🏷️ Basic Information

Make:

Suzuki

Model:

RG500 Gamma

Model Variant:

RG500 "Gamma"

Year:

1985-1987

👋 Introduction

Positioning:

The Suzuki RG500 Gamma was a homologation special, designed to meet racing regulations for AMA Superbike and other international series. It was a high-performance, cutting-edge sportbike of its era.

Competitors:

Competed against other large-displacement 2-stroke sportbikes and early 4-stroke superbikes like the Yamaha FZ750 and Honda VF1000R.

Engine Type:

Water-cooled, 2-stroke, 4-cylinder, rotary valve induction.

Power Output:

Approximately 95 hp (claimed) in stock form, with significant tuning potential.

Racing Heritage:

Directly derived from Suzuki's RG500 Grand Prix racing motorcycles, making it a road-legal race replica.

Usefulness:

Essential for owners and mechanics needing to maintain, diagnose, and repair this complex and high-performance machine.

📋 Manual Details

Engine:

Complete Engine Overhaul and Repair

Transmission:

Gearbox Inspection, Repair, and Clutch Service

Chassis:

Frame, Suspension, and Steering System Maintenance

Brakes:

Front and Rear Brake System Service and Overhaul

Electrical:

Ignition System, Lighting, and Charging System Troubleshooting

Fuel System:

Carburetor Tuning, Fuel Tank, and Lines

Cooling System:

Radiator, Hoses, and Water Pump Service

Bodywork:

Fairing Removal, Installation, and Minor Body Repairs

Troubleshooting:

Diagnostic Procedures for Common Issues

Total Pages:

234

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Printed Manual

📖 Manual Coverage

Engine Assembly:

Detailed disassembly, inspection, and reassembly of the 2-stroke, 4-cylinder engine.

Cooling System:

Maintenance and repair of the liquid-cooled system, including radiator, thermostat, and water pump.

Ignition System:

Service for the CDI ignition, ignition timing, and component testing.

Carburetion:

Comprehensive guide to Mikuni VM26SS carburetors, including jetting, synchronization, and troubleshooting.

Lubrication System:

Details on the oil injection system, oil pump, and oil change procedures.

Exhaust System:

Information on the expansion chambers and mufflers.

Transmission Gearbox:

Six-speed gearbox disassembly, inspection, and reassembly, including gear selection and shifting mechanisms.

Clutch:

Wet multi-plate clutch service, including plate replacement and adjustment.

Frame And Suspension:

Front fork (Telescopic, Cartridge type) overhaul, rear monoshock suspension service, and linkage maintenance.

Steering:

Headset bearing inspection and replacement, steering damper adjustments.

Wheel And Tires:

Wheel bearing service, tire pressure recommendations, and rim specifications.

Braking System:

Dual front disc brakes and single rear disc brake service, including caliper overhaul, pad replacement, and hydraulic system maintenance.

Electrical System:

Wiring diagrams, lighting system troubleshooting, battery maintenance, and charging system (alternator/stator) checks.

Instrumentation:

Speedometer, tachometer, and gauge cluster servicing.

Body Fairings:

Removal and installation procedures for body panels and aerodynamic components.

Engine Rebuild:

Step-by-step instructions for complete engine disassembly, cleaning, inspection, part replacement (pistons, rings, crank seals, bearings), and reassembly.

Carburetor Tuning:

Guidance on adjusting idle speed, mixture screws, float levels, and synchronized jetting for optimal performance.

Suspension Adjustment:

Instructions for adjusting front fork preload, compression, and rebound damping, as well as rear shock preload and damping.

Brake System Maintenance:

Procedures for bleeding brake lines, replacing brake pads and discs, and rebuilding calipers.

Electrical Troubleshooting:

Systematic diagnostic routines for electrical faults, using wiring diagrams and multimeter testing.

Clutch Replacement:

Detailed steps for removing and replacing clutch plates, springs, and pressure plates.

Wheel Bearing Service:

Instructions for removing, cleaning, greasing, and reinstalling wheel bearings.

Cooling System Flushing:

Procedure for draining, flushing, and refilling the radiator and coolant system.

Spark Plug Replacement:

Correct spark plug types and replacement intervals.

Chain And Sprocket Maintenance:

Lubrication, tension adjustment, and replacement guidance.

Depth:

Comprehensive, covering routine maintenance to full engine and component rebuilds.

Diagnostics:

In-depth diagnostic procedures for common and intermittent faults, including electrical and mechanical issues.

Specifications:

Includes all essential torque values, clearances, tolerances, and fluid capacities.

Illustrations:

Features clear, detailed line drawings and exploded views to illustrate repair procedures.

Troubleshooting Charts:

Extensive charts for diagnosing problems based on symptoms.

📊 Manual Specifications

Format:

Printed Book

Paper Quality:

Durable, heavy-weight paper designed for workshop environments.

Print Clarity:

High-resolution printing for clear text and diagrams.

Binding:

Staple-bound or perfect-bound (typical for this era of manuals), designed for lay-flat reading.

Technical Terminology:

Uses standard automotive and motorcycle engineering terms.

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 2-stroke, 4-cylinder in-line

Displacement:

498 cc (30.4 cu in)

Bore X Stroke:

56.0 mm x 50.6 mm (2.20 x 1.99 in)

Compression Ratio:

7.2:1 (approx.)

Valves:

Rotary disc valves

Ignition:

Suzuki PEI (Pointless Electronic Ignition) CDI

Horsepower:

Approx. 95 hp @ 9,500 rpm (claimed, depending on market regulations)

Torque:

Approx. 70 Nm (52 lb-ft) @ 8,000 rpm (claimed)

Carburetors:

Four Mikuni VM26SS constant velocity carburetors

Fuel Delivery:

Fuel pump driven

System:

Suzuki C.C.S. (Clean Air System) Auto Lube (oil injection)

System:

Liquid-cooled, pressurized radiator with fan

🔧 Transmission

Type:

6-speed constant mesh, sequential

Clutch:

Wet, multi-plate, cable-actuated

Final Drive:

O-ring sealed chain

Gear Ratios:

Specific gear ratios detailed within the manual for each gear.

Clutch Fluid:

Refer to manual for specific clutch fluid type and capacity (typically brake fluid DOT 3/4).

📐 Dimensions

Length:

Approx. 2,150 mm (84.6 in)

Width:

Approx. 750 mm (29.5 in)

Height:

Approx. 1,160 mm (45.7 in)

Wheelbase:

Approx. 1,425 mm (56.1 in)

Dry Weight:

Approx. 183 kg (403 lbs)

Wet Weight:

Approx. 200 kg (441 lbs) (with all fluids)

Fuel Tank:

21 liters (5.5 US gal)

Cooling System Capacity:

Approx. 2.1 liters (2.2 US qt)

Transmission Oil Capacity:

Approx. 1.2 liters (1.3 US qt) - refer to manual for specific type (e.g., SAE 80W/90 GL-4)

🛡️ Safety Features

Safety Classification:

N/A (Motorcycle - no formal crash ratings like cars)

Braking:

Dual front disc brakes, single rear disc brake, linked braking not present.

Suspension:

Adjustable front forks and rear monoshock for stability and control.

Tires:

Performance-oriented tires, specific sizes detailed in manual.

Lighting:

Halogen headlamp, tail lamp, turn signals.

Ergonomics:

Sport-oriented riding position.

💡 Technology Features

Features:

N/A (This is a 1980s sportbike; technology is focused on performance, not rider comfort or entertainment systems).

Features:

N/A (No electronic rider aids like ABS, traction control, etc.)

System:

Advanced (for its time) CDI ignition and 2-stroke engine design with rotary valves and a sophisticated oil injection system.

🔧 Maintenance

Oil Change:

Refer to manual; typically every 3,000-5,000 km (1,800-3,000 miles) for engine oil if applicable, but gearbox oil changes are more critical.

Spark Plugs:

Every 5,000-10,000 km (3,000-6,000 miles), depending on usage and plug type.

Air Filter:

Clean/inspect every 5,000 km (3,000 miles), replace as needed.

Chain Lubrication:

Every 500-1,000 km (300-600 miles) and after washing/rain.

Brake Fluid Flush:

Every 1-2 years.

Coolant Flush:

Every 2 years.

Engine Top End Rebuild:

Recommended based on mileage and wear, typically between 20,000-40,000 km (12,000-25,000 miles), but highly dependent on maintenance and usage.

Engine Oil Type:

Refer to manual for 2-stroke oil injection system (high-quality 2-stroke motorcycle oil).

Gearbox Oil Type:

SAE 80W/90 GL-4 hypoid gear oil.

Coolant Type:

Ethylene glycol based antifreeze mixture.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Engine Seals:

Crankshaft and transmission seal degradation can lead to air leaks and performance issues.

Carburetor Wear:

desgaste interno dos carbohidratos pode afetar o desempenho e a sincronização.

Clutch Slippage:

Aggressive riding or worn clutch plates can cause slippage.

Cooling System Leaks:

Hose degradation or radiator damage can lead to coolant leaks.

Electrical Gremlins:

Older wiring harnesses can develop faults over time, affecting ignition or lighting.

📚 Vehicle History

Heritage:

Suzuki has a long and successful history in motorcycle racing, particularly in the 500cc Grand Prix class with riders like Barry Sheene and Marco Lucchinelli. The RG500 Gamma is a direct descendant of these championship-winning machines.

Predecessors:

The RG500 Gamma built upon Suzuki's experience with previous 2-stroke road racers like the GT series and earlier RG models.

Era Context:

Represented the pinnacle of 2-stroke technology for street-legal motorcycles in the mid-1980s, a period when 4-stroke technology was beginning to dominate.

Production Years:

1985-1987

Production Location:

Japan

Rarity:

Produced in limited numbers as a homologation special, making it a collectible item.

🏆 Awards & Recognition

Racing Success:

While not an 'award' in the consumer sense, the RG500 Gamma's close relation to its Grand Prix racing namesake signifies its performance pedigree and recognition within the motorsport world.

Status:

Highly sought after by collectors and enthusiasts for its iconic status and raw performance.