Suzuki RG500 Workshop Service Repair Manual

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🏷️ 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...

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Type: Motorcycle

Vendor:

Sku: 133790

Tags: Motorcycle Motorcycles RG Series RG500 Suzuki

Product variants

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

RG500 Gamma

Model Code:

RG500H

Year:

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:

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:

Searchable:

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.