Suzuki Rg500 User manual

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1

Table of contents

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Vale engineering '02

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

01-05 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