GS500 Starting Problem and Generator Rotor Repair

Sometimes the generator rotor comes loose. The starter gear is attached to it. When that happens, your bike makes a whirring sound and won't turn over. Here's how to fix it with simple tools and a little time.
CORRECTION: The bolt to remove it is M14 x 1.5. I read the stamping in my box of rotor removal parts incorrectly. It is listed correctly in the Haynes manual, chapter 8. I was correct on the 36mm spacer.

[@markjohnson9495]

THANK YOU! You are apparently the only person on the internet that knows how to remove a GS rotor. All the books cop out and say "bring it to the dealer because it was really too hard for us." You have to take it off to overhaul the starter clutch. So 36mm spacer bolt and a big M19x1.00 bolt. Easy. Got it. Saved me a lot of time on my GS450T starter clutch repair. Thanks again!!!

[@Dizzledan110]

Rest in peace dude, you taught me so much.

[@chrisfaulkner6166]

Dizzledan110 did he really die?

[@juniiorcarter3754]

rip

[@psycheward3335]

@Dizzle Dan sorry for your loss brother. He seems a good sort. Bless his generous heart. My brother gave me Gs500f said it was mine if i got it running. Its mine! I build and ride harleys usually,but this thing is soo fun to buzz around in the hood, im putting some cool stuff on it and have some fun! Stay up ,ride fast n take chances!

[@Unlucky13_s]

He didn’t just learn the info. But passed his tips and tricks to the trade before he died. Honestly strive to be as cool as this cat.

[@CarlosHernandez-zr5cz]

Wow... I lived on vashon my whole life (19 years) I remember when this happened. I just got a gs500 and just saw this video.

[@cjwaasdorp2478]

Just founding this searching for some repair info after some nailed me; only I was a bit more fortunate than Adidasguy. He continues to contribute to the GStwin community as he always has... Rest in peace my friend.

[@artoturunen4816]

Thank you for showing what was wrong with my bike. 100% identical symptoms.

[@tufaznail]

I replaced the starter in my atv today and that helped, but it is now making this exact same noise. Going to give this all a try tomorrow. Thanks a lot.

[@vijayam1]

I've been searching for a stater clutch and how it works, this video was very insightful. The locking and unlocking of the sprag and which direction does it lock and which direction it doesn't, gave me pretty good insight. Nice stuff. Thanks!

[@markboza6215]

that is exactly what my gs 750 is doing, awesome vid clean a perfect teacher ,wish they all were like yours,

[@Lajko1]

Yes, it is from the disposable tool company. Works GREAT! I couldn't do forks without it. Great tool. Lots of power.

[@markjohnson9495]

BTW, to do this on a GS450, the big bolt is an M14x1.50, and the 36mm push rod is the same (I cut the head off a 3/8" bolt and made it 36mm long). Your bike looks the same... Doesn't look like a big M19 hole on yours but you did it.

[@dflem563]

Did the rotor come off easily with the 3/8 bolt

[@dflem563]

How did you keep the rotor from turning??

[@dflem563]

Also my bike is an 2004 Suzuki gs500f

[@1955porsche]

great utube just solved my 80 gs450 issue...u saved me 100 hrs of pissed off n mystery,, thank u ,, keep putting out utubes!

[@MichelBeirouthy]

Thank you so much for your videos, they're so in-depth, don't skip over crucial parts and are very clear and easy to see and understand. Just wondering, do you have a video for the crankcase side? I crashed my GS500 and damaged the crankcase cover, bought all the new OEM parts and put it back together but the bike doesn't sound right and dies when I give it some throttle. I'm very green at all of this so I'm not sure what I'm looking for, but it sounds to me like the ignition is out of time or something like that. Any help would be so greatly appreciated. Thanks you!

[@willardpekk4563]

You rock my man! Thanks for the tips on how to pull the flywheel without specific tools!

[@leandrolibaneo]

Olá, meu nome é Leandro e sou do Brasil. Tenho uma Suzuki GS 500 E, ano 2009 (último modelo) e estou com o mesmo problema. Graças ao seu vídeo, consegui identificar o passo a passo para arrumar minha motocicleta. Obrigado pelas informações, espero que eu consiga fazer também.

[@jtraimundo]

Olá Leandro, ele de certeza que fica feliz com o teu agradecimento, este senhor era conhecido na internet com o "Adidas Guy", participando activamente no forum gsTwin, faleceu em Abril de 2014 num acidente de mota. Um abraço

[@Lajko1]

When installing forks, that spacer on the lower right fork MUST be loose when tightening the axle. That lets the forks settle in to being parallel. Yours might have excessive wear because the forks are bent or weren't allowed to "float straight" before that lower right fork spacer on the axle bolt was tightened.

[@Lajko1]

That makes me feel good that I helped get your bike back on the road. Ride safe! Remember: rubber side goes DOWN, shiny side goes UP.

[@leandrolibaneo]

Excelente vídeo. Sou do Brasil e possuo uma GS500 ano 2009 e estou com o mesmo problema. Ela não dá partida, mesmo ruído da sua, vou me basear no vídeo para realizar eu mesmo a manutenção. Grato.

[@hartmutvogel5543]

Danke für dieses informative Video. Dadurch konnte ich mein Problem erkennen und beheben. Liebe Grüße aus Deutschland. Viel Glück und Gesundheit

[@markstainthorpejr]

Mine started doing this today. Thank you! Also, kudos on the clean bike!

[@stannergyxD]

This repair video is one of the best! Very clear & extra informative. I wonder, the method of locking the gears with an allen wrench, to torque the crank bolt: did you ever break a sprocket tooth/cauze a problem? Do you only do it to smaller bikes, or do you use it all the time? Kind regards from Belgium

[@Lajko1]

I work on GS500'smostly. I can not offer advice on what to do with other types of bikes. I do know the gears are extremely strong and it would be very difficult to break one.

[@stannergyxD]

Lajko1 Not the answer I hoped for, none the less, Many thanks for the video & the quick reply! I hope you post more video's in time :)

[@clutchup2103]

R.I.P. Adidasguy....

[@tRRickedOut]

Thanks. Ive been on and off the fence about getting one for some time. Next time I will pick one up

[@Lajko1]

If you ever had to get at the stator, this is how you would get to it and button things back up. Once in a while a stator will burn out. When opened up, I was pointing out the stator. A couple bolts to remove and install a new one. I should have mentioned to insure the magnets didn't pick up any stray bits of metal.

[@kevinjerome4925]

Glad Adidasguy decided not score the press fit mating surfaces of the tapered shaft. God bless & R.I.P.

[@ylism]

Real nice bike you have there, it has good colors, looking into a bike like this for my son, to learn on, he does not like the 250 bikes, thinks there to small...lol But he is the one buying. thought these might make a good choice. Went to look at a K4 GS500f, the other day, with less than 5 thousand miles, after he started it, and had it running, I noticed a noise, something like click slapping mechanical type sound, these were sporadic, while at fast idle, that made the motor jerk a little, and seem to cut power, for a millisecond, and seemed to be coming from that area you opened. Using a metal rod as a stethoscope, to better hear where the nose was from, it seemed loudest in that area, not knowing the motor's makeup, if it had a chain, or a gear counter balancer whatever, I stopped it, thinking maybe the stator was lose ? Did sound sorta like a tensor chain being loose too, but no real noise from that area. The bike was a wrecked bike, and had a salvage title, I did not buy the bike, but was curious as to why it did that. It would rev on up to 8k rpms no problem, he did that not me. It did seem to clear the problem when reved, or covered it up. Have you, or anyone else ever run across this problem before ? BTW you did a good job on the bike, so I thought maybe it was somthing like in the parts you was working on. Thanks. yl

[@Lajko1]

Forks do not have a drain. The screw on the bottom right is to tighten a floating spacer once the wheel is on and the forks all tightened up in the triple clamps. It is best to remove and drain by hanging upside down and pumping a couple times. Otherwise, support bike and remove the fork caps. Suck out as much oil as you can then put in new to the required level which depends on the springs you have.

[@nalyrt]

Hi! I've just finished repairing my bike and everything works just perfect - thanks for your tips. Video is great, you're the man! :)

[@willriseabove6858]

I’ve got a 07 gs500f and it acts like a fuel problem or air problem but now I’m leaning maybe more towards stator? Sometimes it’ll crank up fine and sometimes you have to give it some gas or it’ll cut out. I can drive for a few miles perfectly but then it will struggle to keep up the speed and die. (Sounds like fuel or air right?) I cleaned the carbs, got new lines, new filter, cleaner petcock and tank, changed oil, put new spark plugs in it, adjusted chain, clutch and throttle (very loose when I got it) and it still does this.

[@Butterfly07949]

Nice concise video. I was wondering if the flywheel has a tendency to fall off and it only stays on by an interference fit and oviouly the main bolt. Could I use a light smear of threadlock on the mating surface? Oh and what make and model of torque wrench do you use? I wouldn't mind buying one of these.

[@hohtz]

Thanks i will do it. The last time when one of the forks was disassembled, because of a leakage from the seal, instead of oil there was black dirt, because of the huge wear inside the fork. I suppose the other will be the same inside. May be the fork oil have never been replaced.

[@amitrubi1]

I recently changed my left side gasket after leaking. Your video was very helpful. Thanks!

[@Lajko1]

What did you make the spacer from? Sounds like soft steel. Best to make one from a hard, steel bolt. I probably should have stressed that. Soft bolts from Home Depot are too soft compared to the hardened steel bolts used on a motorcycle. An old axle bolt or bolt from the shock assembly can work very well. Use a dremel or other cutter as they are too hard for a hack saw.

[@idobartana2790]

That was a great video. thanks for putting it out! I have one question though, did you hear a strange buzz at 4500 RPM before the bike stopped starting?

[@jacobd4955]

Bingo thanks😅 i was able to find an old gear key and a grinder blade that was the same sized took some time with a file to create the groove on the actual stator/start clutch side but i dont think ill have this issue again

[@RogueLogzz]

I have a 05'[ GS500F that has a starting issue. The lights work and everything but when you go to hit the electrical starting switch the lights dim and there is no noise from the starter. I checked the battery and it is fully charged at 12.9V. Also, if I do a roll start it starts and runs just fine. Let me know what you think about this.

[@calebstuff5495]

Have you figured out what was wrong? I have the same problem?

[@RogueLogzz]

Yeah the connection cable under the clutch handle was loose. Simple fix. It wasn't registering that the clutch was engaged.

[@Unlucky13_s]

Does it have problems down shifting?

[@dantee323]

Do you have to replace anything or could you just tighten the bolt more

[@stephenkinsley2483]

why is there no woodruff key on the crank i wonder, it would stop this from happening, ? i would put some threadlock on the shaft too.

[@Lajko1]

Yep - many thanks for them!

[@mahhaymrbeyo]

What happens if you can't get the bolt off? I turn the bolt while holding the magnet, but instead of getting loose it turns while makes this hissing sound. Also there's a smaller circle located towards the left of the magnet assembly that rotates alongside the bolt. Any help would be greatly appreciated.

[@nikosmelidis6961]

Hello I have the same problem but i noticed that also my battery doesn’t charge when i jump started it to go back home .. is it possible that i have the same problem or my rotor exploded and and it destroyed the coil ?

[@Batpimpn]

haha love that you have a long hammer IPA there. Hopefully one of mine that i brought over!

[@christophermcbeigh9275]

I did what you showed. After putting it back together the starter would not disengage. Any ideas?

[@BirdEyeViewsos]

I'm going to try working on mine now

[@hohtz]

Do you know if it is possible to change the fork oil of a Suzuki GS500 1996 model without disassembling and removing the forks. I think i saw on one video a screw on the bottom part of the fork where the wheel is mounted. It would be good to change the oil only by removing the front wheel and unscrew the screws below.

[@balloutyves]

Bonjour,j'ai un suzuki 500 gse,et j'ai de l'allumage que sur 1 cylindre,peux tu me donner le remède ? MERCI

[@kali556]

Hi i have gs500 and i change my voltage regulator but he again was crash :( I check a voltage on AC generator and its 60 , 60 , 60VAC on 5000 rpm earlier that was a 70 , 70, 65 VAC. Do you think that can be because rotor comes loose?

[@Lajko1]

That handlebar setup is the OEM clip-ons that were sold in Europe and other places besides the USA from n1990-1996. If you log onto gstwins.com and post a question about it you will be referred to all the info about them and how to get them.

[@jerichokikovictorino2800]

Please help me What Vendix drive Can replace GS500. What Motorcycle vendix drive?

[@SawyerScarff1994]

I was wondering what oil you usually use when you change the oil. I need to change my oil and was wondering what is the best oil for the GS500. Thanks

[@tothethreshold.9965]

It was made from a bolt and worked fine on the first rotor . I tried to post link to thread on GS twins but youtube is beyond awkward and wont let me . Search GS500E stripped / damaged crank threads and it should come up .

[@Lajko1]

I've been following it on gstwins. Seems others are giving good advice to fix the threads.

[@edgarsegle]

I can't seem to find any information on how to remove starter motor from my gs500e 1995, can you help me on how to approach this because i have no idea what is the minimum i have to remove to get it out.

[@conorearsley4883]

Can I get your info adidas guy? I just bought this bike it’s my first and I followed you diligently and I noticed some wear on the inside parts and I would like to pick your brain. I’m excited as heck to join the road on my bike. Please respond and thank you

[@viveresobreviver2123]

I found it very good its initiative to fix the start of his 500 gs . I'm from Brazil and looked for this explanation here and we thought , was where I found your channel. desire all sorts of world peace and health. my question is this , need special tool to remove the induced ? ( Larger gear ) . thank you and peace !

[@Lajko1]

Oh, what was the reason for removing the rotor? That is the same part for all years. Was the one on the good engine bad?

[@typhoongaming7736]

What size socket was the bolts . I can’t seem to find it😭😭

[@OhioCycle]

Where is the Regulator Rectifier located on the GS500 ??

[@Bedeish]

Great videos help me with a few issues

[@wyattgreeson5706]

I had a left side layover and scraped up the magnet pulling that side cover off, anyone know if I should definitely have to replace magnet? There are a few obvious scrapes in the magnets but they are all still in tact

[@dosomethingaboutitnow]

Excellent video

[@martinkaspar5095]

which screw did he use to help to get the rotor off - M19 x 1 !? - Please confirm

[@Herkkk]

I need this info too, Im guessing M12 with 1mm thread, but im unsure and need it now :D

[@mikestar9505]

I HAVE 96GS 500E SUZUKI PUT TWO NEW SPARK PLUGS IN ABOUT 15MIN THROTTLE SIDE FOULS NOT WET .DRY THEN BIKE BOGGS OUT PLEASE NEED HELP!

[@Lajko1]

Stock oil for engines that need oil to flush them out for 100 miles or so (like engines that have been sitting for a year). For regular permanent oil I use AmsOil

[@junaidrahaman8893]

great work . you have available Suzuki gs500f CDI wiring diagram ?

[@stoned66neves]

Bacana seu vídeo meu camarada, bem explicado...bom serviço feito!!!

[@zakhash]

on my 05 gs500f it's a M12 x 1.25 pitch fine thread. they got it at ACE. warning those aren't the spacers your looking for

[@jasonchaconm]

Quien me podría decir acerca del rotor Magneto de cuáles modelos y años es compatible con la GS 500. 89 ya que he escuchado que es compatible con otros modelos

[@diabloxxx6666]

Video helped too much! Thanks

[@tRRickedOut]

That looked like an electric HF impact gun. Do you like it?

[@newton5651]

Thank you !

[@mikesentra]

Great video. Thanks!

[@scottiek711]

Great video, thank you for posting it!!

[@markboza6215]

my 1979 gs 750 does this but the nut wasn't really loose, I cant get that dam rotor and fly wheel assembly off, I tried spacer no luck this thing is on there like nobodys business. please help.

[@marinbarge3013]

I have the same problem, did you actually find the answer ?

[@doitalldavey8788]

Couldnt you just tighten the 17mm bolt?

[@pirana6]

David Johnsoñ He was doing a whole replacement example for those that need to take it off entirely, which is often as the bolts that hold that middle piece to the front magnet piece often break. Also he wanted to clean it.

[@doitalldavey8788]

I did this repair already my bolt was loose worse that his.

[@savinggracechurch4112]

You would have thought that the clever people at Suzuki would have used a woodruff key arrangement instead of a interference fit!

[@RikWCrlsn]

same problem on my katana 600.. i cant get clutch off... no tool i think there is oil on it..

[@jcourt626]

Nice tutorial.

[@mbeydiya1]

Hello there, I appreciate your videos. I recently bought my first 2008 Suzuki GS500F, it has a black hose that comes out by the rear brake pedal, I don't know what it's for. There is no way to send a picture. Can you please send me your contact so I could send you a picture? Thank you in advance from Connecticut!

[@Adhanks91]

I'm sure you may be aware by now, but addidasguy is no longer with us, he's passed down invaluable information about the gs though, many of his post still around on gstwins (GS500 forum), you can probably find what you need there, hope you got whatever you were working on fixed!

[@ThePattonboy123]

Mine is cranking but not starting over thoughts?

[@Motogamna]

Thank you for you teachings 2019

[@zakhash]

So how do I get the 36mm soft metal spacer thats stuck in there out?

[@tothethreshold.9965]

If you have made a spacer to the right size you should be able to pull it out with tweezers or a magnet. It shouldn't be stuck in the hole at all ? .

[@zakhash]

thnx

[@px4storm83]

Looking for the handlebar setup thats in video hate the standard setup on the 05 gs500f

[@hohtz]

And what can i do, which parts should i replace with new ones?

[@moisesdemenezes4354]

Lajko1 parabéns seu trabalho yes amigo Moisés 🇧🇷😀

[@patrykkacpers]

15:15 Did not damage the gear teeth?

[@hoodknown5875]

I think the problem is the poor gasket placement leading to leakage then loosening the bolt.

[@garthsutcliffe1540]

I'm surprised it doesn't have a key way on the shaft, mm

[@sandrahernandezcriado4221]

Está impecable la moto.

[@jasonbaumgardner6552]

would that also cast no spark

[@Unlucky13_s]

What the fuck! Torques it to spec..... then busts out a 1/2” air gun and slams the trigger down twice. Come on man. It was a high torque but I would have had to throw a flag on the play if I was recording. Like.... the air gun really?! That thing is probably 300 ft pounds per quick hit.

[@moisesdemenezes4354]

Ok ok minha GS500 motor mesmo não funcionava perfeitamente trabalho ok parabéns Moisés motociclistas litoral praia grande SP Brasil ok yed parabéns ok yes you ferramentas ok.moises Suzuki yes

[@Bedeish]

One problem I can't understand is my loss of power.... I changed my battery, fixed my flywheel, changed my oil and I can start it if jumped by a car but it doesn't last long. Please help soon this is my work bike

[@mahhaymrbeyo]

THANK YOU!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

[@Lajko1]

Best to log on to gstwins.com. This video isn't really a support thread for GS500's. Your regulator is probably bad or battery. Lots of help on gstwins.com Get out your volt meter and check things according to the gstwins WIKI.

[@vojjta96]

Thank you so much :)

[@namelesssnitchy]

they should remake this bike but with injection instead.

[@squritair]

what gasket is it

[@tothethreshold.9965]

Swapping parts from a blown engine to a good one ....all went well stripping the blown engine . But the damned 36 mm spacer bent inside the shaft on the good engine when i removing the rotor :(. Drilling i out bit by bit :(.

[@moisesdemenezes4354]

Laiko yes Moisés litoral praia grande SP Brasil yes pergect motos Suzuki yes Moisés amigo 😀😀😀🇧🇷

[@zakhash]

RIP

[@Bedeish]

I believe its electrical. When the bike is started I can go for a ride but 2mins later she loses power. Most if not every time it cuts off while riding, so I start again in mid run and afterwards when I give a little or lot of throttle there a loss in in power shown on my rpms and then she shuts off I will upload a video on my page so you can see