The Suzuki RG500 Gamma, produced between 1985 and 1987, stands as a remarkable testament to high-performance sportbike engineering. Directly derived from Suzuki's legendary RG500 Grand Prix racing machines, this homologation special features a unique 498cc liquid-cooled, two-stroke, square-four engine, a technological marvel of its era. Designed for exhilarating acceleration and top speeds, the RG500 Gamma was built to bridge the gap between track performance and road legality, offering an unmatched riding experience. Its rarity and direct lineage to racing success make it a highly sought-after motorcycle for enthusiasts and collectors alike.
This comprehensive workshop service and repair manual provides detailed guidance for the mechanical and electrical servicing of the Suzuki RG500 Gamma. It covers all essential aspects, including complete engine disassembly and reassembly of the Square Four engine, fuel and cooling systems, electrical components, and chassis. The manual also includes periodic maintenance schedules, troubleshooting procedures, and information on specialized tools. Its expert-level detail, complete with exploded views and diagrams, makes it an indispensable resource for technicians, experienced mechanics, and dedicated owners aiming to maintain and repair this iconic sportbike.
SUZUKI RG500 RG 500 WORKSHOP SERVICE REPAIR MANUAL (PDF version)
very rare manual
This is a very comprehensive and structured workshop service manual for your Suzuki RG500. This manual has been written in a format that is designed to meet the needs of Suzuki technicians worldwide. You will never be dissapointed with the content of this workshop manual.
01 General Information 01-01 Fuel, Oil & Coolant Recommendation 01-02 Breaking-In Procedures, Cylinder Identification 01-03 Special Materials 01-05 Precaution & General Instruction 01-06 Specifications 02 Maintenance 02-01 Periodic Maintenance Schedule 02-02 Lubrication Points 02-03 Battery, Engine Bolds & Nuts 02-04 Head, Cylinder & Muffler; Air Cleaner 02-05 Spark Plugs 02-06 Carburetors 02-07 Fuel Lines 02-08 Oil Pump; Clutch 02-09 Transmission Oil 02-10 Cooling System 02-11 Drive Train 02-12 Brakes 02-15 Tires 02-16 Steering; Front Fork; Rear Suspension 02-17 Chassis Bolts & Nuts 03 Engine 03-01 Engine Components Removable with Engine in Place 03-02 Engine Removal and Reinstallation 03-11 Engine Disassembly 03-24 Engine Components Inspection & Servicing; Head, Cylinder, Exhaust Valve 03-25 Piston 03-27 Piston Rings 03-28 Bearings; Oil Seals; Crankshaft 03-29 Clutch Plates 03-31 Transmission Gears & Related Parts 03-32 Countershaft 03-33 Drive Shaft 03-35 Engine Reassembly 03-36 Exhaust Valve 03-37 Transmission 03-38 Pilot Shaft 03-39 Primary Drive Gear 03-41 Clutch 03-43 Crankshaft 03-44 Upper Crankcase; Rotary Disc Valve 03-46 Magneto 03-47 Piston and Rings 03-48 Cylinder 03-49 Cylinder Head 04 Cooling System 04-01 Cooling System 04-02 Cooling Solution 04-03 Radiator & Water Hoses 04-04 ThermoStat 04-06 Water Pump 04-11 Water Temp. Meter & Temp. Gauge 05 Fuel and Lubrication 05-01Fuel Tank & Fuel Cock 05-02 Carburetor Construction 05-03 Specifications; I.D. No. Location 05-04 Removal & Disassembly 05-06 Needle Valve Inspection 05-07 Float Height Adjustment; Reassembly & Mounting 05-08 Fuel Level Inspection 05-09 Balancing Carburetors 05-10 Oil Pump Bleeding Air; Checking 06 Electrical System 06-01 Charging System 06-05 Ignition System 06-08 Exhaust Valve Control Unit & Actuator 06-12 Water Temp. Meter 06-14 Oil Gauge 06-15 Lamps 06-16 Speedometer 06-18 Switches 06-19 Battery 07 Chassis 07-01 Fairing 07-04 Front Wheel 07-09 Front Brake 07-16 Front Fork 07-24 Steering Stem 07-29 Rear Brake 07-36 Rear Wheel 07-42 Tire & Wheel 07-48 Rear Swingarm & Suspension 08 Servicing Information 08-01 Troubleshooting 08-07 Wiring Diagram 08-12 Cable, Harness & Hose Routing 08-18 Special Tools 08-21 Tightening Torque 08-24 Service Data 09 Appendix 09-01 3rd/4th Drive Gear & 5th Drive Gears 09-02 Overflow Pipes Routing 09-04 Transmission Oil Capacity 10 RG500H ('87 Model) 10-01 Service Data 10-06 2nd & 6th Driven Gears 10-07 Under Cowling Installation
SUZUKI RG500 RG 500 WORKSHOP SERVICE REPAIR MANUAL (PDF version)
very rare manual
This is a very comprehensive and structured workshop service manual for your Suzuki RG500. This manual has been written in a format that is designed to meet the needs of Suzuki technicians worldwide. You will never be dissapointed with the content of this workshop manual.
01 General Information 01-01 Fuel, Oil & Coolant Recommendation 01-02 Breaking-In Procedures, Cylinder Identification 01-03 Special Materials 01-05 Precaution & General Instruction 01-06 Specifications 02 Maintenance 02-01 Periodic Maintenance Schedule 02-02 Lubrication Points 02-03 Battery, Engine Bolds & Nuts 02-04 Head, Cylinder & Muffler; Air Cleaner 02-05 Spark Plugs 02-06 Carburetors 02-07 Fuel Lines 02-08 Oil Pump; Clutch 02-09 Transmission Oil 02-10 Cooling System 02-11 Drive Train 02-12 Brakes 02-15 Tires 02-16 Steering; Front Fork; Rear Suspension 02-17 Chassis Bolts & Nuts 03 Engine 03-01 Engine Components Removable with Engine in Place 03-02 Engine Removal and Reinstallation 03-11 Engine Disassembly 03-24 Engine Components Inspection & Servicing; Head, Cylinder, Exhaust Valve 03-25 Piston 03-27 Piston Rings 03-28 Bearings; Oil Seals; Crankshaft 03-29 Clutch Plates 03-31 Transmission Gears & Related Parts 03-32 Countershaft 03-33 Drive Shaft 03-35 Engine Reassembly 03-36 Exhaust Valve 03-37 Transmission 03-38 Pilot Shaft 03-39 Primary Drive Gear 03-41 Clutch 03-43 Crankshaft 03-44 Upper Crankcase; Rotary Disc Valve 03-46 Magneto 03-47 Piston and Rings 03-48 Cylinder 03-49 Cylinder Head 04 Cooling System 04-01 Cooling System 04-02 Cooling Solution 04-03 Radiator & Water Hoses 04-04 ThermoStat 04-06 Water Pump 04-11 Water Temp. Meter & Temp. Gauge 05 Fuel and Lubrication 05-01Fuel Tank & Fuel Cock 05-02 Carburetor Construction 05-03 Specifications; I.D. No. Location 05-04 Removal & Disassembly 05-06 Needle Valve Inspection 05-07 Float Height Adjustment; Reassembly & Mounting 05-08 Fuel Level Inspection 05-09 Balancing Carburetors 05-10 Oil Pump Bleeding Air; Checking 06 Electrical System 06-01 Charging System 06-05 Ignition System 06-08 Exhaust Valve Control Unit & Actuator 06-12 Water Temp. Meter 06-14 Oil Gauge 06-15 Lamps 06-16 Speedometer 06-18 Switches 06-19 Battery 07 Chassis 07-01 Fairing 07-04 Front Wheel 07-09 Front Brake 07-16 Front Fork 07-24 Steering Stem 07-29 Rear Brake 07-36 Rear Wheel 07-42 Tire & Wheel 07-48 Rear Swingarm & Suspension 08 Servicing Information 08-01 Troubleshooting 08-07 Wiring Diagram 08-12 Cable, Harness & Hose Routing 08-18 Special Tools 08-21 Tightening Torque 08-24 Service Data 09 Appendix 09-01 3rd/4th Drive Gear & 5th Drive Gears 09-02 Overflow Pipes Routing 09-04 Transmission Oil Capacity 10 RG500H ('87 Model) 10-01 Service Data 10-06 2nd & 6th Driven Gears 10-07 Under Cowling Installation
