Segment:
High-performance sport motorcycle, renowned for its four-cylinder two-stroke engine and racing heritage.
Competitors:
Competed against other 500cc two-stroke sportbikes of its era, such as the Yamaha RD500LC and Honda NS400R.
Engine Configuration:
Unique 498cc liquid-cooled, 2-stroke, V4 engine with rotary disc valves.
Performance Focus:
Designed for aggressive performance and track capability, derived from Suzuki's Grand Prix racing technology.
Owner Benefit:
Empowers owners to perform essential maintenance and complex repairs, saving money and ensuring optimal performance.
Primary Coverage:
Comprehensive workshop repair and service information for the 2002 Suzuki RG500 motorcycle.
Secondary Coverage:
Includes information applicable to RG500H variants from the 1987 model year, suggesting overlap or evolution of components.
Estimated Page Count:
Varies by specific publication, but professional workshop manuals typically range from 300 to over 800 pages for comprehensive coverage.
Type:
Workshop Repair Manual / Service Manual
Compatibility:
All Versions of Windows & Mac
Software Requirement:
Adobe PDF Reader
Engine:
Detailed engine disassembly, assembly, inspection, and repair procedures for the RG500's rotary valve two-stroke engine.
Cooling System:
Information on the liquid cooling system, including radiator, thermostat, water pump, and coolant specifications.
Fuel And Lubrication:
Comprehensive coverage of the fuel delivery system (carburetors, fuel pump), fuel tank, and the automatic oil injection/lubrication system.
Electrical System:
Wiring diagrams, ignition system, lighting, charging system, starter motor, and component testing procedures.
Chassis:
Frame, suspension (front forks, rear shock), steering system, brakes (front and rear), wheels, and tires.
Servicing Information:
General maintenance, adjustments, lubrication points, and routine servicing procedures.
Appendix:
Likely includes specifications, torque values, special tools, and diagnostic charts.
Maintenance:
Scheduled maintenance checks, oil changes, filter replacements, chain adjustment, spark plug replacement.
Troubleshooting:
Diagnostic procedures for common issues, fault finding, and solutions.
Repair:
Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly.
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical resistance values, and other critical data.
Depth:
Comprehensive, covering everything from basic rider maintenance to in-depth engine rebuilding and electrical system diagnostics.
Engine Type:
Liquid-cooled, 2-stroke, V4
Displacement:
498 cc (30.4 cu in)
Bore X Stroke:
56.0 x 50.6 mm (2.2 x 2.0 in)
Valvetrain:
Rotary disc valves
Horsepower:
Approximately 95 HP @ 9,500 rpm (at the crankshaft, specifications may vary by market and regulations)
Torque:
Approximately 73 Nm (54 lb-ft) @ 8,000 rpm (at the crankshaft)
Carburetion:
4x Mikuni VM28SS carburetors
Fuel Type:
Unleaded gasoline, Minimum Octane Rating: 91 (RON+MON)/2
Oil System:
Automatic oil injection system for 2-stroke oil
Engine Oil Type:
Suzuki recommends specific high-quality 2-stroke motorcycle oil; manual will specify viscosity (e.g., SAE 10W-30 or 10W-40 for the gearbox/transmission).
Length:
Approximately 2,120 mm (83.5 in)
Width:
Approximately 730 mm (28.7 in)
Height:
Approximately 1,170 mm (46.1 in)
Dry Weight:
Approximately 177 kg (390 lbs)
Gross Vehicle Weight Rating:
Will be specified in the manual, typically around 360 kg (794 lbs).
Fuel Tank Capacity:
Approximately 20 Liters (5.3 US gal)
Safety Classification:
High-performance sport motorcycle; safety relies heavily on rider skill and adherence to maintenance. No formal crash ratings like cars.
Braking System:
Dual 290mm disc brakes with 4-piston calipers (front), Single 240mm disc brake with 2-piston caliper (rear)
Lighting:
Halogen headlight, taillight, and turn signals for visibility.
Oil Change Interval:
Gearbox oil should be changed per manual recommendations, typically every 3,000-5,000 km or annually. The 2-stroke oil injection system's reservoir requires regular refilling.
Spark Plug Replacement:
As per manual, typically every 5,000-10,000 km, depending on usage and plug type (e.g., NGK BR9EG).
Air Filter Cleaning:
Regular cleaning and inspection (e.g., every 2,000-4,000 km), replacement as needed.
Transmission Oil Type:
API GL-4, SAE 80W-90 hypoid gear oil is a common recommendation for vintage motorcycles of this type. Manual will confirm exact specification.
Coolant Type:
A 50/50 mix of ethylene glycol-based coolant and distilled water. Manual will specify preferred brand and type.
2 Stroke Oil Type:
High-quality, low-smoke, JASO FD or equivalent rated 2-stroke motorcycle oil.
Engine Wear:
High-performance 2-strokes are sensitive to maintenance. Issues can include cylinder wear, piston ring wear, and power valve sticking if not properly maintained and fueled.
Carburetor Maintenance:
Carburetors require meticulous cleaning and synchronization due to the four-cylinder setup and the demands of a 2-stroke engine.
Electrical Aging:
As with any 20+ year old vehicle, electrical connectors, wiring insulation, and components like the stator or CDI can degrade and require attention.
Brand Reputation:
Suzuki has a strong legacy in motorsport, particularly in Grand Prix racing with 500cc two-stroke technology.
Rg Lineage:
The RG500Gamma evolved from Suzuki's successful RG500 Gamma racer, bringing GP technology to the street.
Production Years:
The RG500 was primarily produced from 1985 to 1987. The 2002 reference might indicate a later market adaptation or a specific variant, though unusual for this model's typical production run. The RG500H reference points to the 1987 model, suggesting the manual covers a broad spectrum or has archived data.
Motorcycle Reviews:
The RG500 Gamma was widely praised upon its release for its incredible performance and handling, often lauded as one of the most potent street-legal 500cc two-strokes ever made.
Performance Ratings:
Consistently rated highly for its speed, acceleration, and track-oriented chassis by contemporary motorcycle publications.
Manufacturing Standards:
Manufactured to Suzuki's internal quality and performance standards of the era.
