-05101 SCREW (5X12) 1 MODEL K3
20 13101-01D40 PIPE, INTAKE 2
18 11 21 09280-40010 .O RING (D:2.4, ID:39.7) 2
22 02112-16163 SCREW 4
16 23 09402-54208 CLAMP 2
9
6A 6B

8 9

10

GS500K6 P02_003
CYLINDER HEAD
GN125H P2
GS500K
FIG.4 (B-5) CYLINDER
REF.NO PART.NO DESCRIPTION QTY REMARSK
1-1 11210-01D20-0F0 CYLINDER 1 MODEL K3
1-1 MODEL K4/K5/K6 P24
1-2 11210-01D30-0F0 CYLINDER 1 MODEL K4/K5/K6 P2, P19, P54
2 09108-10112 STUD BOLT (L:168) 4
3 09108-10041 STUD BOLT (L:178) 4
4 04211-11169 PIN 2

2 5 11241-01D00 GASKET, CYLINDER 1

GS500K6 P02_004
CYLINDER
GN125H P2
GS500K
FIG.5
FIG.5 (B-6) CRANKCASE
16 9 8 16
REF.NO PART.NO DESCRIPTION QTY REMARSK
14 16 1-1 11301-44890 CRANKCASE SET 1 GS500/U
4 4 1-2 11301-01810 CRANKCASE SET 1 GS500F/FU
12 12 2 09206-13004 .PIN 2
5 5 3 09206-11007 .PIN 2
4 07130-08703 .BOLT (8X70) 2
5 6 5 09103-08182 .BOLT (8X125) 3
7
7

10
12
12
6 17
6
7
8
9
09103-08134
09103-08230
01550-08653
01550-08453
.BOLT (8X110)
.BOLT (8X100)
.BOLT (8X65)
.BOLT (8X45)
2
2
1
2
2
10 09103-06033 .BOLT (6X125) 1
11
26 9 11 09103-06067 .BOLT (6X105) 2
11 12 01550-06903 .BOLT (6X90) 4
13 01550-06703 .BOLT (6X70) 1
15 13 15 14 01550-06653 .BOLT (6X65) 1
15 01550-06507 .BOLT (6X50) 2
20
16 01550-06453 .BOLT (6X45) 3
21 17 09168-08016 .GASKET 1
18 09493-22010 .JET, OIL GALLERY MISSION 1
19 09493-32002 .JET, OIL GALLERY BAL SHAFT 2
26 24 20 09493-24008 .JET, OIL GALLERY CYLINDER 2
28 21 09280-03003 .O RING (D:1.1, ID:3.1) 2
22 09103-10137 BOLT (10X255) 1
23 09103-10154 BOLT (10X245) 1
24 09103-10127 BOLT (10X170) 1
25 09103-10278 BOLT (10X160) 1
1 26 09159-10078 NUT 4
27 11611-01D10 SPACER (L:16.8) 2
28 11610-45410 SPACER (L:65) 2
29 11521-44100 PLATE, OIL SEPARATOR 2
30
28 30 09125-06110 SCREW 4
3 22
18 31 11532-46E00 JET, OIL GALLERY 1 GS500F/FU
19

29
29
26
27
25
2

31 27

23

GS500K6 P02_005
CRANKCASE GS500K P2
FIG.6 (B-7) CRANKCASE COVER
REF.NO PART.NO DESCRIPTION QTY REMARSK
1 11341-01D10 COVER, CLUTCH 1
2 11482-44110 GASKET, CLUTCH COVER 1
3 04211-13189 PIN 2
4 09103-06216 BOLT 2
5 09103-06214 BOLT 2
6 09103-06212 BOLT 1

2 7
8
9
10
11970-44110
09280-26006
09247-14012
09168-14002
GAUGE, OIL LEVEL
O RING (D:3.1, ID:26.4)
PLUG, OIL CHECK
GASKET
1
1
1
1
11 11381-01D10 COVER, CONTACT BREAKER 1
12 09103-05016 BOLT 3
13-1 68233-01D00 EMBLEM 1 MODEL K3
13-2 68233-01D10 EMBLEM 1 MODEL K4/K5/K6
14 11351-01D10 COVER, MAGNETO 1
15 11483-44110 GASKET, GENERATOR COVER 1
16 04211-13189 PIN 1
17 09103-06214 BOLT 0
18-1 68233-01D00 EMBLEM 1 MODEL K3
18-2 68233-01D10 EMBLEM 1 MODEL K4/K5/K6
19 11361-01D10 COVER, ENGINE SPROCKET 1
20 04211-09129 PIN 1
21 09103-06239 BOLT 2
22 09103-06238 BOLT 1
23 09103-06215 BOLT 2
24 11387-01D10 CAP, CLUTCH RELEASE 1
25 02122-05127 SCREW 2
26 11382-01D00 COVER, STARTER MOTOR 1
27 01547-05083 BOLT 2
28 37820-33D10 SWITCH ASSY, OIL PRESSURE 1
29 37822-33D00 .BOLT 1

GS500K6 P02_006
CRANKCASE COVER GN125H P2
GS500K
FIG.7 FIG.7 (B-8) OIL FILTER-OIL PUMP
REF.NO PART.NO DESCRIPTION QTY REMARSK
1-1 11511-44100 PAN, OIL 1 GS500/U
6 1-2 11511-01D00 PAN, OIL 1 GS500F/FU
2-1 11489-44110 GASKET, OIL PAN 1 GS500/U
2-2 11489-01D00 GASKET, OIL PAN 1 GS500F/FU
13 3 01550-06303 BOLT 1 2
4 09247-14026 PLUG, OIL DRAIN 1
7
14
5
6
7
8
09168-14002
16440-11D00
16510-45040
16518-45000
GASKET
VALVE ASSY, OIL RELIEF
FILTER, ENGINE OIL
O RING
1
1
1
1
2
10 8 9
9 09440-32004 SPRING 1
10 16512-45D00 CAP, ENGINE OIL FILTER 1
11 01421-06208 STUD BOLT 3
12 08313-20063 NUT 3
17 13 16520-01D01 STRAINER, ENGINE OIL 1
14 01570-06123 SCREW 3
15 16400-44100 PUMP ASSY, ENGINE OIL 1
21 16 09280-13004 O RING (D:1.9, ID:13) 2
11 17 02112-06253 SCREW 3
18 16331-01D10 GEAR, DRIVEN (NT:27) 1
18 19 09181-10158 WASHER 1
19 20 09261-04009 PIN 1
20
21 08331-31106 CIRCLIP 1
12 16
15 16

3 5

GS500K6 P02_007
OIL FILTER/OIL PUMP
GS500K P2
GN125H
FIG.8
FIG.8 (B-9) CRANKSHAFT
REF.NO PART.NO DESCRIPTION QTY REMARSK
10 1 12160-44100 ROD ASSY, CONNECTING 2
2 09159-08033 .NUT 4
3-1 12164-01D01-0A0 BEARING, CRANK PIN (GREEN) 4
3-2 12164-01D01-0B0 BEARING, CRANK PIN (BLACK) 4
3-3 12164-01D01-0C0 BEARING, CRANK PIN (BROWN) 4
13
3-4 12164-01D01-0D0 BEARING, CRANK PIN (YELLOW) 4

2 12
9
4
5
6-1
6-2
12220-01D02
09202-03016
12229-01D01-0A0
12229-01D01-0B0
CRANKSHAFT
.PIN
BEARING, CRANKSHAFT (GREEN)
BEARING, CRANKSHAFT (BLACK)
1
1
8
8
6-3 12229-01D01-0C0 BEARING, CRANKSHAFT (BROWN) 8
6-4 12229-01D01-0D0 BEARING, CRANKSHAFT (YELLOW) 8
11 7 12228-44106 BEARING, THRUST 2
8 09283-22015 OIL SEAL, RH (22X40X8) 1
12
9 12111-01D01-0F0 PISTON 2
10 12140-01D20 RING SET, PISTON 2
11 12151-45501 PIN, PISTON 2
12 09381-18002 CIRCLIP 4
1 3 13 12100-01D00-050 PISTON SET (OS:0.5) 2 OPT
14 21111-44100 GEAR, PRIMARY DRIVE (NT:28) 1
15 09140-24007 NUT 1
16 09164-25001 WASHER 1
17 08341-31059 KEY 1
2
17

8
15 3
16

14 5

7 4

GS500K6 P02_008
CRANKSHAFT
GN125H P2
GS500K
FIG.9 (B-10) CRANKSHAFT BALANCER
REF.NO PART.NO DESCRIPTION QTY REMARSK
1 12650-01D01 BALANCER, CRANKSHAFT 1
2 09420-04008 .KEY 1
3 12666-44001 GEAR, DRIVEN (NT:46) 1
4 09160-24026 WASHER 1
5 09440-15007 SPRING 3
6 09201-08001 PIN 6

5
6
7
8
9
10-1
09180-24009
09160-12039
01500-12203
12229-01D01-0A0
SPACER
WASHER
BOLT
BEARING (GREEN)
1
1
1
4
2
10-2 12229-01D01-0B0 BEARING (BLACK) 4
10-3 12229-01D01-0C0 BEARING (BROWN) 4
10-4 12229-01D01-0D0 BEARING (YELLOW) 4

9 6

8
7
1

10
10

10

10

GS500K6 P02_ 009


CRANK BALANCER GS500K P2
FIG.10 (B-11) STARTER CLUTCH
REF.NO PART.NO DESCRIPTION QTY REMARSK
1 12611-01D00 GEAR, STARTER IDLE (NT:55/19) 1
2 09206-13003 PIN 1
3 12600-44835 CLUTCH SET, STARTER 1
4 09261-15001 .ROLLER 3
5 09440-04015 .SPRING 3

2
6 12633-31000 .PIECE, PUSH 3
7 07130-08163 BOLT 3
8 12649-45000 SHIM 1

GS500K6 P02_010
STARTER CLUTCH GS500K P2
FIG.11 (C-2) CAMSHAFT-VALVE
REF.NO PART.NO DESCRIPTION QTY REMARSK
5
2B 1 12710-01831 CAMSHAFT SET, INTAKE 1
6
2A 2-1 09181-22167 .WASHER (T:1.0) 1
2-2 09160-22074 .WASHER (T:1.1) 1 OPT
2B
2-3 09160-22075 .WASHER (T:1.2) 1 OPT
3 2-4 09160-22076 .WASHER (T:1.3) 1 OPT
2A 09164-22012 .WASHER, WAVE 1

8B
8A
11
12
1
2B
3
4
5
09181-22132
12740-45042
12748-44000
09111-06027
.WASHER (T: 0.7)
SPROCKET, INTAKE (NT:30)
PIN
BOLT (6X12.5)
2
1
1
2
2
8B
6 12747-44000 WASHER 1
2
7-1 12720-01820 CAMSHAFT SET, EXHAUST 1 MODEL K3
9
7-2 12720-01841 CAMSHAFT SET, EXHAUST 1 MODEL K4/K5/K6
8-1 09181-22167 .WASHER (T:1.0) 1
8-2 09160-22074 .WASHER (T:1.1) 1 OPT
4 8-3 09160-22075 .WASHER (T:1.2) 1 OPT
8-4 09160-22076 .WASHER (T:1.3) 1 OPT
22
8A 09164-22012 .WASHER, WAVE 1
8B 09181-22132 .WASHER (T: 0.7) 2
13 9 12750-45041 SPROCKET, EXHAUST (NT:30) 1
10 12748-44000 PIN 1
19
11 09111-06027 BOLT (6X12.5) 2
18 12 12747-44000 WASHER 1
10 7
13 12891-15501 TAPPET, INTAKE 2
14 12891-45001 TAPPET, EXHAUST 2
8
22 15 12911-01D00 VALVE, INTAKE 2
17
16 12912-01D00 VALVE, EXHAUST 2
14 17 12920-44110 SPRING SET, VALVE 4
18 12931-45000 RETAINER, SPRING 4
19 21 19 12932-45010 COTTER, VALVE 8
18 20 12933-45001 SEAT, SPRING 4
20 21 09289-07002 OIL SEAL (7X14.4X9) 4

17
15
21
20

16

GS500K6 P02_011
CAM SHAFT/VALVE GS500K P2
FIG.11 (C-3) CAMSHAFT-VALVE
REF.NO PART.NO DESCRIPTION QTY REMARSK
5
2B 22-1 12892-45000-215 SHIM, TAPPET (T:2.15) 4
6 22-2 12892-45000-220 SHIM, TAPPET (T:2.20) 4
2A
22-3 12892-45000-225 SHIM, TAPPET (T:2.25) 4
2B
22-4 12892-45000-230 SHIM, TAPPET (T:2.30) 4
3 22-5 12892-45000-235 SHIM, TAPPET (T:2.35) 4
22-6 12892-45000-240 SHIM, TAPPET (T:2.40) 4

2 8B
8A
11
12
1
22-7
22-8
22-9
22-10
12892-45000-245
12892-45000-250
12892-45000-255
12892-45000-260
SHIM, TAPPET (T:2.45)
SHIM, TAPPET (T:2.50)
SHIM, TAPPET (T:2.55)
SHIM, TAPPET (T:2.60)
4
4
4
4
8B
22-11 12892-45000-265 SHIM, TAPPET (T:2.65) 4
2 22-12 12892-45000-270 SHIM, TAPPET (T:2.70) 4
9 22-13 12892-45000-275 SHIM, TAPPET (T:2.75) 4
22-14 12892-45000-280 SHIM, TAPPET (T:2.80) 4
22-15 12892-45000-285 SHIM, TAPPET (T:2.85) 4
4 22-16 12892-45000-290 SHIM, TAPPET (T:2.90) 4
22-17 12892-45000-295 SHIM, TAPPET (T:2.95) 4
22
22-18 12892-45000-300 SHIM, TAPPET (T:3.00) 4
22-19 12892-45000-305 SHIM, TAPPET (T:3.05) 4
13 22-20 12892-45000-310 SHIM, TAPPET (T:3.10) 4
19
18
10 7

8
22 17

14
19 21
18
20

17
15
21
20

16

GS500K6 P02_01 1
CAM SHAFT/V ALVE GS500K P2
FIG.12 (C-4) CAM CHAIN
REF.NO PART.NO DESCRIPTION QTY REMARSK
1 12760-45040 CHAIN, CAM SHAFT DRIVE (120L) 1
2 12771-45052 GUIDE, CAM CHAIN NO.1 1
3 12782-49200 GUIDE, CAM CHAIN NO.2 1
4 02112-05103 SCREW 2
5 12791-45040 GUIDE, CAM CHAIN NO.3 1
6 01550-06123 BOLT 2
7
8
9
10
09168-06023
12810-01D00
12814-44101
12830-01D12
WASHER
TENSIONER, CAM CHAIN
CUSHION
ADJUSTER ASSY, TENSIONER
2
1
2
1
2
11 12838-38200-H17 .GASKET 1
12 12839-38200 PLUG 1
13 12837-24A10 GASKET, ADJUSTER 1
14 07130-06253 BOLT 2

GS500K6 P02_012
CAM CHAIN

GS500K P2
FIG.13 (C-5) CARBURETOR (GS500K3/UK3)
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 P19
2-1 13202-01DE0 CARBURETOR ASSY, RH 1 GS500K3 P2, P19, P24,P54
2-2 13202-01DG0 CARBURETOR ASSY, RH 1 GS500UK3 P19
3 13573-19E00 .SPRING 2
4 13418-33E00 .HOLDER 2

2 5
6
7
8
09280-05004
13481-13F00
13382-19E00
13387-13F00
.O RING (D:1.9, ID:4.8)
.SPRING
.WASHER
.E RING
2
2
2
2
9 13383-01DE0 .NEEDLE, JET (5DH41-4) 2
10 13502-07F00 .COVER, DIAPHRAGM 2
11-1 13501-29FA0 .VALVE, PISTON 2 GS500K3 P2, P19, P24,P54
11-2 13501-01DG0 .VALVE, PISTON 2 GS500UK3 P19
12 13507-17C01 .DIAPHRAGM 2
13 13247-02340 .SCREW, DRAIN 2
14 09492-17016 .JET, PILOT 2
15 13247-33E00 .SCREW 4
16 13258-44B00 .GASKET, FLOAT CHAMBER 2
17 13250-04F00 .FLOAT ASSY 2
18 13254-01010 .PIN, FLOAT 2
19 02112-04083 .SCREW 2
20 13602-05A10 .SCREW 2
21 13370-33E80 .VALVE ASSY, NEEDLE 2
22 09491-23012 .JET, MAIN (115) 2
23 09491-60010 .JET, MAIN (60) 2
24 13385-07F00 .HOLDER, JET 2
25 13246-43010 .O RING 2
26 09494-00949 .JET, NEEDLE (P-5M) 2
27 13279-33E00 .SCREW, PILOT (2 3/4) 2
28 13268-47070 .SPRING 2
29 13291-29900 .WASHER 2
30 13295-29900 .O RING 2
31 13267-13F00 .ADJUSTER RH 1
32 13271-33C00 .SPRING RH 1
33 13411-05300 .PLUNGER ASSY 2
34 13682-31210 .CAP 2
35 13418-44080 .HOLDER, GUIDE 2
36 13417-26D00 .SPRING 2
37 13278-47090 .O RING 2
38 13247-33E00 .SCREW 4
39 09493-33002 .JET, AIR (165) 2
40 13274-84000 .CAP 1

GS500K6 P02_013
CARBURETOR

GS500K P2
FIG.13 (C-6) CARBURETOR (GS500K3/UK3)
REF.NO PART.NO DESCRIPTION QTY REMARSK
41 09401-06101 .CLIP 1
42 13295-33010 .O RING 2
43 13268-96111 SPRING 1
44 13271-44B00 SPRING 1
45 13267-44B00 SCREW 1
46 13683-01DF0 HOSE 1
47
48
49
50
13413-01DE0
13602-04F00
13557-33E00
13683-01DE0
PLATE
SCREW
PACKING
HOSE
1
2
2
1
2
51 13683-01DB0 HOSE 1
52 13673-44B00 SEAL 2
53 13685-33EQ0 NIPPLE 1
54 13565-01DE0 BRACKET 1
55 02122-05103 SCREW 1
56 13685-01DB0 PIPE 2
REFERTO FIG. 14 (C-8) FOR GS500HK3/HUK3
REFERTO FIG. 14A (C-11) FOR MODEL K4/K5/K6

GS500K6 P02_013
CARBURETOR

GS500K P2
FIG.14 (C-8) CARBURETOR (GS500HK3/HUK3)
REF.NO PART.NO DESCRIPTION QTY REMARSK
1-1 13201-01DF1 CARBURETOR ASSY, LH 1 GS500HK3 P19
1-2 13201-01DK0 CARBURETOR ASSY, LH 1 GS500HUK3 P19
2-1 13202-01DF1 CARBURETOR ASSY, RH 1 GS500HK3 P19
2-2 13202-01DK0 CARBURETOR ASSY, RH 1 GS500HUK3 P19
3 13573-01DB0 .SPRING 2
4 13507-17C01 .DIAPHRAGM 2
5-1 13501-29FA0 .VALVE, PISTON 2 GS500HK3 P19
5-2 13501-01DK0 .VALVE, PISTON 2 GS500HUK3 P19
6 13418-33E00 .HOLDER 2
7 09280-05004 .O RING (D:1.9,ID:4.8) 2
8 13481-13F00 .SPRING 2
9 13382-44030 .WASHER 2

3 10
11
12-1
13394-17E60
13387-13F00
13383-01DF0
.E RING
.RING
.NEEDLE, JET (5DH41-3)
2
2
2 GS500HK3
12-2 13383-01DE0 .NEEDLE, JET (5DH41-3) 2 GS500HUK3
13 09494-00949 .JET, NEEDLE (P-5M) 2
14 13246-43010 .O RING 2
15 13385-07F00 .HOLDER, JET 2
16-1 09491-26016 .JET, MAIN (130) 2 GS500HK3
16-2 09491-27008 .JET, MAIN (135) 2 GS500HUK3
17 13295-29900 .O RING 2
18 13291-29900 .WASHER 2
19 13268-48700 .SPRING 2
20 13279-33E00 .ADJUSTER (2 5/8) 2
21 13370-33E80 .VALVE ASSY, NEEDLE 2
22 02112-04083 .SCREW 2
23 13602-05A10 .SCREW 2
24 13250-04F00 .FLOAT ASSY 2
25 13254-01010 .PIN, FLOAT 2
26 09492-17016 .JET, PILOT (17.5) 2
27 09491-60005 .JET, MAIN (60) 2
28 09493-34003 .JET, PILOT AIR (170) 2
29 13258-04F00 .GASKET 2
30 02112-04107 .SCREW 2
31 13247-02340 .PLUG, DRAIN 2
32-1 13502-01DB0 .COVER ASSY, DIAPHRAGM LH 1
32-2 13502-01DC0 .COVER ASSY, DIAPHRAGM RH 1
33 13411-05300 .PLUNGER ASSY 2
34 13417-26D00 .SPRING 2
35 13278-47090 .O RING 2
36 13418-44080 .HOLDER, GUIDE 2
37 13682-31210 .CAP 2
38 02112-05127 .SCREW 4
39 13274-84000 .CAP 1
40 09401-06101 .CLIP 1
GS500K6 P02_014
CARBURETOR

GS500K P2
FIG.14 (C-9) CARBURETOR (GS500HK3/HUK3)
REF.NO PART.NO DESCRIPTION QTY REMARSK
41 13267-13F00 .ADJUSTER 1
42 13271-33C00 .SPRING 1
43 09355-35755-600 HOSE 1 L:600 --> 175
44 13683-10F60 HOSE 2
45 13685-04F10 NIPPLE 1
46 95569-78040 CHECK VALVE ASSY 1
47 18115-70G10 SOLENOID ASSY 1
48 13683-01DB0 HOSE 1
49 13683-01DE0 HOSE 1
50 13683-46D10 3 WAY 1
51 13683-01DC1 HOSE 1
52 09401-16401 CLIP 1

3 53
54
55
09408-00033
13413-01DE0
02142-04083
CLIP
LEVER
SCREW
2
1
2
3
56 13557-33E00 PACKING 2
57 13550-13D60 SENSOR ASSY 1
58 13605-20C00 SCREW 2
59 09355-35755-600 HOSE 1 L:600 --> 165
60 09355-35755-600 HOSE 1 L:600 --> 40
61 09355-35755-600 HOSE 1 L:600 --> 35
62 09367-04007 NIPPLE 1
63 09355-35755-600 HOSE 1 L:600 --> 55
64 13685-01DC0 ROD 2
65 13685-01DB0 PIPE 2
66 13268-96111 SPRING 1
67 13271-44B00 SPRING 1
68 13267-44B00 SCREW 1
69 13673-44B00 SEAL 2
70 13685-33EQ0 NIPPLE 1
71 18780-32E00 FILTER, AIR CLEANER NO.2 1
72 09355-35755-600 HOSE, CONTROL AIR 1 L:600 --> 360
73 09355-50105-600 HOSE, FUEL COCK VACUUM 1 L:600 --> 480
74 13715-04F00 CHAMBER, VACUUM 1
75 D1557-06205 BOLT 1

GS500K6 P02_014
CARBURETOR

GS500K P2
FIG.14A FIG.14A (C-10) CARBURETOR (GS500HK3/HUK3)
REF.NO PART.NO DESCRIPTION QTY REMARSK
71
1-1 13201-01DN0 CARBURETOR ASSY, LH 1 GS500/F P2, P19, P24,P54
1-2 13201-01DP0 CARBURETOR ASSY, LH 1 GS500U/FU P19
51 74 2-1 13202-01DN0 CARBURETOR ASSY, RH 1 GS500/F P2, P19, P24,P54
77 38
76 75 2-2 13202-01DP0 CARBURETOR ASSY, RH 1 GS500U/FU P19
32
3 13573-19E00 .SPRING 2
73 4 13507-17C01 .DIAPHRAGM 2
59 5-1 13501-29FA0 .VALVE, PISTON 2 GS500/F P2, P19, P24,P54
44 3 5-2 13501-01DK0 .VALVE, PISTON 2 GS500U/FU P19
50 6 13418-44080 .HOLDER 2
7 09280-05004 .O RING (D:1.9, ID:4.8) 2
63
8 13481-13F00 .SPRING 2

3 45 62 43
48
49
6
7
8
9
10
11
9
10
11
12
13382-19E00
13394-17E60
13387-13F00
13383-01DN0
.WASHER
.E RING
.RING
.NEEDLE, JET (5DH57-3)
2
2
2
2
46 13 13341-01DN0 .JET, NEEDLE (P-5M) 2
44 64 4 12 14 13246-43010 .O RING 2
15 13385-07F00 .HOLDER, JET 2
69 70 5 16-1 09491-26016 .JET, MAIN (130) 2 GS500/F P2, P19, P24,P54
16-2 09491-27008 .JET, MAIN (135) 2 GS500U/FU P19
58 69
65 17 13295-29900 .O RING 2
18 13291-29900 .WASHER 2
60
19 13268-48700 .SPRING 2
68 20 13279-01DN0 .ADJUSTER (2 5/8) 2
72 57 67 21 13370-04F00 .VALVE ASSY, NEEDLE 2
62 2
22 02112-04083 .SCREW 2
53 42 66 33 28
34 23 13602-05A10 .SCREW 2
35 24 13250-04F00 .FLOAT ASSY 2
61
39 25 13254-01010 .PIN, FLOAT 2
52 41 21
40 23 26 09492-17016 .JET, PILOT (17.5) 2
27 09491-60010 .JET, MAIN (60) 2
25 28 09493-34003 .JET, PILOT AIR (170) 2
17 22 36 37
18 29 13258-04F00 .GASKET 2
13 24
19 14 30 02112-04107 .SCREW 2
15 31 13247-13A00 .PLUG, DRAIN 2
20 26
16 32-1 13502-01DB0 .COVER ASSY, DIAPHRAGM LH 1
47 29 27 32-2 13502-01DC0 .COVER ASSY, DIAPHRAGM RH 1
33 13411-05300 .PLUNGER ASSY 2
55 56 54 34 13417-26D00 .SPRING 2
35 13278-47090 .O RING 2
36 13418-44080 .HOLDER, GUIDE 2
30 37 13682-31210 .CAP 2
31 38 02112-05127 .SCREW 4
1 39 13274-84000 .CAP 1
40 09401-06101 .CLIP 1

GS500K6 P02_014A
CARBURET OR

GS500K P2
FIG.14A FIG.14A (C-11) CARBURETOR (GS500HK3/HUK3)
REF.NO PART.NO DESCRIPTION QTY REMARSK
71
41 13267-13F00 .ADJUSTER 1
42 13271-33C00 .SPRING 1
51 74 43 09355-35755-600 HOSE 1 L:600 --> 175
77 38
76 75 44 09355-35755-600 HOSE 2 L:600 --> 60
32
45 13685-04F10 NIPPLE 1
46 95569-01DN0 CHECK VALVE ASSY 1
73 59 47 18115-70G10 SOLENOID ASSY 1
48 13683-01DB0 HOSE 1
44 3
49 13683-01DN0 HOSE 1
50
50 13683-01DP0 3 WAY 1
63 51 13683-01DC1 HOSE 1
52 09401-16401 CLIP 1

3 45 62 43
48
49
6
7
8
9
10
11
53
54
55
09408-00200
13413-01DE0
13602-04F00
CLIP
LEVER
SCREW
2
1
2
3
46 56 13557-33E00 PACKING 2
44 64 4 12 57 13550-13D60 SENSOR ASSY 1
58 13605-20C00 SCREW 2
69 70 5 59 09355-35755-600 HOSE 1 L:600 --> 165
60 09355-35755-600 HOSE 1 L:600 --> 40
58 69 61 09355-35755-600 HOSE 1 L:600 --> 35
65
62 09367-04007 NIPPLE 1
60 63 09355-35755-600 HOSE 1 L:600 --> 55
68 64 13685-01DC0 ROD 2
72 57 67 65 13685-01DB0 PIPE 2
62 2
66 13268-96111 SPRING 1
53 42 66 33 28 67 13271-44B00 SPRING 1
34
35 68 13267-44B00 SCREW 1
61 69 13673-44B00 SEAL 2
39
52 41 21 70 13685-33EQ0 NIPPLE 1
40 23
71 18780-32E00 FILTER, AIR CLEANER NO.2 1
25 72 09355-35755-600 HOSE, CONTROL AIR 1 L:600 --> 360
17 22 36 37 73-1 09355-50105-600 HOSE, FUEL COCK VACUUM NO. 1 1 L:600 --> 100 P2, P19, P54
18 13 24 73-2 09355-50105-600 HOSE, FUEL COCK VACUUM NO. 1 1 L:600 --> 480 P24
19 14
74 09355-50105-600 HOSE, FUEL COCK VACUUM NO. 2 1 L:600 --> 380 P2, P19, P54
20 15 26 75 09367-06002 JOINT 1 P2, P19, P54
16
27 76 13715-04F00 CHAMBER, VACUUM 1
47 29
77 D1557-06205 BOLT 1
55 56 54

30
31

GS500K6 P02_014A
CARBURETOR
GS500K P2
FIG.15 FIG.15 (C-14) AIR CLEANER
REF.NO PART.NO DESCRIPTION QTY REMARSK
1-1 13700-01D71 CLEANER ASSY, AIR 1 GS500K3 P2, P19, P24,P54
1-1 GS500UK3 P19
1-2 13700-01D61 CLEANER ASSY, AIR 1 GS500HK3 P19
1-2 GS500HUK3 P19
1-2 GS500K4/K5/K6 P24
1-2 GS500FK4/K5/K6 P24
1-3 13700-01D90 CLEANER ASSY, AIR 1 GS500K4/K5/K6 P2, P19, P54
1-3 GS500UK4/K5/K6 P19
1-3 GS500FK4/K5/K6 P2, P19, P54
1-3 GS500FUK4/K5/K6 P19
2-1 13780-01D51 .FILTER ASSY 1 GS500K3 P2, P19, P24,P54
2-1 GS500UK3 P19
2-2 13780-01D00 .FILTER ASSY 1 GS500HK3 P19
2-2 GS500HUK3 P19
2-2 MODEL K4/K5/K6
3 02142-05087 .SCREW 4
4 13881-01D60 .TUBE, OUTLET 2

4 5
6
7
8
09402-64203
09352-11153-600
09401-14301
13870-21458
.CLAMP
.TUBE, BREATHER
.CLIP
.TUBE, DRAIN
2
1
2
1
L:600 --> 200

9 09401-13409 .CLIP 1
10 09404-06432 .CLAMP 2
11 13859-41B10 .PLUG 1 MODEL K3
12 11 MODEL K4/K5/K6 P24
11 13
12 09401-14301 .CLIP 1 MODEL K3
12 MODEL K4/K5/K6 P24
13 D1557-06165 BOLT 2
14 D8321-51065 WASHER 2
15 09404-06433 CLAMP 1

GS500K6 P02_015
AIR CLEANER
GS500K P2
FIG.15A FIG.15A (C-16) 2ND AIR (MODEL K4/K5/R (MODEL K4/K5/K6 P2, P19, P54)
REF.NO PART.NO DESCRIPTION QTY REMARSK
1 18420-01D01 PIPE, 2ND AIR RH 1
2 18430-01D01 PIPE, 2ND AIR LH 1
3 18441-12D10 GASKET 2
4 18445-01D20 HOSE , 2ND AIR REED VALVE RH 1
5 18446-01D20 HOSE , 2ND AIR REED VALVE LH 1
8 6 18450-10F03 VALVE ASSY, 2ND AIR REED 1
12
7 18610-01D20-E0Z BRACKET, 2ND AIR VALVE 1
8 18711-01D20 HOSE, 2ND AIR CLEANER 2
9 11 9 09359-40701-600 HOSE 1 L:600 --> 270
14 10 09401-13409 CLIP 4
11 11 09401-15101 CLIP 2
12 09404-06429 CLAMP 1
13 01421-06163 BOLT 4
15 14 D1557-06125 BOLT 2
7 15 D7107-06165 BOLT 2
16 D8320-10065 NUT 4
5
6 1 16600-01D01 COOLER ASSY, OIL 1
10

4
10 2 16621-0BE00-E0N BRACKET, OIL COOLER 1
3 16628C27A00J000 CUSHION 1
4 D1507-06205 BOLT 2
4A D8322-91065 WASHER 2
5 09180C06310J000 SPACER (6.5X10X10) 2
6 09320-10501 CUSHION 2
7 16460-01D00 HOSE, OIL COOLER RH 1
8 16470-01D00 HOSE, OIL COOLER LH 1
4 9 09168-14015 GASKET (16X22X2) 4
10 10 09280-12005 O RING (D:2.4, ID:11.8) 2
10
11 09360-14012 BOLT (16X32) 2
12 D7107-06165 BOLT 4
13 16480-01D00-E0N CLAMP, OIL HOSE RH 1
14 D1557-06125 BOLT 4
15 16492-01D00-E0N GUIDE, OIL HOSE 2
16 16490-01D00-E0N CLAMP, OIL HOSE LH 1

1
13

3
2
16

GS500K6 P02_015A
2ND AIR
GS500K P2
FIG.15B FIG.15B (C-16) OIL COOLER (GS500FK4/K5/K6/FUK4/K5/K6)
REF.NO PART.NO DESCRIPTION QTY REMARSK
1 16600-01D01 COOLER ASSY, OIL 1
2 16621-0BE00-E0N BRACKET, OIL COOLER 1
3 16628C27A00J000 CUSHION 1
4 D1507-06205 BOLT 2
4A
4A D8322-91065 WASHER 2
6
5 09180C06310J000 SPACER (6.5X10X10) 2
4 5 6 09320-10501 CUSHION 2
7 16460-01D00 HOSE, OIL COOLER RH 1
8 16470-01D00 HOSE, OIL COOLER LH 1
9 09168-14015 GASKET (16X22X2) 4
10 09280-12005 O RING (D:2.4, ID:11.8) 2
11 09360-14012 BOLT (16X32) 2
12 D7107-06165 BOLT 4
13 16480-01D00-E0N CLAMP, OIL HOSE RH 1
14 D1557-06125 BOLT 4
10 15 16492-01D00-E0N GUIDE, OIL HOSE 2
16 16490-01D00-E0N CLAMP, OIL HOSE LH 1

4 14
3

2
1

10

7
12

13
8
16

9 15 14

11

GS500K6 P02_015B
OIL COOLER GS500K P2
FIG.16 FIG.16 (D-2) MUFFLER
REF.NO PART.NO DESCRIPTION QTY REMARSK
1 14181-01D00 GASKET, EXHAUST PIPE 2
2 D7109-08405 BOLT 4
2A D8322-01085 WASHER 4
3-1 14301-01DB1-E02 MUFFLER ASSY 1 GS500K3 P2, P19, P24,P54
3-1 GS500UK3 P19
3-2 14301-01DA1-E02 MUFFLER ASSY 1 GS500HK3 P19
3-2 GS500HUK3 P19
3-3 14301-01DE0-E02 MUFFLER ASSY 1 GS500K4/K5/K6 P2, P19, P54
3-3 GS500UK4/K5/K6 P19
3-3 GS500FK4/K5/K6 P2, P19, P54
3-3 GS500FUK4/K5/K6 P19
3-4 14301-01DF0-E02 MUFFLER ASSY 1 GS500K4/K5/K6 P24
3-4 GS500FK4/K5/K6 P24
4-1 09103-08256 BOLT (8X40) 1 MODEL K3
4-2 09103-08392 BOLT 1 MODEL K4/K5/K6
5 09160-08136 WASHER (8.5X28X1.6) 1
6 09180-08152 SPACER (8.6X12X20.1) 1

4
7 09320-12048 CUSHION 1
8 08316-10083 NUT 1

GS500K6 P02_016
MUFFLER GS500K P2
FIG.17 FIG.17 (D-3) CLUTCH
REF.NO PART.NO DESCRIPTION QTY REMARSK
1 21200-44102 GEAR, PRIMARY DRIVEN (NT:76) 1
2 09181-25223 WASHER (25X38X1.0) 1
3 21411-44101 HUB, SLEEVE 1
4 09140-20001 NUT 1
5 09167-20006 WASHER (20.5X38X0.8) 1
6 09160-20015 WASHER (20X44X3) 1
7 21441-37400 PLATE, DRIVE 7
8 21451-28C31 PLATE, DRIVEN 6
9 21462-14301 DISK, PRESSURE 1
10 09440-20019 SPRING 6
11 09100-06145 BOLT (6X40) 6
12 21414-01D00 SPACER 6
13 23121-44100 PIECE, PUSH 1
14 09263-15003 BEARING (15X28X2) 1
15 09160-15045 WASHER (15.5X28X1) 1
16 16321-01D10 GEAR, OIL PUMP DRIVE (NT:39) 1
17 09261-06002 PIN 1

4
18 08331-31383 CIRCLIP 1
19 23110-44111 ROD, PUSH RH 1
20 23111-24A01 ROD, PUSH LH 1
21 09285-06011 OIL SEAL (6X34X10) 1
22 23117-44102 HOLDER, OIL SEAL 1
23 01500-06123 BOLT 2
24 23200-01D00 SCREW ASSY, RELEASE 1
25 09134-06010 .SCREW 1
26 08310-00067 .NUT 1
27 03141-06163 SCREW 2
28 09443-08001 SPRING 1

27

28

24

25
26

GS500K6 P02_017
CLUTCH GS500K P2
FIG.18 FIG.18 (D-4) TRANSMISSION
REF.NO PART.NO DESCRIPTION QTY REMARSK
1 24121-01D01 COUNTERSHAFT (NT:13) 1
2 24221-44001 GEAR, 2ND DRIVE (NT:18) 1
3 24231-20F03 GEAR, 3/4 DRIVE (NT:21/24) 1
4 24251-20F02 GEAR, 5TH DRIVE (NT:26) 1
5 24252-19F00 BUSH 1
6 24260-01D01 GEAR, 6TH DRIVE (NT:27) 1
7 09181-25167 WASHER (25X34X1.0) 1
8 09380-25010 CIRCLIP 1
9 09262-25051 BEARING, RH (25X62X17) 1
10 09390-62012 C RING 1
11 09263-20025 BEARING, LH (20X34X20) 1
12 04221-07129 PIN 1
13 24741-44102 HOLDER, BEARING 1
14 09126-06014 SCREW (6X16) 3
15 24131-01D00 DRIVESHAFT 1
16 24310-44001 GEAR, 1ST DRIVEN (NT:32) 1
17 09181-20251 WASHER (20X34X1) 1

4
18 24321-20F00 GEAR, 2ND DRIVEN (NT:32) 1
19 24322-19F00 BUSH 1
20 09380-25010 CIRCLIP 1
21 24331-44003 GEAR, 3RD DRIVEN (NT:29) 1
22 09167-25012 WASHER (25.1X31X1.0) 1
23 09167-25013 LOCK WASHER 1
24 09380-25010 CIRCLIP 1
25 24341-44003 GEAR, 4TH DRIVEN (NT:27) 1
26 09167-25012 WASHER (25.1X31X1.0) 1
27 09169-25001 LOCK WASHER 1
28 09380-25010 CIRCLIP 1
29 24351-44001 GEAR, 5TH DRIVEN (NT:25) 1
30 24361-44010 GEAR, 6TH DRIVEN (NT:23) 1
31 09390-62012 C RING 1
32 09283-32015 OIL SEAL (32X62X7) 1
40 33 09263-20027 BEARING, RH (20X34X17) 1
34 09262-25065 BEARING, LH (25X62X17) 1
35 09282-32002 OIL SEAL 1
36 27511-01D01 SPROCKET, ENGINE (NT:16) 1
37 27531-01D10 SPACER (L:32.7) 1
38 08331-31256 CIRCLIP 1
39 27600C01C10J110 CHAIN, DRIVE (DID520VM,110LE) 1
40 27620C01C10J000 .JOINT SET, CHAIN 1

GS500K6 P02_018
TRANSMISSION GS500K P2
FIG.19 FIG.19 (D-5) GEAR-SHIFTING
REF.NO PART.NO DESCRIPTION QTY REMARSK
1 25211-44001 FORK, GEAR SHIFTING NO.1 1
2 25221-44001 FORK, GEAR SHIFTING NO.2 1
3 25231-44000 FORK, GEAR SHIFTING NO.3 1
4 25411-18900 SHAFT, GEAR SHIFTING FORK 1
5 09125-06115 SCREW (6X8) 1
6 08211-06141 WASHER 1
7 25311-01D00 CAM, GEAR SHIFTING 1
8 09261-04001 PIN 5
9 09209-04013 PIN 1
10 09181-26001 WASHER (26X32.5X0.3) 1
11 25322-44000 HOLDER, DRIVE PIN 1
12 02112-06163 SCREW 1
13 25341-33300 GUIDE, CAM 1
14 09111-06054 BOLT (6X14.6) 1
15 09103-06240 BOLT 1
16 09263-40001 BEARING (40X47X12) 1
30
31 17 25350-44000 STOPPER, CAM NO.1 1

4
18 09443-09007 SPRING 1
19 25351-30010 STOPPER, CAM NO.2 1
20 25354-30000 HOLDER, SPRING 1
21 09440-06020 SPRING 1
22 09168-14002 GASKET (13.8X18.8X0.4) 1
23 25510-44100 SHAFT, GEAR SHIFTING 1
24 09448-13008 SPRING 1
25 08332-11073 E RING 1
32 26 09444-26013 SPRING 1
27 09180-12068 SPACER (12X20X15.3) 1
28 25671-01011 STOPPER 1
29 09285-12002 OIL SEAL (12X22X9) 1
30 25600-01D02 LEVER ASSY, GEAR SHIFTING 1
31 25652-20C00 .RUBBER 1
32 D1507-06205 BOLT 1
33 37720-47D00 BASE ASSY, GEAR SHIFT 1 GS500K3 P2, P19, P24,P54
33 GS500UK3 P19
34 37720-01D00 BASE ASSY, GEAR SHIFT 1 GS500HK3 P19
34 GS500HUK3 P19
34 MODEL K4/K5/K6
35 09280-26007 O RING (D:2.4, ID:25.7) 1
36 02112-75203 SCREW 2
37 09209-05011 CONTACT 1
38 09440-04010 SPRING 1

GS500K6 P02_019
GEAR SHIFTING
GS500K P2
FIG.20 FIG.20 (E-2) STARTING MOTOR
REF.NO PART.NO DESCRIPTION QTY REMARSK
1 31100-20C00 MOTOR ASSY, STARTING 1
2 31310-27A01-H17 .ARMATURE 1
3 31153-43400 .OIL SEAL 1
4 31170-43400 .SHIM SET 1
5 31264-44110 .O RING 2
6 31132-27A01 .BRUSH HOLDER ASSY 1
7 31135-65010 ..SPRING 2
8 31130-38300 .BRUSH 1
9 31172-38300 .BUSHING (A) 1
10 31171-38300 .BUSHING (B) 1
11 31143-38300 .O RING 1
12 31281-88C00 .BOLT 2
13 31156-38300 .O RING 2
14 09280-24003 .O RING (D:3.0, ID:24.5) 1
15 09128-06024 BOLT (6X25) 1
16 08361-35068 NUT 1

GS500K6 P02_021
GENERATOR
GS500K P2
FIG.21 FIG.21 (E-3) GENERATOR
REF.NO PART.NO DESCRIPTION QTY REMARSK
1 31401-01D10 STATOR 1
2 31402-01D00 ROTOR 1
3 02112-35303 SCREW 3
4 09103-12004 BOLT (12X60) 1
5 31497-45000 CLAMP 2
6 02112-05083 SCREW 2
7 31498-45000 CLAMP 1
8 02112-06103 SCREW 1
9 09404-06429 CLAMP (L:45) 1

GS500K6 P02_021
GENERATOR
GS500K P2
FIG.22 FIG.22 (E-4) SIGNALGENERATOR
REF.NO PART.NO DESCRIPTION QTY REMARSK
1-1 32900-01D40 IGNITOR 1 GS500K3 P2, P19, P24,P54
1-1 GS500UK3 P19
1-2 32900-01D50 IGNITOR 1 GS500HK3 P19
1-2 GS500HUK3 P19
2 32900-01DA0 IGNITOR 1 MODEL K4/K5/K6
3 33110-01D00 SIGNAL GENERATOR ASSY 1
4 33120-01D20 CLAMP (L:45) 1
5 09103-06064 BOLT (6X60) 1
6 02112-05103 SCREW 2
7 09404-06429 CLAMP (L:45) 2
1

GS500K6 P02_022
SIGNAL GENERATOR
GS500K P2