User Manuals: Suzuki rg500 Road Racing Motorcycle

Manuals and User Guides for Suzuki rg500 Road Racing Motorcycle. We have 1 Suzuki rg500 Road Racing Motorcycle manual available for free PDF download: Service Manual

Suzuki rg500 Service Manual (238 pages)

Brand: Suzuki | Category: Motorcycle | Size: 13 MB

RG Cutaway Diagram
2
View of Suzuki RG500
5
Left/Right Side
5
General Information
7
Serial Number Location
8
Fuel
8
Engine Oil
8
Transmission Oil
8
Break-In Procedures
9
Cylinder Identification
9
Coolant
9
Water for Mixing
9
Special Materials
10
Precaution and General Instruction
12
Use of Genuine Suzuki Parts
12
Specifications
13
Dimensions and Dry Mass
13
Periodic Maintenance and Tune-Up Procedures
15
Periodic Maintenance Schedule
16
Periodic Maintenance Chart
16
Lubrication Points
17
Maintenance and Tune-Up Procedures
18
Battery
18
Engine Bolts and Nuts
18
Cylinder Head Bolts and Nuts
18
Cylinder Head, Cylinder and Muffler
19
Air Cleaner
19
Exhaust Pipe Bolts and Nuts
19
Spark Plugs
20
Carburetors
21
Idle RPM Adjustment
21
Recommended Spark Plug
21
Fuel Lines
22
Throttle Cable
22
Choke Cable
22
Oil Pump
23
Clutch
23
Cooling System
25
Drive Chain
26
Cleaning and Lubricating
27
Brakes
27
Brake Fluid Level
27
Brake Pads
28
Brake Pedal Height
28
Brake Light Switches
28
Bleeding Air from the Brake Fluid Circuit
29
Tires
30
Tire Tread Condition
30
Tire Pressure
30
Tire Tread Depth Limit
30
Steering
31
Front Fork
31
Rear Suspension
31
Chassis Bolts and Nuts
32
Engine
34
Engine Components Removable with the Engine in Place
35
Engine Removal
36
Engine Reinstallation
41
Engine Disassembly
45
Rear Cylinder Head
45
Front Cylinder Head
45
Engine Components Inspection and Servicing
58
Cylinder Head
58
Cylinder and Exhaust Valve
58
Piston
59
Cylinder Bore
59
Decarbon
59
Piston Diameter
60
Piston-Cylinder Clearance
60
Piston Pin Bore
60
Piston Pin O.D.
60
Piston Rings
61
Piston Ring End Gap
61
Piston Ring Free End Gap
61
Piston Ring to Groove Clearance
61
Oversize Piston Ring
62
Bearings
62
Oil Seals
62
Crankshaft
62
Condition of Big End Bearing
63
Con-Rod Small End Bore I.D.
63
Clutch Plates
63
Clutch Spring Free Length
64
Clutch Bearings
64
Sleeve Hub Spring Washer
65
Transmission Gears and Related Parts
65
Gear-Shifting Fork Clearance
66
Countershaft Disassembly
66
Drive Shaft Disassembly
67
Engine Reassembly
69
Cooling System Description
86
Cooling Solution
87
Anti-Leakage Material
87
Coolant Density-Boiling Point Curve
87
Coolant Density-Freezing Point Curve
87
Radiator and Water Hoses Removal
88
Radiator and Water Hoses Inspection
88
Radiator Hose
89
Thermostat Removal
89
Thermostat Inspection
90
Water Pump
91
Water Temperature Meter and Temperature Gauge
96
Temperature Gauge Specification
97
Fuel and Lubrication System
98
Fuel Tank and Fuel Cock
99
Carburetor Construction
100
Carburetor Specifications
101
Needle Valve Inspection
104
Float Height Adjustment
105
Fuel Level Inspection
106
Balancing Carburetors
107
Bleeding Air from the Oil Pump Circuit
108
Checking Oil Pump
108
Electrical System
109
Charging System Description
110
Charging Output Check
112
AC Generator No-Load Performance
112
AC Generator Continuity Check
113
Regulator/Rectifier
113
Ignition System Description
114
Ignition System Operation
114
Ignition Coils
115
Pick-Up Coil
116
Stator Coils
116
CDI Unit
116
Automatic Exhaust Control Unit and Actuator
117
Exhaust Valve Operation
118
Actuator
118
Actuator Pulley
119
Exhaust Valve Control Unit
120
Water Temperature Meter
121
Water Temperature Meter Inspection
122
Oil Level Gauge
123
Lamps
124
Headlight
124
Tail/Brake Light
124
Turn Signal Light
125
Speedometer
125
Speedometer Wiring Inspection
126
Switches
127
Battery Specifications
128
Initial Charging
128
Battery Servicing
129
Recharging Operation
130
Chassis
131
Fairing Construction
132
Front Wheel Construction
135
Front Wheel Removal and Disassembly
135
Front Wheel Inspection
137
Wheel Bearings
137
Axle Shaft
137
Wheel
137
Disc
139
Speedometer Gearbox
139
Caliper
139
Front Brake
140
Brake Pad Replacement
140
Caliper Removal and Disassembly
141
Caliper and Disc Inspection
142
Cylinder and Piston
142
Rubber Part
142
Caliper Reassembly and Remounting
143
Caliper Bolts
143
Master Cylinder Removal and Disassembly
144
Master Cylinder Reassembly
146
Damper Rod, Oil Lock Piece and Washers
150
Inner and Outer Tubes
151
Fork Spring
151
Posi-Damp Unit
151
Inner Tube Metal
151
Oil Lock Piece and Washers
152
Damper Rod Bolt
152
Outer Tube Metal, Washer and Oil Seal
152
Fork Oil
153
Inner Tube
153
Clamp Bolts and Cap Bolts
154
Front Fork Setting
154
Front Fork Spring
154
Fork Air
154
Steering Stem
155
Outer Races
158
Bearing
158
Stem Unit
159
Rear Brake
160
Cylinder
166
Rear Brake Pedal
166
Rear Wheel Construction
167
Wheel and Sprocket Mounting Drum Bearings
171
Sprocket Mounting Drum Bearing
172
Brake Disc
172
Rear Sprocket
172
Rear Axle Shaft
172
Tire and Wheel
173
Tire
175
Valve Inspection
176
Valve Installation
176
Tire Mounting
177
Rear Swingarm and Suspension
179
Rear Shock Absorber
180
Cushion Lever and Cushion Rod
181
Swingarm
184
Shock Absorber
185
Swingarm Pivot Shaft
186
Cushion Lever
186
Cushion Rod
187
Torque Link Mounting
187
Final Inspection and Adjustment
192
Servicing Information
193
Wiring Diagram
200
Cable, Harness and Hose Routing
205
Cable Routing
205
Wiring Harness Routing
206
Oil Pump and Carburetor Hose Routing
207
Fuel Hose Routing
208
Stator Lead Wire Routing
209
Transmission Case Breather Hose Routing
209
Water Hose Routing
210
Special Tools
211
Tightening Torque
214
Tightening Torque Chart
216
Service Data
217
3Rd/4Th Drive Gear and 5Th Drive Gear
223
Overflow Pipes Routing
224
Transmission Oil Capacity
226
Rg500H
227

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User Manuals: Suzuki rg500 Road Racing Motorcycle

Suzuki rg500 Service Manual (238 pages)

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