Positioning:
High-performance sportbike, homologation special for racing.
Competitors:
Honda NS400R, Yamaha RD500LC, Kawasaki KR-1S.
Engine Type:
Liquid-cooled, 2-stroke, 4-cylinder, 90-degree V-engine.
Power Delivery:
Renowned for its incredible power band and smooth acceleration, derived from Grand Prix racing technology.
Chassis Design:
Aluminium twin-spar frame for rigidity and light weight.
Manual Value:
Essential resource for owners and mechanics to maintain and repair this iconic, technically complex motorcycle.
Primary Coverage:
Complete service and repair for Suzuki RG500 Gamma motorcycles
Secondary Coverage:
Maintenance, troubleshooting, diagnostics, and specifications
Estimated Page Count:
High (Detailed factory-style content, exact number not specified but implied extensive)
Type:
Service Repair Workshop Manual
Delivery Method:
Instant Download
Software Requirements:
Adobe PDF Reader, WinZip (for extraction)
Platform Compatibility:
Windows (all versions including Vista 32/64, XP, ME, 98, NT, 2000), Mac
Engine Mechanical:
Yes (Removal, Installation, Crankcase, Piston, Cylinder, Crankshaft, Transmission, Balancer, Cylinder Head, Valves)
Fuel System:
Yes (Fuel System, Fuel Injection System)
Lubrication Cooling:
Yes (Lubrication and Cooling, Lubrication System, Cooling System)
Transmission Drivetrain:
Yes (Gearbox & Clutch, Crankshaft/Transmission/Balancer, Transmission System)
Electrical System:
Yes (Alternator/Starter Clutch, Battery/Charging System, Ignition System, Electric Starter, Lights/Meters/Switches, Wiring Diagrams)
Chassis Suspension:
Yes (Front Wheel and Steering System, Rear Wheel System, Chassis, Suspension)
Braking System:
Yes (Braking System)
Bodywork Exhaust:
Yes (Fenders and Exhaust Pipe, Frame/Body Panels/Exhaust System, Body & Fixtures)
Wheels Tires:
Yes (Wheels & Tyres)
Maintenance:
Yes (Periodic checks & Adjustments, General Maintenance)
Repair:
Yes (All repair procedures covered, from simple to complicated)
Troubleshooting:
Yes (Troubleshooting section included)
Diagnostics:
Yes (Implied through troubleshooting and technical information)
Installation:
Yes (Engine Removal and Installation covered)
Depth:
Comprehensive (Factory-level detail, suitable for professional mechanics and serious DIYers)
Visuals:
High (Includes exploded pictures and diagrams)
Searchability:
Likely (Standard for modern PDF manuals)
Quality:
High (Designed for detailed diagrams and text)
Type:
Digital (Not applicable for PDF download)
Type:
Digital (Not applicable for PDF download, but printable)
Engine Type:
Liquid-cooled, 2-stroke, 90-degree V4
Bore X Stroke:
54.0 mm x 54.0 mm
Carburetion:
4 x Mikuni VM26SS (dual throttle valve) carburetors
Horsepower:
Approx. 95 hp @ 9,000 rpm (depending on market regulations)
Torque:
Approx. 51 lb-ft @ 8,000 rpm
Fuel Type:
Unleaded gasoline (high octane recommended, often requiring pre-mix fuel or self-mixing oil injection)
Fuel Injection System Note:
While the manual lists 'Fuel injection system', the RG500 primarily utilized carburetors. This may refer to the electronic control unit (ECU) managing ignition timing or potentially a different market variant or a misunderstanding in the product description.
System:
Suzuki C.C.S. (Crankcase Circle Injection) oil injection system or pre-mix.
Safety Ratings:
Not applicable in the traditional sense for motorcycles of this era; focus is on rider safety through design and handling.
Braking System Front:
Dual 270 mm discs with twin-piston calipers
Braking System Rear:
Single 240 mm disc with twin-piston caliper
Suspension Front:
Telescopic fork, adjustable preload and damping
Suspension Rear:
Monoshock, adjustable preload and damping (Full Floater system)
Lighting:
Halogen headlamp, taillight, turn signals.
Infotainment System:
Not applicable; analog instrumentation typical of the era.
Driver Assistance Features:
Not applicable.
Connectivity Features:
Not applicable.
Ignition System:
CDI (Capacitor Discharge Ignition) with electronic timing advance.
Cooling System:
Forced air and liquid cooling system for optimal temperature management.
Spark Plugs:
Check/replace every 3,000-5,000 km (refer to manual for exact intervals)
Chain Lubrication:
Every 500-1,000 km, or after washing/rain.
Air Filter:
Clean/inspect every 3,000 km, replace as needed.
Coolant:
Check level regularly, flush and replace coolant every 2 years.
Engine Oil:
2-stroke specific premix oil (e.g., Yamalube, Castrol) or Suzuki's own 2-stroke injection oil. Refer to manual for exact specifications.
Transmission Oil:
SAE 80 API GL-4 or GL-5 gear oil (e.g., Suzuki Gear Oil SAE 80). Capacity: approx. 1.0 L.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Coolant:
Mixture of ethylene glycol and distilled water (50/50 ratio).
Common Problems:
Carburetor synchronization, reed valve wear, piston ring wear, electrical gremlins due to age, expansion chamber sealing issues.
Maintenance Focus:
Crucial for maintaining peak performance due to its highly tuned 2-stroke engine. Regular top-end rebuilds may be necessary for high-mileage examples.
Heritage:
Suzuki has a strong racing heritage, particularly in Grand Prix motorcycle racing with their RGV and RG series machines.
Evolution:
The RG500 Gamma was a homologation special, built to meet production racing rules and to bring Grand Prix technology to the road. It was a significant step up from earlier two-stroke triples.
Production Years:
1985-1987
Significance:
Considered one of the most potent and iconic 500cc road-legal two-strokes ever produced.
