Dear guys,
since this is my very 1st message here, a quick presentation: my name's Alessandro and I live near Milan, Italy. I'm 33 and I ride 2 wheels (with engine) from when 20 years
Currently I own a fantastic TL1000S with about 65000km (more than 43000 miles) which runs fine as a Swiss clock, plus a heavily tuned Cagiva Mito 125 for some small circuit runs, and recently I've taken a GS500F K5 in order to introduce my girlfriend to this world (she made me to promise to teach her to ride a motorcycle )

Now let's go straight to the point: this GS, despite of its relatively low mileage (about 20k miles), and despite the fact that the original owner was a very slow driver, had a big problem in the engine. In fact I bought it for few money (500 US$ at current change) because its destination was the demolition.
Externally it's in VERY good condition, but most probably it broke a connecting rod, or it has some similar problem.
The previous owner was a very poor engine knower and, believing his mechanic, he drove with a beginning of excessive clearance on a rod until, when he was stuck at a Milan traffic light, he heared a _bad_ noise and the engine stopped to run...
I should have the knowledge and all the tools to fix it (if the expense is not too high), plus both Suzuki and Haynes manuals. But they arrive only at 1997 (Haynes) and at 1999 (Suzuki)...

In order to fix it in the correct way, I'd like (and I'm asking here) if it's possible to have the 3 Haynes manual pages that represent the dimensions, clearances and so on of the 2005 GS500(F) model. I paste here a little example of the pages I'm referring to.

Many many thanks in advance!
And when I'll open the engine, I'll try to document (with photos too) all my job the best I can

This is the mentioned example page:

Apparently you can download the shop manuals:
http://gstwins.com/gsboard/index.php?topic=45475.0

Quote from: beRto on December 11, 2008, 08:55:52 AM
Apparently you can download the shop manuals:
http://gstwins.com/gsboard/index.php?topic=45475.0

Thanks Berto, but these are the ones that I just have 

GenTLe

I don't have my gs or the manual i had for it anymore but i am nearly 100% sure that the engine internals, aside from the carbs, have not changed one but since the original gs500.  They did start putting wavy washers in around 05-06 to take up the some of the sideplay in the cams.  Other than that no changes.
edit: and the addition of an oil cooler due to fairings but this may not apply to unfaired models that were not available state side.

Sorry i can't help more ...

I have the manual, I will scan the pages you need tonight and I can send them to you in pdf format.

Well, that's great!

Thanks guys!!!!

I have the k4 ('04) service supplement as a pdf.  I don't think there are any changes from 04-05.  PM me and I'll try to email it to you.  It's about 1.5 MB so it should go over ok.

Hi GenTLe,

Well, I cannot say much more than what the others have said already.
Yes, you'll probably be fine with the Haynes manual AFAIK since the GS 500 engine internals have been pretty much the same since the beginning of time... 

But, bloody hell, how come a new-ish engine went bust in such a short time/mileage? (just out of curiosity) Seems odd to me. Bad maintenance maybe?

Good luck with your repair job.
Oh, and BTW, looks like we're fellow countrymen.
If you need contacting me in our language, PM.

(But given your mechanical knowledge, I'll be more likely to ask YOU for help rather than the opposite )

Quote from: simon79 on December 11, 2008, 02:56:59 PM
Hi GenTLe,

Well, I cannot say much more than what the others have said already.
Yes, you'll probably be fine with the Haynes manual AFAIK since the GS 500 engine internals have been pretty much the same since the beginning of time... 

I think so too, it's directly derived from models of eighties but you know, better more informations, then less

QuoteBut, bloody hell, how come a new-ish engine went bust in such a short time/mileage? (just out of curiosity) Seems odd to me. Bad maintenance maybe?

Well, I'm not completely sure about the damage: I still have to open it: my girlfriend doesn't know anything about this present, but she asked me, in case I've something technical to do in my lab, to do it together (she's a sailing ship captain too and she loves to do manual stuff).
So I'll wait for her (she's from Poland and will come on Dec-31) to open it. Also because I'm still waiting a couple of tools (a Mitutoyo micrometer and a couple of Plastigauge boxes) from UK.

QuoteOh, and BTW, looks like we're fellow countrymen.

Ah! Vivi in USA o fai l'infiltrato come me? (for the American speakers: I asked him if he lives in USA or he's an "infiltrated" like me)

Ciao

Wow, a skilled couple...so nice and so rare to see!
Good luck with the repair works, I hope that the damage's not too serious.

Oh yes, I'm an "infiltrated agent"...I live in the Alessandria province.

Bye!

Sorry Gentle, I got sucked into the football game last night. I will make sure I get this to you when I get home from work today.

GenTLe~
Email has been sent. Came from the Haynes 86 to 06 manual. Manual part number is 3238. Hope it helps!!