Suzuki Rg500 User manual

RG500 Service Manual

Erik's RG500 Resources

Forward Picture

RG Cutaway Diagram

01 General Information

01-01 Fuel, Oil & Coolant Recommendation

01-02 Breaking-In Procedures, Cylinder Identification

01-03 Special Materials

01-04

01-05 Precaution & General Instruction

01-06 Specifications

01-07

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

02-13

02-14

02-15 Tires

02-16 Steering; Front Fork; Rear Suspension

02-17 Chassis Bolts & Nuts

02-18

03 Engine

03-01 Engine Components Removable with Engine in Place

03-02 Engine Removal and Reinstallation

03-03

03-04

03-05

03-06

03-07

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RG500 Service Manual

03-08

03-09

03-00

03-11 Engine Disassembly

03-12

03-13

03-14

03-15

03-16

03-17

03-18

03-19

03-20

03-21

03-22

03-23

03-24 Engine Components Inspection & Servicing; Head, Cylinder, Exhaust Valve

03-25 Piston

03-26

03-27 Piston Rings

03-28 Bearings; Oil Seals; Crankshaft

03-29 Clutch Plates

03-30

03-31 Transmission Gears & Related Parts

03-32 Countershaft

03-33 Drive Shaft

03-34

03-35 Engine Reassembly

03-36 Exhaust Valve

03-37 Transmission

03-38 Pilot Shaft

03-39 Primary Drive Gear

03-40

03-41 Clutch

03-42

03-43 Crankshaft

03-44 Upper Crankcase; Rotary Disc Valve

03-45

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RG500 Service Manual

03-46 Magneto

03-47 Piston and Rings

03-48 Cylinder

03-49 Cylinder Head

03-50

04 Cooling System

04-01 Cooling System

04-02 Cooling Solution

04-03 Radiator & Water Hoses

04-04 ThermoStat

04-05

04-06 Water Pump

04-07

04-08

04-09

04-10

04-11 Water Temp. Meter & Temp. Gauge

04-12

05 Fuel and Lubrication

05-01Fuel Tank & Fuel Cock

05-02 Carburetor Construction

05-03 Specifications; I.D. No. Location

05-04 Removal & Disassembly

05-05

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

06-02

06-03

06-04

06-05 Ignition System

06-06

06-07

06-08 Exhaust Valve Control Unit & Actuator

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RG500 Service Manual

06-09

06-10

06-11

06-12 Water Temp. Meter

06-13

06-14 Oil Gauge

<.A> 06-15 Lamps

06-16 Speedometer

06-17

06-18 Switches

06-19 Battery

06-20

06-21

07 Chassis

07-01 Fairing

07-02

07-03

07-04 Front Wheel

07-05

07-06

07-07

07-08

07-09 Front Brake

07-10

07-11

07-12

07-13

07-14

07-15

07-16 Front Fork

07-17

07-18

07-19

07-20

07-21

07-22

07-23

07-24 Steering Stem

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RG500 Service Manual

07-25

07-26

07-27

07-28

07-29 Rear Brake

07-30

07-31

07-32

07-33

07-34

07-35

07-36 Rear Wheel

07-37

07-38

07-39

07-40

07-41

07-42 Tire & Wheel

07-43

07-44

07-45

07-46

07-47

07-48 Rear Swingarm & Suspension

07-49

07-50

07-51

07-52

07-53

07-54

07-55

07-56

07-57

07-58

07-59

07-60

07-61

08 Servicing Information

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RG500 Service Manual

08-01 Troubleshooting

08-02

08-03

08-04

08-05

08-06

08-07 Wiring Diagram

08-08

08-09

08-10

08-11

08-12 Cable, Harness & Hose Routing

08-13

08-14

08-15

08-16

08-17

08-18 Special Tools

08-19

08-20

08-21 Tightening Torque

08-22

08-23

08-24 Service Data

08-25

08-26

08-27

08-28

09 Appendix

09-01 3rd/4th Drive Gear & 5th Drive Gears

09-02 Overflow Pipes Routing

09-03

09-04 Transmission Oil Capacity

10 RG500H ('87 Model)

10-01 Service Data

10-02

10-03

10-04

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RG500 Service Manual

10-05

10-06 2nd & 6th Driven Gears

10-07 Under Cowling Installation

10-08

10-09

10-10

Erik's RG500 Resources

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