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Suzuki RG500 Motorcycle Service & Repair Manual (1985 1986 1987)-PDF

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The Suzuki RG500 Gamma, produced from 1985 to 1987, stands as a remarkable testament to Suzuki's racing heritage, offering near Grand Prix performance on public roads. This iconic machine features...
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Suzuki RG500 Motorcycle Service & Repair Manual (1985 1986 1987)-PDF
The Suzuki RG500 Gamma, produced from 1985 to 1987, stands as a remarkable testament to Suzuki's racing heritage, offering near Grand Prix performance on public roads. This iconic machine features a potent liquid-cooled, 498cc, 2-stroke, 90-degree V4 engine equipped with rotary disc valves, delivering exhilarating acceleration and power. Its advanced aluminum twin-spar frame, derived directly from racing technology, ensures exceptional handling and a lightweight chassis. The RG500 Gamma was engineered to homologate Suzuki's successful racing motorcycles for competition, making it a highly sought-after machine for enthusiasts seeking the pinnacle of two-stroke sportbike technology from its era. This comprehensive service and repair manual provides detailed guidance for the Suzuki RG500 Gamma, covering all essential aspects of its maintenance and repair. Within its pages, you will find in-depth information on engine systems, including complete tear-down and rebuild procedures, fuel and lubrication systems, and cooling. The manual also details transmission, chassis, electrical systems, brakes, and suspension. It offers step-by-step instructions for routine maintenance, troubleshooting common issues, and component-specific repairs, making it an indispensable resource for both do-it-yourself owners and professional technicians aiming to preserve the performance and longevity of this legendary motorcycle.
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
RG500 Gamma
Production Years:
1985-1987
Model Code:
RG500 Gamma (specific chassis codes may vary by market)
👋 Introduction
Market Position
Positioning:
The Suzuki RG500 Gamma was a highly competitive two-stroke racing homologation special for the road, known for its blistering performance and advanced technology for its era.
Competitive Analysis
Competitors:
Key competitors in its class included Yamaha's RD500LC and Honda's NS400R, all targeting riders seeking high-performance, multi-cylinder two-stroke sportbikes.
Key Features
Engine Configuration:
Liquid-cooled, 498cc, 2-stroke, 2x2-cylinder, rotary disc valve, 90-degree V-4 engine.
Performance Highlights:
Renowned for its power output and aggressive acceleration, directly derived from Suzuki's Grand Prix racing machines.
Manual Value Proposition
Owner Benefit:
Enables owners to perform professional-level maintenance, repairs, and diagnostics, saving significant costs compared to dealership service.
📋 Manual Details
Coverage
Manual Type:
Official Service & Repair Manual
Language:
English
Format:
PDF
Delivery Method:
Instant Download
File Requirements:
Adobe PDF Reader, WinZip (for extraction if compressed)
Printability:
Fully Printable
Searchability:
Searchable PDF
Bookmarking:
Bookmarked
Compatibility:
All versions of Windows & Mac
📖 Manual Coverage
Systems Covered
Engine:
Complete tear down and rebuild, combustion system, lubrication, cooling, fuel system, crankcase, piston, cylinder, crankshaft, balancer
Transmission:
Gearbox, clutch, transmission system, crankshaft/transmission components
Chassis:
Front wheel and steering system, rear wheel system, fenders, exhaust pipe, chassis, frame/body panels, wheels & tires
Electrical:
Alternator/starter clutch, battery/charging system, ignition system, electric starter, lights/meters/switches, wiring diagrams
Brakes:
Braking System
Suspension:
Suspension (front and rear)
Fuel System:
Engine Fuel System, Fuel Injection System (if applicable to specific models/markets, otherwise Carburetion)
Bodywork:
Body & Fixtures, Frame/Body Panels
Procedures Included
Maintenance:
Periodic checks & Adjustments, general maintenance procedures
Repair:
Complete tear down and rebuild, component-specific repairs
Diagnostics:
Troubleshooting, diagnostic procedures
Restoration:
Procedures suitable for refurbishing or restoring the motorcycle
Installation:
Engine removal and installation, component installations
Technical Depth
Detail Level:
Comprehensive, covering all diagnostic and repair procedures, detailed illustrations, wiring schematics, torque specs
Target Audience:
Do-it-yourselfer and experienced mechanic
📊 Manual Specifications
File Details
File Format:
PDF
Print Quality:
High quality, suitable for printing individual pages or the entire manual
Page Count:
Not explicitly stated, but described as 'COMPLETE', implying a comprehensive page count typical of official service manuals.
Binding Type:
N/A (Digital PDF format)
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 2-stroke, 90-degree V4
Displacement:
498 cc
Bore X Stroke:
56.0 x 50.5 mm
Fueling:
Mikuni VM26SS carburetors (typical configuration, manual covers carburetor system maintenance/tuning)
Performance
Horsepower:
Approx. 95 hp @ 9,500 rpm (claimed, may vary by market regulations)
Torque:
Approx. 7.0 kg-m (68.6 Nm; 50.6 lb-ft) @ 8,000 rpm (claimed)
Fuel System
Carburetor Type:
Four Mikuni VM26SS
Cooling System
Type:
Liquid-cooled
Lubrication
System:
Suzuki Super Scavenge (TSCC) two-stroke oil injection system
🔧 Transmission
Standard
Type:
6-speed constant mesh
Optional
Availability:
N/A (single standard transmission offered)
Features
Clutch Type:
Wet multi-plate
📐 Dimensions
Exterior
Length:
Approx. 2,160 mm (85.0 in)
Width:
Approx. 735 mm (28.9 in)
Height:
Approx. 1,170 mm (46.1 in)
Wheelbase:
Approx. 1,425 mm (56.1 in)
Weights
Dry Weight:
Approx. 172 kg (379 lbs)
Wet Weight:
Approx. 192 kg (423 lbs)
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Motorcycle, not subject to automotive crash testing standards)
Active Features
Braking System:
Dual front disc brakes, single rear disc brake (specification details in manual)
Passive Features
Lighting:
Full lighting system with headlight, taillight, brake lights, turn signals (details in manual)
💡 Technology Features
Infotainment
Features:
N/A (Focus on performance and mechanicals, no modern infotainment systems).
Driver Assistance
Features:
N/A (No electronic rider aids typical of modern motorcycles).
Connectivity
Features:
N/A
Engine Technology
Reed Valves:
Rotary disc valve intake system, a key performance feature for two-stroke engines of this era.
Cooling Tech:
Advanced liquid cooling system with a large radiator and fan for consistent operating temperatures.
Chassis Tech
Frame:
Aluminum twin-spar frame derived from racing technology for rigidity and light weight.
🔧 Maintenance
Service Intervals
Oil Change:
Refer to manual for specific intervals based on usage. Two-stroke oil injection system requires regular topping up.
Spark Plugs:
Refer to manual for replacement intervals and correct types (likely NGK or Denso).
Chain Lubrication:
Frequent lubrication and adjustment recommended, especially under hard riding conditions.
Fluid Specifications
Engine Oil:
Suzuki Super Scavenge two-stroke oil or equivalent high-quality two-stroke injector oil (manual will specify exact type).
Coolant:
Ethylene glycol-based antifreeze mixture with distilled water (manual will specify ratio and type).
Transmission Oil:
Refer to manual for viscosity and specification, typically a gear oil.
Known Issues
Carburetor Sync:
Can require frequent synchronization due to complexity of the V4 setup. Manual covers procedure.
Power Valve Maintenance:
Mechanical power valves require cleaning and proper function for optimal performance; manual details their maintenance.
Engine Seals:
Age-related degradation of engine seals can lead to air leaks or coolant leaks; thorough inspection is crucial.
Maintenance Schedule Detail
Initial Service:
Refer to manual for break-in procedures and initial service recommendations.
📚 Vehicle History
Brand Heritage
Heritage:
Suzuki has a rich racing heritage, particularly in Grand Prix motorcycle racing, which heavily influenced the RG500 Gamma's design and performance.
Model Evolution
Evolution:
The RG500 Gamma was the road-going homologation version of Suzuki's highly successful RGΓ (Gamma) square-four two-stroke Grand Prix race bikes, designed to meet homologation rules for racing eligibility.
Production
Manufacturing Location:
Japan
Significance:
Represented the pinnacle of two-stroke road bike technology from Suzuki, offering near-GP performance for the discerning enthusiast.
🏆 Awards & Recognition
Recognitions
Performance Awards:
Widely acclaimed by motorcycle press for its revolutionary V4 two-stroke engine and racing pedigree.
Ratings
Track Capability:
Often considered one of the best road-legal superbikes of its era, with a strong following among track day enthusiasts and collectors.
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