Which year GS500E is the best?

[Kokopellian]

I have a 93' GS, and my friend has a 96'.  I also have seen an 89' and a rode a 98' recently.  I've noticed that they are all essentially unchanged in style and performance.  My questions is are all the GS500s the same?  If not, what makes one different or better than the previous model years?

[octane]

They're all pretty much the same. Only main difference in the entire production run is the clip-on bars of the '89. They're all basically the same though.

[danci1973]

You'll probably find more differencies at different markets than years...

Europe, for example, got adjustable spring preload for front...

 D.

[Casimir]

Also, at '01 the tank got bigger, the seat changed and the carbs changed a bit. There was no US '03 and the '04s have a fairing (optional?) and oil cooler.

They are all the same technology level and suffer from the same problems. I like the tank/seat on my '01, but I haven't ridden any other year. The only disadvantages I've seen with it are that I can't use the aftermarket seats that are available for earlier years and I needed and the rejet kits are different.

[The Buddha]

OK well most of this is based on anecdotal evidence and total conjecture, so here goes...
In 96+ they made internal mods to the cases. And they were cut tighter, stronger and more oil pressure tight. They also equiped the 96+'s with a higher pressure oil pump/taller oil drive gear. Hence these bikes made more oil pressure and held oil better. However the flip side is that they made more heat, and if the owners were not checking oil/topping it/changing it these bikes seized up. I have seen far more 96+'s seize up than the earlier ones.The 89-96's had better front brakes... differential bore calipers. So that was a little better. Yes the 89's had clip on's... but I am sorta ambivalent about that now. They look good, but if they break... I am screwed, they also have fitment problems with grips etc. The 91 with my design bar feels better when at speed. Other than that... 89's had issues... The alloy linkage, the no hole for top shock bolt, the removable sub frame bolts being in the wrong place making it harder to take the motor out etc etc are just plain frustrating... So effectively 96+'s are better if you dont let it run low on oil. They did use oil at a lower rate than a correspondingly treated 96- though.
Cool.
Srinath.

[cozy]

OK well most of this is based on anecdotal evidence and total conjecture, so here goes...

Cool.
Srinath.

I just want to say how incredible it is that you know all that.

[pantablo]

except for the internal differences (and the 89 bars) the 89-00 run was *essentially* unchanged. 01+ models saw new bodywork, larger capacity tank, cushier seat, bigger carbs, but rest is exactly same.

[TR]

Perhaps the best model is that with the nicest colour... he he...

[bucho]

1989 :mrgreen:

[Pam G]

Perhaps the best model is that with the nicest colour... he he...

Yep, chose your favorite color & then you'll the "best GS".  I like my '99 yellow/black.

[KevinC]

OK well most of this is based on anecdotal evidence and total conjecture, so here goes...
In 96+ they made internal mods to the cases. And they were cut tighter, stronger and more oil pressure tight. They also equiped the 96+'s with a higher pressure oil pump/taller oil drive gear. Hence these bikes made more oil pressure and held oil better.Srinath.

Hmmm. The oil pump gearing definitely has not changed, and the oil pump still has the same part number for all years.

For that matter, so do the cases and all the bits that fit in the cases. Either any changes made in '96 are backward compatible with all GS's, or there wasn't any changes.

[The Buddha]

They are all backward compatible. I think oil pump is the same, but tighter tolerances in 96+, and geared taller.
Cool.
Srinath.

[KevinC]

As I said, the oil pump gearing is the same in all years. It is driven off the primary drive gear, which is the same for all years, and the gear centres are the same.

From my understanding of gear pitch diameters, it is impossible to change the gear ratio with the centres remaining the same, without changing both gears. Changing the primary gear would be a problem with the mesh off the crankshaft.

I'm also not sure what engine clearances you could change without tightening up the tolerance ranges on the mating parts. The crank, conrod and counterbalancer shaft bearing clearances have not changed up to the 2001 models at least. Since any other new parts have to work with the presumably wider tolerance parts in the older engines already out there to remain backwards compatible, the possible changes would be????

The oil pump is only sold as a unit, so they could have tightend up the clearances in it, to generate more oil pressure. But that would have been a big issue if the older engines were actually "leaky" since they would have to work with the new, higher pressure pump.

[The Buddha]

The oil pump made a little more pressure on a 96+ bike, and the journals etc were made to tighter tolerances. The whole engine wasn't leaky, just the journals and pressurised lube areas were a little more tighter on a 96+. They held up better to oil pressure, or the higher oil pressure made them last longer??? Actually I should quit this topic and give up.... cos I have yet to open a motor. Saw someone open one, and these were just what he said. Now on the cases the journals and other bearing surfaces were the same, but the rest of the case, areas around the journal were thicker and stronger... if that makes sense.. If not... please enlighten me...
Cool.
Srinath.

[KevinC]

The journal clearances are exactly the same for all years up to 2001 at least. The oil pressure test levels are exactly the same too. My Suzuki factory manual doesn't go past there.

I think the guy telling you the 96's were different is full of it.

[Kerry]

Don't forget that the front sprocket was changed around '93.  Model years after that come with a "shoulder" on the sprocket that acts as a spacer or something.

Srinath mentioned this, but the 1996-2000 models have a different front brake caliper.  (Compare the 1989-1995 caliper to the 1996+ caliper to see just how different they are.

Oh, and I've forgotten again.  Are the two pre-2001 styles of front caliper interchangeable as far as bolt pattern, etc?

I thought someone said that the front caliper changed again in 2001.  Is that right?

EDIT: Changed link from sisna.com to bbburma.net

[Blueknyt]

wait, taller gear, are you refering to the Inside gears that displace the oil? i cant see them being taller, but cut deeper maybe,  More volume between the teeth of a displacment type pump would give more volume through the pump body. if its just a pressure change,  with pump being same, aswell as bearing size and clearances, i would have to look at the pressure relief valve, preloading a sprung check valve alittle tighter is cheaper then redoing the pump.   let us meditate on this.   OOOHHHHHMMMMM!   very good class.

[The Buddha]

Don't forget that the front sprocket was changed around '93.  Model years after that come with a "shoulder" on the sprocket that acts as a spacer or something.

Srinath mentioned this, but the 1996-2000 models have a different front brake caliper.  (Compare the 1989-1995 caliper to the 1996+ caliper to see just how different they are.

Oh, and I've forgotten again.  Are the two pre-2001 styles of front caliper interchangeable as far as bolt pattern, etc?

I thought someone said that the front caliper changed again in 2001.  Is that right?

Yea whole calipers will swap over, now I dont think pads will though .. But never seen the 96+ pads so no real definete thing.
Cool.
Srinath.

[Kerry]

Good to know about the full-caliper swap.  Srinath, if you want to see the difference in the pads, check out the links I included above.

No way will the pads swap over.