MOTORCYCLE DIVISION

4-STROKE BULLETIN GS/GSX/GSX-R NO. 139 Revised DATE: 3/21/2006

SUBJECT:

GS500F ENGINE KNOCK AT IDLE

AFFECTED UNITS: GS500FK4/K5 - ENGINE NUMBER M504-125865 & EARLIER REFERENCE: GS500 SERVICE MANUAL (PN 99500-34094-03E)

NOTICE: This bulletin is a revision to the original Service Bulletin GS/GSX/GSX-R NO. 139 dated 5/2/2005. Please place a copy of this bulletin with your dealerships Service Bulletin binder and GS500 Service Manual and discard the original bulletins. Some GS500FK4/K5 motorcycles may exhibit a mild but annoying knocking noise from the cylinder head area. This sound will be heard only at idle or just off idle. Solution This knocking noise may be caused by the camshafts walking side to side during operation due to excessive end play. The walking movement will not cause damage. Note: Test the source of the noise for camshaft walking by carefully leaning the motorcycle over to the left (toward the sidestand) while the engine is running and continue to listen for the noise. The noise will quiet if the camshafts are loaded toward the left hand side. Should you receive a complaint of the above described symptoms, follow the procedure in this Service Bulletin. Parts Information 3 1 4

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Procedure 1. Remove the cylinder head cover, cam chain tension adjuster and camshafts (refer to Service Manual beginning on page 3-10). Remove the sprockets and the 1.0 mm thick thrust washers from the original camshafts. These parts will be reused with the new camshafts. 2. Replace the exhaust tappets using the original adjustment shims. 3. Assemble each new replacement camshaft with one of the original 1.0 mm thick washers at the left side and the two 0.7 mm thick washers mounted on each side of the wave washer on the right side. See Figure 1. 4. Install the cam sprocket with new washers and time the camshafts (refer to Service Manual, beginning on page 3-56). In the timing position, the exhaust camshaft lobe presses on the #1 cylinder exhaust valve lifter. In this position, the bearing surface can easily be damaged by the additional washers if care is not taken when the camshaft journal holders are installed. To prevent damage, rotate the crankshaft 90 in the reverse direction while ensuring that the chain does not become detached from the sprockets. 5. Install the camshaft journal holders and tighten the journal holder bolts to the specified torque. Install the cam chain tension adjuster (refer to Service Manual beginning on page 3-59), confirm that the cam timing is correct and adjust tappet clearance if required (refer to Service Manual beginning on page 2-5). FIGURE 1
Left side
Right side

Wave washer

Thrust washer (t=1.0mm)

Thrust washers

AFFECTED DEPARTMENTS: The following departments in your dealership should be notified of this information: Management Service Warranty Sales Parts Accessories

American Suzuki Motor Corporation Technical Service Department Motorcycle / ATV - 2/2 -