Class:
Superbike / Sportbike
Era:
Iconic 1980s Two-Stroke Era
Competitors:
Yamaha RD500LC, Kawasaki KR-1S, Honda NS400R
Engine Configuration:
Liquid-cooled, 2-stroke, V4 configuration with rotary disc valves.
Performance Focus:
High-revving, powerful two-stroke performance, celebrated for its racing heritage (derived from RG500 Grand Prix racers).
Benefit For Owners:
Empowers owners to perform professional-level maintenance and repairs, understanding the intricate workings of a complex two-stroke V4 engine.
Primary Focus:
Service, Repair, Workshop
Additional Coverage:
General Information, Maintenance, Troubleshooting
Estimated Page Count:
Comprehensive (exact count not specified, typically 300-500+ pages for this level of detail)
Type:
Factory Service Manual / Workshop Manual
File Format:
Adobe Acrobat PDF
Delivery Method:
Instant Digital Download
Engine Management:
Engine overhaul, top-end rebuild, bottom-end assembly, lubrication system, cooling system (liquid-cooled), fuel delivery (carburetors, fuel pump), ignition system, exhaust system
Transmission Drivetrain:
Clutch operation and adjustment, gearbox internal inspection and repair, gear selection mechanism, final drive (chain and sprockets)
Chassis Suspension:
Frame inspection and repair, front fork (Telescopic) overhaul, rear suspension (Monoshock) adjustment and rebuild, wheel bearing service, steering head bearing service
Brakes:
Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, brake line inspection, brake pad replacement
Electrical:
Wiring diagrams, lighting system (headlight, taillight, indicators), charging system (stator, regulator/rectifier), ignition coil testing, battery maintenance and testing, starter system
Bodywork Seats Locks:
Fairing removal and installation, seat system, lock mechanisms, fuel tank and petcock service
Lubrication:
Recommended lubricants, oil change procedures, gearbox oil specifications, general lubrication points
Maintenance:
Routine inspections, oil and filter changes, spark plug replacement, chain adjustment, brake fluid flush, coolant replacement, carburetor cleaning and synchronization
Troubleshooting:
Diagnostic flowcharts for common issues, electrical system fault finding, engine performance problems, starting issues
Repair Rebuild:
Complete engine rebuild procedures, gearbox overhauls, suspension component replacement, brake system overhauls, electrical component replacement
Technical Adjustments:
Carburetor jetting and adjustment, ignition timing settings, suspension sag adjustment, chain slack adjustment
Depth:
Comprehensive, suitable for professional technicians and experienced DIY mechanics. Covers detailed disassembly, assembly, torque specifications, and diagnostic procedures.
Searchability:
Likely text-searchable PDF for efficient information retrieval.
Editability:
Not editable for content modification, but printable.
Print Recommendation:
Printable on demand, allowing users to select specific sections or the entire manual for printing. Recommended for clear reproduction of diagrams and schematics.
User Binding Options:
User can print and bind in 3-ring binders for easy page turning and section organization.
Recommended Paper:
Standard printer paper is suitable; consider heavier stock for frequently referenced sections.
Configuration:
498cc, Liquid-cooled, 2-stroke, V4
Bore X Stroke:
56.0 mm x 50.6 mm
Valvetrain:
Rotary Disc Valves
Horsepower Peak:
95 hp @ 9,000 rpm (approximate, varies by market and tuning)
Torque Peak:
53 lb-ft @ 8,000 rpm (approximate)
Carburetion:
4 x Mikuni VM26SS Carburetors
Fuel Induction:
2-Stroke Oil Injection System (Separate lubrication)
Type:
CDI (Capacitor Discharge Ignition)
Timing:
Refer to manual for specific timing settings and adjustment procedures.
Length:
Approx. 2,095 mm (82.5 in)
Width:
Approx. 750 mm (29.5 in)
Height:
Approx. 1,170 mm (46.1 in)
Wheelbase:
Approx. 1,425 mm (56.1 in)
Dry Weight:
Approx. 187 kg (412 lbs)
Wet Weight:
Approx. 202 kg (445 lbs)
Wheel Type:
Cast Aluminum Alloy
Bolt Pattern:
Not applicable for typical motorcycle spoke/hub arrangements. Wheel hub specifications will be in the manual.
Safety Classification:
As a motorcycle from this era, formal crash safety ratings like modern cars are not applicable. Focus is on rider protection via equipment.
Braking System:
Dual Front Disc Brakes, Single Rear Disc Brake. System details and maintenance within manual.
Suspension Stability:
Performance-oriented suspension designed for stability at speed. Manual covers adjustments.
Frame Construction:
Steel Twin-Spar Frame providing structural integrity.
Instrumentation:
Analog speedometer, tachometer, temperature gauge, and warning lights. Manual covers function and testing.
Rider Aids:
No modern electronic rider aids (e.g., traction control, ABS) as this is an 80s era sportbike. Focus is on mechanical feedback.
Connectivity Features:
None.
Oil Change:
Refer to manual for specific mileage/time intervals, typically every 2,000-3,000 miles or annually. Transmission oil every 5,000-7,000 miles.
Spark Plugs:
Inspect and gap/replace every 3,000-5,000 miles, depending on usage. Manual will specify exact type and gap.
Chain Maintenance:
Lubricate and adjust chain tension every 500-1,000 miles. Manual will specify correct slack.
Coolant:
Ethylene Glycol-based antifreeze coolant, typically a 50/50 mix with distilled water. Capacity specified in manual.
Brake Fluid:
DOT 4 brake fluid is generally recommended for bikes of this era. Manual will confirm specific type and flushing interval.
2 Stroke Oil:
High-quality 2-stroke synthetic or semi-synthetic oil specifically designed for high-performance, liquid-cooled engines with oil injection. Manual will recommend specific types.
Carburetor Issues:
Can be prone to gumming if not run regularly or if stale fuel is used. Carburetor synchronization and cleaning are common maintenance items. Manual details this.
Engine Wear:
High-performance two-strokes require diligent maintenance. Piston ring and cylinder wear can occur if not properly cared for. Manual provides rebuild specifications.
Electrical Gremlins:
Older wiring harnesses can degrade. Manual's wiring diagrams are critical for troubleshooting.
