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Manuals
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Suzuki Manuals
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rg500
Service manual
Suzuki RG500 Service Manual
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Service manual
(248 pages)
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Table Of Contents
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Contents
Table of Contents
Bookmarks
Table of Contents
RG Cutaway Diagram
View of Suzuki RG500
Left/Right Side
General Information
Serial Number Location
Fuel
Engine Oil
Transmission Oil
Break-In Procedures
Cylinder Identification
Coolant
Water for Mixing
Special Materials
Precaution and General Instruction
Use of Genuine Suzuki Parts
Specifications
Dimensions and Dry Mass
Periodic Maintenance and Tune-Up Procedures
Periodic Maintenance Schedule
Periodic Maintenance Chart
Lubrication Points
Maintenance and Tune-Up Procedures
Battery
Engine Bolts and Nuts
Cylinder Head Bolts and Nuts
Cylinder Head, Cylinder and Muffler
Air Cleaner
Exhaust Pipe Bolts and Nuts
Spark Plugs
Carburetors
Idle RPM Adjustment
Recommended Spark Plug
Fuel Lines
Throttle Cable
Choke Cable
Oil Pump
Clutch
Cooling System
Drive Chain
Cleaning and Lubricating
Brakes
Brake Fluid Level
Brake Pads
Brake Pedal Height
Brake Light Switches
Bleeding Air from the Brake Fluid Circuit
Tires
Tire Tread Condition
Tire Pressure
Tire Tread Depth Limit
Steering
Front Fork
Rear Suspension
Chassis Bolts and Nuts
Engine
Engine Components Removable with the Engine in Place
Engine Removal
Engine Reinstallation
Engine Disassembly
Rear Cylinder Head
Front Cylinder Head
Engine Components Inspection and Servicing
Cylinder Head
Cylinder and Exhaust Valve
Piston
Cylinder Bore
Decarbon
Piston Diameter
Piston-Cylinder Clearance
Piston Pin Bore
Piston Pin O.D.
Piston Rings
Piston Ring End Gap
Piston Ring Free End Gap
Piston Ring to Groove Clearance
Oversize Piston Ring
Bearings
Oil Seals
Crankshaft
Condition of Big End Bearing
Con-Rod Small End Bore I.D.
Clutch Plates
Clutch Spring Free Length
Clutch Bearings
Sleeve Hub Spring Washer
Transmission Gears and Related Parts
Gear-Shifting Fork Clearance
Countershaft Disassembly
Drive Shaft Disassembly
Engine Reassembly
Cooling System Description
Cooling Solution
Anti-Leakage Material
Coolant Density-Boiling Point Curve
Coolant Density-Freezing Point Curve
Radiator and Water Hoses Removal
Radiator and Water Hoses Inspection
Radiator Hose
Thermostat Removal
Thermostat Inspection
Water Pump
Water Temperature Meter and Temperature Gauge
Temperature Gauge Specification
Fuel and Lubrication System
Fuel Tank and Fuel Cock
Carburetor Construction
Carburetor Specifications
Needle Valve Inspection
Float Height Adjustment
Fuel Level Inspection
Balancing Carburetors
Bleeding Air from the Oil Pump Circuit
Checking Oil Pump
Electrical System
Charging System Description
Charging Output Check
AC Generator No-Load Performance
AC Generator Continuity Check
Regulator/Rectifier
Ignition System Description
Ignition System Operation
Ignition Coils
Pick-Up Coil
Stator Coils
CDI Unit
Automatic Exhaust Control Unit and Actuator
Exhaust Valve Operation
Actuator
Actuator Pulley
Exhaust Valve Control Unit
Water Temperature Meter
Water Temperature Meter Inspection
Oil Level Gauge
Lamps
Headlight
Tail/Brake Light
Turn Signal Light
Speedometer
Speedometer Wiring Inspection
Switches
Battery Specifications
Initial Charging
Battery Servicing
Recharging Operation
Chassis
Fairing Construction
Front Wheel Construction
Front Wheel Removal and Disassembly
Front Wheel Inspection
Wheel Bearings
Axle Shaft
Wheel
Disc
Speedometer Gearbox
Caliper
Front Brake
Brake Pad Replacement
Caliper Removal and Disassembly
Caliper and Disc Inspection
Cylinder and Piston
Rubber Part
Caliper Reassembly and Remounting
Caliper Bolts
Master Cylinder Removal and Disassembly
Master Cylinder Reassembly
Damper Rod, Oil Lock Piece and Washers
Inner and Outer Tubes
Fork Spring
Posi-Damp Unit
Inner Tube Metal
Oil Lock Piece and Washers
Damper Rod Bolt
Outer Tube Metal, Washer and Oil Seal
Fork Oil
Inner Tube
Clamp Bolts and Cap Bolts
Front Fork Setting
Front Fork Spring
Fork Air
Steering Stem
Outer Races
Bearing
Stem Unit
Rear Brake
Cylinder
Rear Brake Pedal
Rear Wheel Construction
Wheel and Sprocket Mounting Drum Bearings
Sprocket Mounting Drum Bearing
Brake Disc
Rear Sprocket
Rear Axle Shaft
Tire and Wheel
Tire
Valve Inspection
Valve Installation
Tire Mounting
Rear Swingarm and Suspension
Rear Shock Absorber
Cushion Lever and Cushion Rod
Swingarm
Shock Absorber
Swingarm Pivot Shaft
Cushion Lever
Cushion Rod
Torque Link Mounting
Final Inspection and Adjustment
Servicing Information
Wiring Diagram
Cable, Harness and Hose Routing
Cable Routing
Wiring Harness Routing
Oil Pump and Carburetor Hose Routing
Fuel Hose Routing
Stator Lead Wire Routing
Transmission Case Breather Hose Routing
Water Hose Routing
Special Tools
Tightening Torque
Tightening Torque Chart
Service Data
3Rd/4Th Drive Gear and 5Th Drive Gear
Overflow Pipes Routing
Transmission Oil Capacity
Rg500H
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Summary of Contents for Suzuki RG500
Page 2
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 &...
Page 3
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 &...
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