Suzuki RG500 Rg 500 Workshop Service Repair Manual PDF Download

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