The Suzuki RG500 Gamma, produced from 1985 to 1989, represents a pinnacle of performance engineering, directly descended from racing machines. This iconic sportbike features a liquid-cooled, 2-stroke, square-four engine with...
The Suzuki RG500 Gamma, produced from 1985 to 1989, represents a pinnacle of performance engineering, directly descended from racing machines. This iconic sportbike features a liquid-cooled, 2-stroke, square-four engine with a displacement of 498 cc, capable of producing approximately 95 horsepower. Its advanced design includes a 6-speed transmission, dual front disc brakes, and innovative suspension systems like the Full Floater rear shock. The RG500 Gamma was engineered for riders seeking an exhilarating experience, embodying the spirit of racing technology in a street-legal package.
This comprehensive Workshop Service Repair Manual provides essential information for the Suzuki RG500 Gamma (model code RG500H) for the 1987 model year. It covers a wide range of systems including general information, engine, cooling system, fuel and lubrication, electrical system, and chassis. The manual offers detailed troubleshooting guides, step-by-step repair procedures for disassembly and reassembly, and routine maintenance instructions. It is designed to assist owners and mechanics in maintaining the vehicle's optimal performance and ensuring its longevity.
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
RG500 Gamma
Model Code:
RG500H
Year:
1987
Codes
Engine Code:
RG500
👋 Introduction
Market Position
Target Audience:
Suzuki RG500 Gamma owners and independent mechanics
Competitive Analysis
Value Proposition:
Enables self-sufficiency in maintenance and repair, saving costs and ensuring optimal performance.
Key Features
Searchability:
Quickly locate information across all chapters
Detail Level:
Detailed instructions for DIY repairs
Support:
Email support available for inquiries
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
PDF
Compatibility:
Windows, macOS
📖 Manual Coverage
Systems Covered
General Information:
Included
Maintenance:
Included
Engine:
Included
Cooling System:
Included
Fuel And Lubrication:
Included
Electrical System:
Included
Chassis:
Included
Servicing Information:
Included
Appendix:
Included
Procedures Included
Diagnostic Procedures:
Detailed troubleshooting guides for common issues
Repair Procedures:
Step-by-step instructions for component disassembly and reassembly
Maintenance Procedures:
Routine checks, adjustments, and replacements
Technical Depth
Depth Of Coverage:
Comprehensive, covering basic maintenance to complete engine rebuilds
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes
Print Quality
Printability:
High-quality for clear printing
Binding Type
Binding:
Digital (PDF)
Paper Type
Paper Recommendation:
Standard printer paper
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, Rotary Valve Induction
Cylinder Arrangement:
Square Four
Displacement:
498 cc
Bore X Stroke:
54.0 mm x 54.0 mm
Compression Ratio:
7.2:1
Performance
Horsepower:
95 hp @ 9,500 rpm (approx.)
Torque:
70 Nm @ 9,000 rpm (approx.)
Fuel System
Carburetors:
4 x Mikuni VM29SS
Fuel Type:
Unleaded gasoline with 2-stroke oil pre-mix or separate oil injection
Lubrication
Lubrication System:
Suzuki Full Auto Lube (SAFL) or pre-mix
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Clutch Type:
Wet multi-plate
Features
Gear Ratios:
Detailed in manual
📐 Dimensions
Exterior
Overall Length:
2,065 mm (81.3 in)
Overall Width:
750 mm (29.5 in)
Overall Height:
1,135 mm (44.7 in)
Wheelbase:
1,400 mm (55.1 in)
Weights
Dry Weight:
172 kg (379.2 lbs)
Fuel Tank Capacity:
22 L (5.8 US gal)
🛡️ Safety Features
Passive Features
Brakes Front:
Dual 270 mm discs with 4-piston calipers
Brakes Rear:
Single 240 mm disc with 2-piston caliper
Suspension Front:
Telescopic, oil-damped, coil spring (anti-dive system)
Suspension Rear:
Swing arm, oil-damped, coil spring (Full Floater suspension)
Tires Front:
120/80-17
Tires Rear:
130/80-18
💡 Technology Features
Infotainment
Infotainment System:
N/A (Classic Sportbike)
Driver Assistance
Driver Assistance Features:
N/A (Classic Sportbike)
Connectivity
Connectivity Features:
N/A (Classic Sportbike)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific schedules based on usage
Spark Plug Replacement:
Refer to manual for recommended intervals
Chain Lubrication:
Frequent, as detailed in manual
Fluid Specifications
Coolant Type:
Ethylene glycol-based coolant (specifics in manual)
2 Stroke Oil Type:
High-quality 2-stroke motorcycle oil, JASO FD or equivalent (for oil injection system)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Engine Wear:
Potential for reed valve and exhaust port wear; piston ring wear; crankshaft seal leaks. Manual addresses diagnosis and repair.
Carburetor Issues:
Carburetors can be prone to clogging, requiring regular cleaning and synchronization. Manual provides detailed guidance.
Electrical System:
Ignition system components can require periodic checks and maintenance. Manual covers troubleshooting.
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation
Model Evolution
Racing Heritage:
Developed from Suzuki's Grand Prix racing machines, particularly the RG500 square-four two-stroke engine.
Production
Production Period:
1985-1989
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Racing Success:
The RG500 platform was highly successful in motorcycle racing championships, influencing this production model.
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