You guys here have been a great help to me in the past and I have learned a great deal by just doing all the mechanical work in the past. Although my 2005 GS only has 8,000 milkes (I bought it at 2,000); I have done a clutch replacement and a total engine rebuild including replacing a connecting rod and bearings. The reason I had to do that was that one clutch plate shattered and left metal fragments floating in my engine. I have everything cleaned and put back together, and its time to do a valve adjustment. I did everything else without a manual because they do not make a clymers for my bike yet and can't justify paying $90 for a factory manual for something i might use once or twice.
I looked at the infamous valve adjustment video by Kerry Burton and it is pretty much self explanitory. I will order the shims that I need and shouldnt have any problems. My only question is: Are the clearances listed in the Valve kit also true for a 2005 model, or is it the same for all years of this engine? I know it is a silly question but wanted to see if there was a difference in the engine between the models?
(http://www.modthetv.com/Images/GS500_Valve_Shim_Selection_Chart.gif)
If anyone is intersted in what the shattered clutch plate did to my engine, here is some of the evidance.
(http://farm1.static.flickr.com/152/421822831_64e8c001d3.jpg)
Valve clearance specs are the same .03-.08 mm or .001-.003" for all years. It's been my experience with 80k miles on the 97 GS and 59k miles so far on the 02 GS that valve shims for intake valves rarely if ever change. Exhaust valves tend to recede into the seats and require frequent changes to smaller shims after 40k miles.
The standard replacement shims come in 215 to 310 mm sizes, the 315 in Kerry's chart is a typo. I now tend to set exhaust valves to .004 or .005" when changing shims, if your redlining it frequently keep them tighter. My valve check record:
http://img.photobucket.com/albums/v443/jcp8832/valveclearances.jpg
cool, thanks