IMPORTANT: Please read this manual and follow its instructions carefully. To emphasize special information the words WARNING, CAUTION and NOTE carry special meanings and should be carefully reviewed. +++4+ The personal safety of the rider may be involved. Disregarding this information could result in injury to the rider, «These instructions point out special service procedures or pre. cautions that must be followed to avoid damaging the machine, This provide special information to make maintenance easier or important instructions clearer. CAUTION. . NOTE...FOREWORD Welcome to the world of SUZUKI motor- cycles. The confidence you have shown by the pur- chase of our products is very much appreci- ated. Each SUZUKI motorcycle backs this confidence by @ long record of manufactur- ing and engineering excellence. The same ex- cellence that has produced a long history of world-championship racing successes on the race tracks. SUZUKI now presents the new RMS500, a competition proved racing machine, capable of competing on any race course in the world. This handbook is presented as a means whereby you can maintain your RM500 in top working condition at all times. Your rid- ‘ng skill and the maintenance steps outlined in this manual will assure you of top per- formance from your machine under any type of competition conditions. We sincerely wish you and your SUZUKI motorcycle a successful partnership for many years of happy riding. SUZUKI MOTOR CO.,LTD. THIS VEHICLE IS DESIGNED AND MANUFACTURED FOR COMPETI- TION USE ONLY AND IS NOT SUB- JECT TO FEDERAL MOTOR VEHI- CLE SAFETY STANDARDS AS IT IS NOT EQUIPPED OR APPROVED FOR OPERATION ON PUBLIC STREETS, ROADS, OR HIGHWAYS. SOME STATE LAWS FURTHER PROHIBIT OPERATION OF THIS VEHICLE EXCEPT IN AN ORGANI- ZED COMPETITIVE EVENT UPON A CLOSED COURSE CONDUCTED UNDER THE AUSPICES OF A REC- OGNIZED SANCTIONING BODY OR BY PERMIT OF THE LOCAL GOV- ERNMENTAL AUTHORITY MAY- ING JURISDICTION, BEFORE OPERATION, FIRST DE- TERMINE THAT OPERATION IS LEGAL IN YOUR STATE. TABLE OF CONTENTS GENERAL INSTRUCTION . LOCATION OF PARTS . . PERIODICAL INSPECTION SCHEDULE . BREAKIN . , OPERATION... . . : ‘ INSPECTION AND MAINTENANCE . . ENGINE REMOVAL ...... ENGINE DISASSEMBLY .... INSPECTION AND SERVICING ENGINE REASSEMBLING ENGINE PARTS . CARBURETOR ELECTRICAL SYSTEM . FRONT WHEEL FRONT FORK . STEERING . REAR WHEEL . ¢ FUEL FLOATING SUSPENSION an RBaaan +26 “SL +54 REAR SWINGING ARM . SERVICE AND MAINTENANCE AFTER COMPETITION TROUBLESHOOTING . . TIGHTENING TORQUE SPECIAL TOOL . MATERIAL ...... CABLE ROUTING . SPECIFICATIONS . . SERVICE DATA ... 67 $68 on 14 79 +80 pal +82GENERAL INSTRUCTION FUEL Use the highest octane leaded fuel avail- able of at least 90 pump octane (25M meth. od). Nore: ®3™octane ratings are normally listed on all commercial gas pumps. ENGINE OIL Suzuki strongly recommends the use of SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRICANT. If this oil is not available use ‘an equivalent high quality Two Cycle Racing Lubricant, at @ 20 to one ratio only. CAUTION: Do not allow two different brands to get mix in the fuel oil mixtur MIXING RATIO 20 parts gasoline to 1 part oil is the correct gasoline to oil mixture ratio for your engine, For proper engine performance, it is essen- tial that the above fuel/oil mixture should be maintained. FUEL AND OIL MIXTURE RATIO OF 20:1 GASOLINE | OIL | GASOLINE | OIL, t mi (ae (oz) Os 25 05 08 10 50, 1.0 16 18 78 15 24 20 100 20 32 25 125 25 40 3.0 150 3.0 48 35 175 35 56 40 200 40 64 45 225 45 12 5.0 250 50 80 55 275 55 a8 60 ‘300 6.0 96 65 325 65 10.4 70 350 70 12 78 375, 78 12.0. a0 400 80 128. as 425 85 13.6 90 450 90 144 95 475 95 152 10.0 500 | 10.0 166 CAUTION: A mixture containing too little oil wi cause overheating of the en: much oil will cause excessive carbon formation resulting in preignition, fouled spark plug and loss of engine L_ power. MIXING PROCEDURE To mix gasoline and oil, always use a sepa. rate, clean container. Pour the full amount of oil required for the total mixture into the container, add approximately half the amount of gasoline to be mixed and shake thoroughly. Add the remainder of the gasoline and again thoroughly agitate the container.TRANSMISSION OIL Use a good quality SAE 20WW/40 multi-grade motor oil. FRONT FORK OIL Use fork oil of #10. SERIAL NUMBER LOCATION Engine number Frame serial number is stamped on steering head tube and 1.D. plate. Engine serial number is located on right side of crankcase. When registering your machine and marking orders for spare parts, cite these two numbers. Please write down these numbers here for your reference. Frame No. Engine No.: USE OF GENUINE SUZUKI PARTS To replace any part of the machine, use a genuine Suzuki replacement part. Immita- tion parts or parts supplied from any other source than Suzuki, if used to replace parts ‘of Suzuki origin in’ the machine, will lower the inherent capability of the machine and, for worse, could induce costly mechanical trouble.LOCATION OF PARTS (1) Gluten lever (6) Carburetor choke knob (2) Engine stop switch (7) Gearshift lever () Front brake lever (8) Kick starter lever (4) Throttle grip (9) Rear brake pedal (6) FuelcockPERIODICAL INSPECTION SCHEDULE portion Tavera! | Each ce] Every Foon | Gvery ieee | Every Sees every 100 xm | Every 200 4m | Every 300 km | Every $00 tm Remarks Service ier “Srmies)” | “tao mies)” | “trBomies)” | “1800 mies) Piston ring = Replace 7s = “Transmission 3 E Change =] Change a itr TOO Engine sprocket = eS 2 piace Deve cain Tareas = Replace =| Aa Taek every AO er: check nc retighten Sprocket bates nti For sprocket 7 Replace . fet ssbsaquont 10 min {esting and each ‘ote moreso Drive cain bulfer Fa epics | = Dive ain de i = ae E acinten every 10m ened 2 i 1050 em of mieage, oke nipple - > ~ | ital tereter evry 80 vr Rupture, Tawored ond A cleaner, clean = E = | severaiy arty stement ‘ould be replaces. ‘ek srtertever | Apply geass |= = = Throitie, bake z ; clutch eabie sa Z “Seed Bots and nots | Retahten s = = Rerarrer ar 20m Spark pla [heck etenn] = a = Piston = = 2 Front forkail . z ange =| ange ara TOO bremire = 5 a f..3| aoe Fulk Floating supe ‘heck and sly ease tion system pivoting | Check s Z — | pivoting postion fre auentlyBREAK-IN This motorcycle is manufactured using the latest technology relating to the two-stroke engine and thus requires a relatively short break-in operation is necessary: the only thing is that the machine should not con- tinuously operated in full-load condition for the first one hour or 30 km (20 miles). This Practice will help all moving parts to break- in and will assist in aequainting you with machine. Once the machine is fully broken- in, you can be assured of high performance in competition. ATI STARTING THE ENGINE When the engine is cold: Pull the choke knob. Depress the kick starter lever without opening the throttle. Even opening the throttle slightly may make the engine hard to start, Always return the choke knob to the original position when the engine warms up. When the engine is warm: Using the choke knob is not necessary. To start a warm engine, open the throttle 1/8 to 1/4 and kick-start the engine. STOPPING THE ENGINE Ye Engine stop switch 1, Close the fuelcock, 2, Rev the engine 3 or 4 times, 3. Slow down the engine, 4, Operate the engine stop switch to stot the engine. GEARSHIFT LEVER The transmission has 5-speeds. Depress 1! gearshift lever to shift into 1st gear. Rais the gearshift lever into 2nd, 3rd, 4th and 5 Neutral is located between 1st and 2nd.INSPECTION AND MAINTENANCE SPARK PLUG AIR CLEANER When carbon accumulates on the spark plug, a hot, strong spark will not be produced, Remove carbon deposits with a wire or pin and adjust the spark plug gap (1) to 0.5 — 0.6 mm (0.020 — 0.024 in) by measuring with a thickness gauge. Generally, when the spark plug heat range is correct, the plug electrode shows a light brown or tan color. Spark plug of a different heat may be chosen according the following table. | STANDARD TYPE | COLD TYPE [Ensk’ BBEGV | __BSEGV CAUTION: 1, The heat range selection may be made only under the condition that the carburetion is set properly. 2. If another brand of spark plug is to be used other than NGK, consult your authorized SUZUKI dealer. 3. When installing the spark plug, turn in with your fingers to prevent stripping the threads from strip- Ping, then tighten with a torque wrench to 25 — 30 N-m (2.5 — 3.0 kg-m, 18.0 — 22.0 Ib-ft), oe F Non flammable Cleaning solvent How to clean the element, 1. Fill a washing pan of a proper size with non flammable cleaning solvent, Immerse the element in the solvent and wash it clean, 2. Squeeze solvent off the washed element by pressing it between the palms of hands: do not twist and wring the element, or it will develop fissures. Immerse the element in a pool of motor oil, and squeeze the oil off the element to make it slightly wet with motor oil, 2 CAUTION: Before and during the cleaning opera- tion, examine the element to see if it has a rupture or fissure, A ruptured or fissured element must be replaced, CAUTION: Do not clean the element frame and cleaner case with petroleum,Air cleaner installation Shrinked element should be replaced. When. installing the element, do not confuse the location of the two elements. The thicker element should come inside and the thin- ner (coarser) cutside as installed in place. Make sure that there is no clearance all around the element. Before each race, drain out the brown back gasoline and water, if any, by lightly pressing the oil drain) and water drain @) by finger, respectively. TRANSMISSION OIL © ou titer eap ® Drain plug To change the transmission oil, remove the filler and drain plug and drain the oil. Install the drain plug and measure 1 000 mt (1.1 US qt) of a good quality SAE 20W/40 multigrade motor oil, then pour it into the transmission slowly. Tighten the drain plug 15 — 20 N-m (1.5 = 2.0 kg-m, 11.0 — 14.5 Ib-4t), CARBURETOR For correct, safe throttle operation the throttle cable should be adjusted to have 0.5 — 1.0 mm (0.02 — 0.04 in) play at the carburetor, This adjustment can be made at the cable adjuster on the carburetor cap.FUEL FILTER The fuel filter is incorporated in the fuel cock which is mounted on the bottom of the fuel tank at the left side, Accumulation of dirt in the filter will restrict the flow of the fuel and cause the carburetor to malfunc- tion, therefore, the fuel filter should be serviced periodically. 1, Drain the fuel from the fuel tank. 2, Remove the fuel cock by unscrewing the fitting screws. 3. Wash the screen filter in cleaning solvent. CLUTCH The play of the clutch cable should be 4mm (0.16 in) as measured at the clutch lever holder before the clutch begins to desengage. Adjust the clutch cable play with the cable adjuster (D) after loosening the lock nut 2) DRIVE CHAIN 40 — 45 mm Adjusting the drive chain: ‘Adjust the drive chain at the rear axle by loosening right and left sleeve nuts @) . Then adjust the chain tension by turning nut @) in or out. Be sure the marks stamped on the adjuster plate aligns with the same mark on the swingarm on both sides of the motor- cycle. Proper chain tension is obtained when the is 40 — 45 mm (1.6 — 1.8 in) up and down slack is on the chain at a point between the sar sprocket and chain guide roller with the motorcycle held standing erect by block- ing up and lifting and rear wheel off the floor.{Chain joint clip Turning direction CAUTION: When refitting the drive chain, be sure the drive chain joint cl Lubricating the drive chain: The drive chain must be kept well lubricated; otherwise it may break due to increased running resistance. Before lubricating the drive chain, wash it with detergent or gaso- line, and apply chain oil (molybdenum disulfide) to it. If proper chain oil is not available, dip it in gear oil for about three hours and allow to drain before installation. FRONT BRAKE 20-30 mm (08 — 1.2in) 10 (1) Measure the amount of the front brake level distance between the brake lever end and throttle grip when the brake ‘operated. The distance should be 20 30 mm (0.8 1.2in). (2) If adjustment is necessary, loosen both the lock nuts (1) and (2) and by turning the two lock nuts in or out, relocate the Position of the cable end (3) higher or lower as shown until the proper lever distance is obtained. (3) Secure the two lock nuts. REAR BRAKEBefore adjusting the brake pedal travel, adjust the brake pedal position with the brake pedal adjuster (1) until the most suitable position is obtained for quick opera tion. After adjustment of the brake pedal position completed, adjust the brake pedal travel @ with the brake adjusting nut @) to 20 — 30 mm (0.8 — 1.2 in), BRAKE LINING WEAR LIMIT Fig. A The extension line of the index mark is within the range. Fig. B ‘The extension line of the index merk is out of the range. See Fig. A. You can easily check to see if brake linings are worn down to the limit or not on both front and rear brakes, Here's the Procedure: 1) Be sure that brake control is properly adjusted. 2) See if the extension of index mark is within the range and, if so, the linings are not worn down to the limit, If the extension is at the end of, or beyond, the range, have brake shoes replaced by your SUZUKI dealer. Fig. B shows the limit in- dicator in this condition, TIRE PRESSURE Too high or too low tire pressure will affect, the tire traction, which may make the ma- chine slower in acceleration and likely to slide out. Maintain the pressure to the fol- lowing specification, Your RMS00 jis standardly fitted with 100/80-21 4PR tire for front and 140/80-18 PR tire for rear. Use genuine SUZUKI re- placement tires for better roadability. Use of non-standard tires could lead to trouble. Cold inflation tire pressure: Front 70 — 110 kPa and 0.7 — 1.1 kg/cm? Rear 10 — 16 psi "1TOOL KIT The tool kit consists of the following items. @ Too! bag @ Spark plug and spoke nipple wrench 6 mm box driver (for replacing main jet) Screw driver grip Hexagon L type wrench Front fork air pressure gauge y & 06 ' aL 12 ENGINE REMOVAL The procedure of engine removal is sequen- tially explained in following steps. Engine installation is effected by reversing the removal procedures. > 1, Remove the left frame cover. —s 2. Loosen the seat mounting bolts and re- move the seat with rear fender. 3. Remove the spring and loosen the bolt. Remove the second muffler.4. Turn the fuelcock to “OFF” position and disconnect the fuel line, Take off the fuel tank by unhooking rubber band and loosening bolts, 5. Remove the muffler moutning springs. 09920-20310 ‘Spring hook 6. Loosen the muffler mounting bolt and re- move the muffler. 13 7, Loosen the bolt and remove the clutch lever. 9. Remove the reservoir. 10. Disconnect lead wires and spark plug cord.11, Loosen two clamp screws and remove ‘the carburetor, 12. Loosen the bolts and remove the chain guard, 13, Remove the drive chain, 14, Remove the rear shock absorber reservoir holder. 15, Drain the transmission oil by loosening the drain plug, 16, Remove the engine mounting nuts and bolts. CAUTION: Self-lock nuts are used for the engine ‘mounting. Do not reuse these nuts. 17, Remove the swinging arm pivot nut after pulling off the cotter pin and draw out the swinging arm pivot shaft. 4CAUTION: Be careful not to draw out the swing- ing arm pivot shaft completely from the right side swinging arm pivoting hole. Insert the shaft or rod into the left side pivoting hole from the left side of the frame to keep the align- ment of the frame holes and swinging arm pivoting h Oe | 18. Take off the engine. 5 ENGINE DISASSEMBLY. The procedure of engine disassembly is sequentially explained in following steps. Engine reassembly is effected by reversing the disassembly procedures, 1, Remove the gearshift lever. 2. Remove the kick starter lever. 3. Loosen six nuts and remove the cylinder head,5. Remove the piston pin by using special tool. 09910-34510 Piston pin puller | 6. Flatten the engine sprocket lock washer. 7. Loosen the engine sprocket nut by using special tool. 09930-40113 Rotor holder Remove the spacer and “O" ring. 2 9. Remove two screws and the magneto cover. 10. Remove the two screws and the stator. 1611, Remove the magneto rotor nut by hold- the con-rod with special tool. 14. Loosen the screws and remove the clutch cover. 09910-20115 Con-rod holder 12, Draw out the rotor by using special tool. 15. Loosen the bolts and remove the pres- sure plate. (09910-20115 Con-rod holder (09930-30211 Attachment G Attachment A (10 09930-30141 eel 13, Remove the key. 16. Flatten the clutch sleeve hub nut lock washer. 717, Loosen the clutch sleeve hub nut by using special tool, Then draw out the clutch sleeve hub. Clutch sleeve hub holder 09920-53710 18, Loosen the primary drive gear nut by turning it clockwise. 09910-20115 Con-rod holder 19, Draw out the gearshifting shaft. 20. Loosen the screws and remove the paw! lifter and cam guide. 21, Remove the circlip and kick idle gear. 09900-06104 ‘Snap ring pliers 22. Loosen the crankcase fitting screws. 1823. Fit the engine sprocket, inside out, on the drive shaft without the spacer and tighten the nut by finger with the wash- er in place as shown. NOTE: This procedure is necessary to prevent the drive shaft from being drawn out uring disassembly. 24. Fit the crankcase separating tool to the leftside crankshaft and turn its handle to separate the crankcase. This time, both the countershaft and drive shaft right ends should be hit alternately by a plastic hammer to facilitate even separation on the case halves and to avoid their distortion. CAUTION: If the transmission gears and shafts remain on the right side crankcase during disassembly, the gearshift cam stopper spring damage may result. 09920-13111 | Crankcase separating tool 25. Remove the gearshift cam, forks and shafts. 26. Draw out counter and drive shafts with gears. NOTE: Draw out the gears altogether, 27. Remove the circip by using special tool. 09900:06104 | Snap ring pliers29. Remove the crankshaft from the crank- case. 30. Remove the oil seal by using special tool. INSPECTION AND SERVICING ENGINE CYLINDER HEAD Observe the combustion chamber surface, on which more or less carbon will be found, and evaluate the amount and the shade of color of the carbon as a basis for diagnosing the fuel combustion, Remove the carbon and clean the cylinder head. CYLINDER 09913-50121 Oil seal remover, aa 31. Remove the retainer and bearing.Check the cylinder for wear, and determine the piston-to-cylinder clearance, as follows: Using a cylinder gauge, take a total of six iameter readings on the cylinder, at three elevations, shown, in two directions at each elevation: one direction parallel and the other direction transverse to the axis of piston pin, Of the six readings, compute the difference between the largest and the smallest reading, If this difference exceeds the limit, stated below, rebore the cylinder to the next oversize or replace it by new one: 0.1: mm Uneven wear limit {0.004 in) CAUTION: After reboring, be sure to lightly chamfer the port edges with a scraper and smoothen the chamfers with sandpaper. Decarbon the exhaust ports and the upper part of the cylinder, taking care not to damage the cylinder wall surface. CYLINDER AND PISTON 20mm (0,79 in) taal Oa Piston-to-cylinder clearance is the difference between two diameter readings, one taken ‘on the piston at the ehight “A” in the direc: tion traverse to the axis of piston pin hole and the other taken on cylinder bore at “B”” from the cylinder surface. Cylinder bore 88,500 — 88.515 mm (3.4843 — 3.4848 in) Measure at the 20 mm (0.79 in) from top surface Standard Limit {88.550 mm (3.4686 in) Piston diameter Standard “88,415 — 88,430 mm (3.4809 — 3.4815 in) Measure at the 29.5 mm (1.16 in) from skirt end Limit {88,380 mm (3.4795 in) 29.5 mm’ (1.16 in O The clearance of piston-to-cylinder is pre- seribed to be within the following range, Piston-to-cylinder clearance 2 ‘Standard (0,080 — 0,090 mm. (0,0031 — 0,0035 in) Limit (0.120 mm (0.0047 in}To rebore the cylinder to the next oversize, check the available clearance with the re- Placement (oversize) piston and determine the amounts of stock to be removed by boring and honing to bring the resultant clearance into the range specified above. PISTON Observe the carboned condition of the piston crown, This observation, together with the observed condition of the cylinder head, is an important guide for adjusting the carburetor, Decarbon the piston crown, taking care not to mar the metal. Inspect the piston ring groove for carbon or gummy matter. Clean the ring groove, and check to see if each piston ring is capable of smooth movement in the groove, Check the piston pin bore inner diameter. Piston pin bore 78,002 — 18,012 mm Sang (0.7087 — 0.7091 in) _| Service Limit | 18,080 mm (0.7098 in) PISTON PIN A piston found scored at its sliding surface could lower engine performance or roughen the cylinder wall. Such scores, if any, must be eliminated by grinding; for this purpose of smoothening a scored surface, #400 sandpaper may be used. Check the piston pin diameter. 22Piston pin 0.D. 17.995 — 18,000 mm Standard | (0.7085 — 0.7087 in) Service Limit | 17.980 mm (0.7079 in) PISTON RING Check the piston ring for free end gap. Piston ring free end gap Standard — | R | Approx. 8.2 mm (0.32 in) Service Limit | 6.6 mm (0.26 in) To check the piston ring for wear, fit ring around the bottom part of the cylinder and measure the end gap in this condition of the ring, as shown, If the reading taken exceeds the limit, replace it with anew one. Piston ring end gap 03 0.5mm ee (6.01 —0.02 in) ‘Service limit (0.9 mm (0.04 in) Check the piston ring to groove clearance, Piston ring to groove clearance | 0.020 — 0.060 mm Standard | (0.0008 — 0.0024 in) CONNECTING ROD Check the connecting rod small end inner diameter. Connecting rod small end |.D. 23,003 — 23.011 mm Sense (0.9056 — 0.9059 in) 23.040 mm Service limit | {9.9071 ia)CRANKSHAFT CLUTCH Set the crankshaft on “V" blocks, as shown, and, with a dial gauge arranged in the manner indicated, take a runout reading on the shaft on each side, This reading is the crankshaft deflection, which is required to be within this limit: Crankshaft runout Check the drive plate for thickness. 2.9—3.1 mm Seances (0.11 —0.12 in) Service Limit | 2.6mm (0.10 in) Service limit 0,05 mm (0.002 in) Excessive crankshaft runout is often respon- sible for abnormal engine vibration, Such Vibration shortens engine life. Check the drive plate claw width. ab 15.8 — 16.0mm 70,0 + 0.1 mm Se (0.62 — 0.63 in) i276 20.08m) When rebuilding the crankshaft, measure the || Service limit | 15.0 mm (0.59 in) flywheel width with caliper. Crank web to web widthMeasure the clutch spring free length. If any ‘one of them is shorter than service limit, replace all the springs at a time. Service Limit | 38.5 mm (1.52 in) Check the driven plate for distortion, Service limit | 0,15 mm (0.006 in) | CLUTCH RELEASE BEARING Smooth engaging and disengaging actions Presume that the release bearing is in good condition. With this in mind, inspect the bearing for damage and, as necessary, replace it with anew one, CLUTCH SPRINGUsing a thickness gauge, check the shifting fork clearance in the groove of its gear. Shift fork to groove clearance otetae'| 0.2 — 0.3mm wae (0,008 — 0.012 in} service | Not 0.5 mm Lint — [ais {0.020 in) Check the shift fork groove width and shift fork thickness. ‘Standard = snittore | NOt | 5.0—5.1mm groove with | ,% > | (0.20-0.20im) Shift fork Ne 4.8 —4.9mm thickness | > | (0.19—0.19im) If the clearance checked is noted to exceed the specified limit, replace the fork or its gear, or both, BEARING Wash the bearing with cleaning solvent and lubricate with motor oil before inspecting. ‘Turn the inner race and check to see that it turns smoothly. If noise is heard, replace it. REASSEMBLING ENGINE PARTS Apply engine oil to each running and parts before installing BEARING AND OIL SEAL Install the bearing by using special tool. When reassembling the bearing retainer, apply the Thread Lock “1363C”. 99104-32050 | Thread Lock “"1363C"" ] When fitting an oil seal, be sure to have its lip part lightly coated with SUZUKI SUPER GREASE “A” and to install it with the oi seal installing tool. this tool, the oi seal can be held true and square as it goes into its position,CRANKSHAFT Use a plastic hammer to drive the crankshaft into its position. Be sure to deliver light blows to the end of crankshaft in order to force it into the righthand half of crankcase, as shown, CAUTION: Bear in mind that this crankshaft does not require any shim (or washer) between crank journal bearing and itself, INSIDE OF ENGINE After installing the crankshaft into the right crankcase, be sure to install the spacer on ight side of crankshaft with the spacer's ing facing inside of engine. KICK STARTER CAUTION: When installing the kick starter to the shaft, be sure to match the two punch- ed marks, The kick starter return spring is to be in- stalled after setting the shaft in the crank- case. To install this spring, hitch the inner end of the spring to the stopper provided on the crankcase, turn the shaft clockwise as viewed from kick lever side end until the shaft will not tum any further, and then rotate the spring about 180 deg, to insert the other end of the spring into the hole pro- vided in kick starter shaft. Insert the spring and retain it by fitting a circlip, 2TRANSMISSION Mounting the transmission gears Be sure to mount the gears in the correct order. Refer to the cross sectional view while and after mounting the gears. O O temoved from a shaft, it should be iscarded and a new circlip must be installed. When installing a new must be taken not to expand the end sep larger than necessary to After installing a circli that it is completely seated in its groove and securely fitted,GEARSHIFTING MECHANISM Install the gearshift cam, forks and shafts. Bring the gearshift cam to the neutral posi- tion, Install the two cam drive gear pawls proper- ly. ® should face outside, Apply Thread Lock “1363C’ when tightening the cam gui lifter. to screws and pawl 99104-32050 Thread Lock “13600” | INCORRECT Install the shifting shaft return spring pro- perly to the shifting shaft, 9Be sure to mesh gears (f) and @) with their center lines coinciding with each other. PRIMARY DRIVE GEAR (1) Nut (2) Primary drive gear (8) Spacer (4) "0" ring The relative position of parts associated with the primary drive gear are as shown in this illustration. CLUTCH Tighten the clutch sleeve hub nut and bend the washer, 40 — 60 Nem 4.0 — 6.0 kgm 29.0 — 43.5 Ib-ft Tightening torque Fix the pressure plate and the spring, tighten. the clutch spring set bolts in the indicated manner. Tighten the primary drive gear nut and bend the washer, 80 — 100 N-m Tightening torque | 8.0 — 10.0 kgm 58.0 — 72.5 Ib-ft Fix the clutch release arm so that the slit of, release arm matches the marking on the clutch release camshaft, 30ENGINE SPROCKET @ Washer @ nur @ "0" ring @® Specer @ Engine sprocket Be sure to install “O” ring between bearing and spacer. Oil leakage from the often due to absence of this “0” order of mounting the parts on the drive shaft is as shown in this illustration. CAUTION: Note the position of “0” ring in this cross section, The spacer has its one end chamfered: ‘the chamfered end comes on transmis- sion side. MAGNETO Apply Thread Lock Super “1332B” to the magento rotor nut and tighten the nut. 3.0— 4.0 kgm 21.5 ~ 29.0 lb-ft Tightening torque Tighten the engine sprocket and bend the washer. 80— 100 N-m 8.0 — 10.0 kgm 58.0 — 72.5 lb-ft Align the engraved line (@ on the stator to ‘the aligning mark @) at the crankcase and secure the stator in that position, 31PISTON The arrow mark on the piston crown points to exhaust port side. a Sa” Piston ring must be so positioned in the groove as to bring its marked side (near joint) to top side and to locate the joint at the locating pin. ‘Apply Bond '"1215” to the crankcase of (A). Apply the engine oil to the piston surface and insert the piston in the cylinder. CYLINDER Install the cylinder onto the piston, Before putting the piston ring is properly seated in the groove, with its end neatly matched. 32EXHAUST SIDE Oo t 7 oO 3 ASI Oo Oo After installing the cylinder, gradually tight- en the nuts in order of number as shown in illustration, 36-40 Km pone 36 — 40 Nm 26.0 - 29.0 lb-ft After installing the cylinder head, gradually tighten the nuts in order of number as shown in the photo, Check the clearance @) between reed valve and its seat. If the clearance @) is noted to exceed 0.2mm (0,008 in), replace the reed valve @). Reed valve fitting | 0.8 — 1.2 Nem screw tightening | 0,08 — 0.12 kg-m torque ©) 0.5—1.01b-ft Foreign marr) Just before installing the reed valve assembly, make sure that there is not foreign matter stuck between the reed valve and its stopper. ENGINE MOUNTING F 26 —30Nm suishtentog 2.6 — 3.0 kg-m eee 19.0 — 21.5 Ib-ft Tighten the engine mounting bolts and nuts REED VALVE to the specification as shown below. Nem [tom | ibft [37 — 45] 3.7 — 45] 265 — 325 Tightening |(@)[30—38|3.0—3.8|21.5 — 27:5 torque (©|s0 — 80/5.0 — 8.0] 36.0 ~ 58.0 ‘© [20 — 90]8.0— 9.0) 68.0 — 65.9] 33TRANSMISSION OIL Pour the transmission oil of specified amount as follows. pears 1100 mi (1.2 US at) |_ overhaul Change oil | 1.000 mi (1.1 US at) CARBURETOR The carburetion of your motorcycle was carefully selected after extensive testing. You will find thet the RM carburetion will function smoothly under many varied operating conditions, For best results we re- ‘commend that the adjustments and carbure- tion jetting be left “‘as is” from the factory. Some riders may operate their motorcycle under extreme operating conditions such as: very high altitudes, extreme cold and hot temperatures or driven on sandy terrain. In ‘these circumstances the jetting of the carbu- retor or other adjustments may need to be altered slightly. Riders who are not familiar with the operation and jetting procedures of the Mikuni carburetor should have their local authorized Suzuki dealer perform these alterations, Mechanically experienced riders can alter the carburetor settings based on the following information and specifications, CARBURETOR SPECIFICATIONS Bore ee ———t Main jet ee00 lana a | Needle jet sins Cutaway a Pilot jet #50 Pilot air adjusting rr screw Float height 11.4205 Optional main jets #280, #290 and #310 ‘The main jet is usually the component which is most often changed. A convenient method of replacement is provided,Carburetor MAIN JET REPLACING 1, Move fuelcock lever to OFF position. 2. Remove the drain bolt on float chamber ‘to empty the chamber of fuel. 3. Loosen clamp screws on both sides of carburetor and turn the carburetor around to bring its float chamber toward you, 4. Insert the main jet replacing too! into the drain bolt hole and, with this tool, re- move the main jet, 5. Install the main jet of another number in the carburetor, Plug up the float chamber by refitting the drain bolt, 6. Restore the carburetor (which is now in tilted condition) to the original posit- tion by turning it around, and tighten the clamp screws on both sides to secure the carburetor in place. ‘The spare main jets listed below are furnish- ed with each motorcycle, #280, #290, #310 ‘Spare ELECTRICAL SYSTEM SUZUKI “PEI” SYSTEM In the M500, ignition energy is supplied to the spark plug through electronically trig- gered capacitor discharge in a system com- Prising the magneto, CDI unit, ignition coil and spark plug. Three outstanding advantages of this proprietary system are: 1, High voltage induced in the secondary winding of the ignition coil is stable over ‘the entire range of engine speeds, so that the ignition performance of the plug is dependable, regardless of whether the engine is running fast or slow. 2. There is no need of so frequently check- ing and adjusting the ignition system ‘components as in the conventional system based on a breaker mechanism for make-break contacting action. Make- break action is electronic in the SUZUKI “PEI” system, 3. Ignition timing is automatically advanced in a manner best suited to the operating characteristic of the engine.‘SUZUKI “PEI” CIRCUIT DIAGRAM Engine stop switch ed Ignition 20 Color code: B/W= Black with white tracer B/Y = Black with yellow tracer B/R = Black with ved racer WIBI = White with blue tracer IW ~ Red with white tracer CHECKING CDI UNIT Use a circuit tester as an ohmmeter, provid- ed that it has a megohm range; if not, use an chmmeter capable of measuring resistances of the megohm order. In either case, the two testing prods, (+) and (~), are to be put to terminals of the CDI unit in reference to the chart below. The CDI unit has five terminals, The (+) prod or pointer is to be put to one of the terminals listed in the top horizontal row, and the (—) prod or pointer to the corres: ponding terminals listed in the vertical column. What the circuit tester or ohmmeter should indicate for the two terminals is given in the intersecting box (ON, OFF, CON or ABOUT 2 MEGOHMS). The meanings of these terms are as follows: = Sintcnee ON | Thesster shows creutcontouty. Tine nse sens nail lrg | OFF | Seance, hare, The indcating Rand deflects aie con | but promoty fotos tote infty endl ot the we CAUTION: Never use an insulation-resistance meter (so-called megger) for this pur- pose or circuit elements inside the CDI unit will suffer rupture. NOTE: 1, Before putting the probe pointers of the tester to two terminals, touch the two with a jumper lead to form a momentary shortcircuit in order to neutralize the charges, if any. 2. For the instrument to be used, a circuit tester of the type used by radio repair. men will do. However, a high-grade circuit tester or an ohmmeter is preferred. 3. If the instrument gives an indication ‘other than what is shown in the inter- secting box in the chart for any pair of terminals, it means that the CDI unit is defective and needs replacement.MQ. range Positive (+) probe pin Bw BY B/R RW wet £ ON E BW ON J>aacaseanaerllis 26 ON con 8 ON : | CON “musa anne tate SON. con 2] oR cON ON cON cON : =| Rw OFF OFF OFF OFF ON w/t con CON || “sore eCOM CHECKING IGNITION COIL CHECKING MAGNETO Using the circuit tester, check the high-speed and low-speed coils for ohmic resistance. Coils in good condition will exhibit these values: The ignition coil is to be checked for con: inuity in both primary and secondary wind- ings. Exact ohmic readings are not necessary, but, if the windings are in sound condition, their continuity will be noted with these approximate ohmic values: Primary | BLACK/WHITE — WHITE/BLUE : winding 0-19 ‘Secondary | Plug cap — BLACK/WHITE : winding 10-119 37 RED/WHITE = BLACKMWHITE Uae RED/WHITE = BLACK/RED eReIGNITION TIMING ADJUSTMENT Unlike conventional contact-breaker ignition systems the PEI system maintains its original ignition timing until the system becomes disturbed as in engine overhauling: ignition timing does not change at all as long as the system remains undisturbed. The following adjusting procedure is a pro- cedure to be followed in remounting the magneto stator to re-establish the specified ignition timing: Align the engraved line > on the stator to the aligning mark (2) at the crankcase and secure the stator in that position. FRONT WHEEL REMOVAL \ 2. Loosen the axle shaft holder bolts, i 5 —25N: Tightening | 1 ~ Fo kom conn 11,0 — 18.0 Ib-ft 3. Loosen and pull out the front axle. , 50 — 80 Nm Siansepena 5.0-8.0 kgm TORU 36,0 — 58.0 Ib-ftINSPECTION AND SERVICING 1, Check the bearing noise and measure the inner diameter of brake drum. Service Limit 130.7 mm (5,15 in) 2, Measure the thickness of brake shoe, Service Limit | 1.5mm (0.06 in) 3. Apply grease on cam, UK SUPER 99000-25030 EASE UA FRONT BRAKE ADJUSTMENT y D Punch mark @ Index mark 1, Install the brake cam lever, matching the punch mark on the brake cam lever with the index mark on the brake cam shaft. 2, Check that both the right and left side brake cam levers are seated properly. @ Lock nut ®em © Brake shoe 393. Loosen the lock nut. 4, Turning the connecting rod to the right or left, adjust the brake shoe and cam so that the contact surfaces of the shoe and cam, right and left, meet evenly. 5. Tighten the lock nut slightly. 6. Moving the brake cam lever by hand, check to make sure the angle of rotation of the right and left brake cams is equal, and also that the right and left brake shoes begin expanding at the same time. 7. Tighten the lock nut securely. CONSTRUCTION 2-4Nm 0.2-0.4 kam 1.5 -3.0 Ibft 50-80Nm 6° 50-80 keen 36.0 ~ 58.0 IbftFRONT FORK DISASSEMBLY 1. Remove the front wheel. 2. Remove handlebar. 3. Loosen the upper clamp bolt. NOTE: To facilitate the subsequent steps, have the inner tube cap bolts loosened after loosening the upper clamp bolts. 5. Loosen the lower clamp bolts. Pull down ‘the front fork, 6. Remove the front fork cap bolt, 7. Draw out spacer, spring stopper and fork spring. 8. Remove boot, 9. Invert the fork, and stroke it several times to let out the oil inside, Under the condi- tion (inverted condition), hold the fork for a few minutes. x 10, Remove bolt securing cylinder to outer tube by using special tools, 8 09940-34520 | Thandie 09940-34590 | Attachment G L type 10 mm hexagon 7 wrench | aRemove the damper rod, spring and the oil lock piece, un. Check the “DU” metal for wear and damage. REASSEMBLY 13. Remove the oil seal holder and oil seal by slowly pulling out the inner tubs Be careful not to damage the inside of the tube, INSPECTION AND MAINTENANCE Measure the free length of the fork spring. Service Limit 647 mm (25.5 in) Install the oil seal slowly by using special tool. Front fork oil seal installer 09940-50112 SUZUKI BOND NO.4 ‘Thread Lock 1342" When reassembling, apply both Thread Lock ™4363C" and SUZUKI BOND *1215” to the damper rod bolt as shown. Thread Lock “1363C” SUZUKI BOND “1215” ‘99104-32050 99104-31110140 mm (6.5 in) With the fork fully compressed and the spring removed, set the oil level gauge as shown and check the oil level as measured from the top face of the inner tube. Adjust the oil level to the specification. 09943-74111 | Front fork oil level gauge Oil level 140 mm (5.5 in) Oil capacity | 641.5 ml (21.68 US oz) AIR PRESSURE ADJUSTMENT 1. Hold the machine standing erect by blocking up and keeping the front wheel off the floor. 2. Push in the valve to let out the pressure. Be sure to bleed the pressure out com- pletely. When replacing the air valve, apply Thread Lock 1363C” to the air valve screw. Tighten the front fork cap bolts, upper clamp bolts and lower clamp bolts, Fon] 5=30Nm forceap | 15 Botem Gey | toa sion : Upper | 20.—301Nm Tiattonng | Stes | 2020 kgm bolt @) | 145-215 ibst Tower | 18—28 New soe} 20- tet bolt @ | 11.0— 18.0ib-f 99000-32057 | Thread Lock 1363C”" 3. Set up the pressure gauge as shown, Tighten up knob 1) and knob (2). Front fork pressure 09940.44120 4 regulating gauge4, Inject water-free compressed air through valve @) until the pressure gauge reads the desired level not higher than 2.5 kg/em? (35 psi). 5, Back away (loosen) knob (2) to bleed out the excess pressure, if any, to secure the desired air pressure inside the fork. REQUIREMENTS ON AIR * Be sure that the compressed air supply comes through a de-watering filter. Instead of air, nitrogen gas may be used, * Just before charging air in, see that the valve is not loose by using the valve tightener. * Be sure to inject water-free compressed air not higher than 2.5 kg/cm? (35 psi). This is the maximum pressure to avoid fork oil seal and valve damage. Try to equalize the air pressure of the two forks, right and left, as closely as possible. The maximum permissible difference is 0.1 kg/em? (1.4 psi). Before riding out, be sure to check that the air pressure is at the prescribed level. Standard 2 Sir pressure | 0 Ka/em? (0 psi) NOTE: The above method is based on the use of the special-tool pressure gauge avail- able from SUZUKI but, instead of this gauge, the one furnished with each RM500 machine may be used. The furnished gauge (included in the kit) must be used in this manner: 1) fit to the valve squarely, and 2) upon reading the pressure, let it off the valve snappily. OIL LEVEL ADJUSTMENT 1. Hold the machine in self-supporting con- dition by blocking up. Push in the air valve to relieve the air pressure complete- ly. Remove the handlebar. 2. Remove the cap bolt, spacer, spring seat and spring, WARNING Push down the cap bolt while turning it loose. Remember, the fork spring force acting on the bolt is so great that the bolt might fly off if no push were exerted to it,3. Compress the fork gently by pushing in the inner tube fully, and hold the fork in vertical position, 4, Loosen the drain screw and drain the oil. 5, When reassembling, apply SUZUKI BOND +1215" to the oil drain screw, 99104-31110 6, Pour the fork oil. SUZUKI BON! 7. With the fork fully compressed and the spring removed, set the oil level gauge as shown and check the oil level as measured from the top face of the inner tube. Ad- just the oil level to the specification. Front fork oil level 9943-74111 | ice Oil level 140 mm (6.5 in) Oil capacity | 641.5 mi (21.68 US oz) ‘CAUTION: Be sure to equalize the oi ‘two forks. 8. Stretch the fork gently, and install the spring, spring seat, spacer and cap bolt. Front fork cap bolt Tightening torque 9, Adjust the air pressure, 45DAMPING FORCE ADJUSTMENT The front fork damper provides both the extension and compression damping force — the compression damping being adjustable for diversity of requirements by rider weight, the race track condition etc. To increase or decrease the damping force, ‘turn the adjuster screw as shown below. SOFTER : STIFFER, @ Adjuster serew @ Screw driver The compression damping force is stiffest when the adjuster is fully turned in and softest when turned back by 8 complete turns from lock position. The adjuster can further turn from this position. However, the damping force remains as that in 8 turn Adjuster’s turn back amount (counter- clockwise as viewed from bottom) Lock - --- STIFFEST 1 2 STIFFER 3 t STANDARD 6 sre R v -- SOFTEST sure to adjust the damping force of the two forks equally. Making one side iffer than the other disturbs the run- ning stability. NOTE: The machine is delivered from the factory with both the dampers adjusted to 4 turn back position.CONSTRUCTION i 3) 15—25N-m 1.5 ~ 2.5 kam 11.0- 18.0 bt 18 — 25Nm 15-25 kgm 11,0 — 18.0 b-ft Outer tube Bolt Screw Cap Air valve Cap Oring Spacer ‘Spring guide Spring Inner tube Metal . Boot 20-30Nm 2.0 ~ 3.0 kgm 14, 15. 16, 7. 18, 19. 20, 21 22, 23. 24. 25. 21.8 Ib-ft ‘Snap ring Dust seal case Dust teal Oi! seat Washer Slide metal Rebound spring Damper rod Oil lock piece Outer tube Washer Bott 47STEERING DISASSEMBLY 1, Remove the front wheel, 2. Take off the number plate. 3. Remove the front fork. 4, Remove the front fender. 5, Remove the handlebar clamp bolts and take off the handlebar, 6. Loosen the steering stem upper clamp bolt and remove the steering head bolt, AS 7. Remove the steering stem nut with the special tool. Draw out the steering stem lower bracket. 09940-11410 | Steering stem nut wrench 8. Draw out bearing by using special tool. Bearing inner race 09941-84510 hareuer Be 9, Take out the bearing balls. 10, Remove upper bearing outer race.BEARINGS pee 11. Remove lower bearing outer race by using special tool. Press in the lower be: (09941-54911 | Steering race remover | | tool. Steering bearing : 5 09941-74910 | reer daosiaaare Steering bearing installer REASSEMBLY Reassemble and remount the steering stem in the reverse order of disassembly and removal and also carry the following steps: OUTER RACES 19 by using special ‘Apply grease on upper and lower bearing be- fore remounting the steering stem, ‘99000-25030 Press in the upper and lower outer races using special tool, Steering outer race ogog-34511 | ened | 49 iSTEERING STEM Taper roller type bearing is applied on the steering system for better handling. Steering should be adjusted properly for smooth manipulation of handlebar and safe running. ‘Too stiff steering prevents smooth manipula- tion of handlebars and too loose steering ing stem, © Loosen the stem nut slightly and tighten the steering stem head center bolt, When the fork is moved right and left, it must move freely. If there is any play in the forks, loosen the center bolt, tighten the stem nut slightly and retorque the center bolt. will cause poor stability. Follow the steps | @ Install the handlebars. below for adjusting and checking the steer- Tightening torque Nem [kom | ibe ‘Steering stem head Senter Bole (ty [9550 | 3550 | 255360 ‘Steering stem upper Samp Role | 15-25 | 1.525 | 11.0180 Handlebars clamp tar 1220]1.220| 95.145 © Temporarily tighten the steering stem nut to 4.0 — 5.0 kgm (40 — 50 Nm, 29.0 — 36.0 Ib-ft) by using special tool, Steering nut socket ooeao.r1410 | Steer © Move the steering stem right and left five or six times to seat the bearing. © Loosen the steering stem nut to 0 kgm. Then retighten very lightly so that no play can be detected in the stem. © Install the steering stem upper bracket and temporarily tighten the steering stem. head center bolt. © Tighten the steering stem upper clamp bolt. Inspect and check the removed parts for the following abnormalities. ° Handlebar distortion Handlebar clamp wear Race wear and brinelling Worn or damaged steel rollers Distortion of steering stem ° e ° Set the handlebar so that the clearance ahead of and behind the handlebar are equalized. 50HANDLEBAR DAMPER ADJUSTMENT REAR WHEEL. DISASSEMBLY The damping effect can be varied as desired by tightening the nuts @) more or less hard. Tightening torque range This adjustment should be made to suit the damping action to the racing course condi- tions or to the rider's preference. 1, Remove the engine sprocket cover and chain guide plate, Remove the drive chain by removing the chain joint clip. 2. Remove the rear brake cable. Loosen the rear torque link bolt after pulling out the cotter pin. 3. Spherical ball bearings and oil seals are used for this joint portion. Apply grease when installing these bearings. 514, Remove the axle nut after pulling out the cotter pin, 5, Draw out the axle shaft. Pull the wheel assembly reward and remove it from the swinging arm, INSPECTION Measure the inner diameter of the brake drum, Service limit 130.7 mm (5.15 in) ] 1,5 mm (0,08 in) ‘Measure the thickness of the brake shoe. 1.5mm (0. in) Check and retighten the spoke nipples to prevent damage of nipples and rim. 09186-00086 | Spoke nipple wrench] Adjust looseni ‘the rim runout by tightening or ing the spoke nipples. ‘Service Lit (Axial and Radial) 2.0 mm (0,08 in) Check the axle shaft for deflection by using a dial gauge. 0.25 mm (0.010 in) ‘Servi Limi 52After each race, retighten the rear sprocket securing bolts. 33-37 Nem Tightening torque | 3.3 — 3.7 kg-m 24.0 — 27.0 Ib Axle nut FB omvogsen=1h TH SYSTEM. sPENSION. DISASSEMBLY AND REASSEMBLY 1, Remove the right and left frame covers, seat and mud guard. 2, Remove the upper and lower shock ab- sorber mounting bolts, 3. Remove the upper and lower mounting bolts and take off the rods. 4, Loosen the air cleaner mounting bolts and remove the reservoir. 5. Draw out the Bell Crank pivot shaft after loosening the nut, and remove the Bell Crank, INSPECTIONSpherical ball bearing is used for upper and lower shock absorber pivoting por- tion, CAUTION: Be sure to apply SUZUKI MOLY PASTE to the upper and lower side of ‘the rear shock absorber mounting Portion. 99000-25140 | SUZUKI MOLY PASTE for upper side. Bushing with used for lower side. When reassembling, apply SUZUKI MOLY PASTE, Needle rollers are used in the Bell Crank Pivot, Place the rollers all around the pivot bores, right and left, and apply SUZUKI SUPER GREASE “A” before the assembly,CONSTRUCTION SUZUKI MOLY PASTE Bepspmaana Washer Needle bearing Ball crank Sepvemaen= Spring Spring adjuster ring Adjuster lock Oring’ ‘Spherical ball bearing