This manual pertains to the 1990 Suzuki RG500, a high-performance motorcycle renowned for its racing heritage, derived from successful Grand Prix machines. Featuring a potent 498cc two-stroke, liquid-cooled V4 engine producing approximately 95-100 horsepower, the RG500 offers an exhilarating riding experience. Its engineering is characterized by a lightweight chassis, dual front disc brakes, and a 6-speed transmission, all contributing to its exceptional performance and handling. This iconic model, produced from 1985 to 1990, represents a significant era in sportbike technology and design.
This comprehensive service repair manual provides essential information for owners, DIY enthusiasts, and independent repair shops. It covers a wide array of critical systems, including general information, periodic maintenance, engine, fuel system, exhaust, cooling, lubrication, chassis, and electrical systems, along with emission control information and wiring diagrams. The manual offers step-by-step repair instructions, detailed diagnostic procedures for systems like the fuel injection, and guidance on essential maintenance tasks specific to two-stroke engines, such as power valve cleaning and carburetor tuning. With dealer-level technical depth and numerous illustrations, this English-language manual is designed to empower users to maintain and repair their Suzuki RG500 effectively, enabling cost savings and ensuring optimal performance.
Target Audience:
Suzuki RG500 owners, DIY enthusiasts, independent repair shops
Manual Value Proposition:
Enables cost savings through self-repair, provides dealer-level information
Ease Of Use:
Very easy to follow, step-by-step instructions for any skill level
Accessibility:
Instant download, no shipping costs or waiting
Manual Coverage Type:
Service Repair Manual
Estimated Page Count:
Comprehensive (specific number not provided, but described as 'very detailed')
Manual Type:
Service Repair Manual
General Information:
Included
Periodic Maintenance:
Included
Fi System Diagnosis:
Included
Lubrication System:
Included
Electrical System:
Included
Servicing Information:
Included
Emission Control Information:
Included
Repair Instructions:
Step-by-step repair instructions
Diagnostic Procedures:
Diagnosis and troubleshooting
Maintenance Procedures:
Periodic maintenance and servicing
Technical Expertise Level:
Dealer-level technician equivalent
Diagnostic Capabilities:
Detailed FI System Diagnosis
Visual Aids:
Tons of pictures and diagrams
Compatibility:
Windows/Mac
Printability:
All pages are printable
Binding:
Digital Download (No physical binding)
Paper Type:
N/A (Digital PDF)
Engine Type:
Two-stroke, liquid-cooled, V4 (RG500 Gamma typically)
Displacement:
498cc (RG500 Gamma)
Horsepower:
Approx. 95-100 HP (RG500 Gamma, depending on market and tune)
Fuel Delivery:
Carbureted (typically 34mm Mikuni VM34SS or similar for RG500 Gamma)
Ignition System:
Electronic Ignition (CDI)
Starting System:
Kick starter
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet, multi-plate
Dry Weight:
Approx. 155-160 kg (RG500 Gamma, depending on specification)
Braking System Front:
Dual Disc Brakes (RG500 Gamma)
Braking System Rear:
Single Disc Brake (RG500 Gamma)
Lighting:
Headlight, taillight, turn signals
Infotainment System:
N/A (Focus on mechanical and electrical systems)
Rider Assistance:
N/A (Focus on mechanical and electrical systems)
Oil Change Interval:
Detailed in manual (typically based on mileage or operating hours for 2-stroke)
Spark Plug Replacement:
Detailed in manual
Engine Oil Type:
High-quality 2-stroke motorcycle oil (specific grade provided in manual)
Coolant Type:
Ethylene glycol-based coolant (specific mixture ratio provided)
Two Stroke Specifics:
Manual will cover typical 2-stroke maintenance like power valve cleaning, exhaust port cleaning, carburetor tuning.
Engine Wear:
Tips for identifying and addressing wear on pistons, rings, and cylinders.
Manufacturer:
Suzuki Motor Corporation
Racing Heritage:
Based on Suzuki's successful Grand Prix racing motorcycles (e.g., RGB500)
Production Period:
RG500 Gamma produced from 1985 to 1990
Performance Recognition:
The RG500 Gamma was renowned for its exceptional performance and racing pedigree, often considered a homologation special.