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Suzuki T500 User Manual

Suzuki T500
31 pages
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Suzuki T500 Specifications

General IconGeneral
Engine TypeTwo-stroke, parallel twin
Displacement492 cc
Bore x Stroke70 mm x 64 mm
Compression Ratio6.6:1
Cooling SystemAir-cooled
Fuel SystemCarburetor
Transmission5-speed
Final DriveChain
Front SuspensionTelescopic fork
Rear SuspensionSwingarm with twin shock absorbers
Front BrakeDrum
Rear BrakeDrum
Power47 hp
FrameSteel double cradle
Seat Height800 mm
Fuel Capacity16 L
Torque57 Nm @ 6, 000 rpm
Dry Weight395 lbs (claimed)

Summary

Owner's Manual Foreword

Consumer Information and Performance Data

Vehicle Stopping Distance

Braking performance under various conditions.

Acceleration and Passing Ability

Passing times and distances for low and high speeds.

Engine Break-in Procedures and RPM Limits

First 100 Miles (160 KM) RPM Limit

Engine RPM limit below 3,500 RPM.

Up to 500 Miles (800 KM) RPM Limit

Engine RPM limit below 4,000 RPM.

Up to 1,000 Miles (1,600 KM) RPM Limit

Engine RPM limit below 5,000 RPM.

Motorcycle Specifications: Dimensions and Performance

Dimensions and Weight

Overall length, width, height, wheelbase, clearance, tires, dry weight.

Performance Specifications

Maximum speed of the motorcycle.

Motorcycle Specifications: Engine, Systems, and Electrical

Engine Specifications

Type, displacement, bore, stroke, cylinders, compression, power, torque.

Fuel System Specifications

Carburetors, air cleaner, fuel tank capacity.

Lubrication System Specifications

Engine oil, transmission oil, oil tank capacity.

Ignition System Specifications

Type, timing, spark plugs.

Transmission System Specifications

Clutch, gearbox, gear shifting, ratios.

Reduction Ratios and Drive Chain

Gear ratios and drive chain size.

Suspension and Steering

Front/rear suspension and steering geometry.

Brakes and Electrical Equipment

Brake types and electrical system components.

Suzuki CCI Lubrication System Explained

Motorcycle Controls: Left and Right Side Identification

Left Side Controls Identification

Identification of controls on the left side of the motorcycle.

Right Side Controls Identification

Identification of controls on the right side of the motorcycle.

Motorcycle Controls: Meter, Switches, and Plates

Combination Meter and Switches

Identification of gauges and switches on the handlebar.

Identification and Certification Plate

Location and purpose of vehicle identification numbers.

Fuel Tank Cap Operation

How to open and lock the fuel tank cap.

Fuel Cock and Kick Starter Operation

Fuel Cock Operation

Positions and function of the fuel cock lever.

Kick Starter Lever Operation

Procedure for starting the engine with the kick starter.

Brakes and Gear Shifting Operation

Brake Lever and Pedal Operation

How to operate front and rear brakes.

Gear Shifting Lever Operation

Procedure for shifting gears using the lever.

Carburetor Choke and Throttle Grip Operation

Carburetor Choke Lever Operation

Function and operation of the choke lever.

Throttle Grip Operation

How engine speed is controlled by the throttle grip.

Lighting, Dimmer Switch, and Indicator Lamps

Lighting/Dimmer Switch Operation

Operation of headlight and beam control.

Indicator Lamps Meaning

Meaning of neutral and high beam indicator lights.

Pre-Ride Inspection Checklist

Fuel Level Check

Ensuring sufficient fuel in the tank.

Engine Oil Level Check

Checking and replenishing engine oil.

Brake System Check

Verifying proper function of front and rear brakes.

Brake Adjustments and Tire Pressure Guidelines

Rear Brake Adjustment

Adjusting pedal position and travel.

Tire Pressure Guidelines

Recommended tire pressures for various riding conditions.

Headlamp, Turn Signal, and Tail/Brake Lamp Checks

Head Lamp Operation Check

Verifying headlight function and beam adjustment.

Turn Signal Lamp Check

Ensuring turn signal lamps flash correctly.

Tail/Brake Lamp Adjustment

Adjusting the brake lamp switch for proper activation.

Clutch Lever, Horn, and Throttle Checks

Clutch Lever Play Adjustment

Checking and adjusting clutch lever free play.

Horn Operation Check

Verifying the horn sounds properly.

Steering Operation and Tool Kit Contents

Steering Operation Check

Ensuring smooth handlebar movement without play.

Tool Kit Contents

Listing tools provided for maintenance.

Riding Tips: Starting the Engine

Starting a Warm Engine

Procedure for starting a warm motorcycle engine.

Starting a Cold Engine

Procedure for starting a cold motorcycle engine.

Riding Tips: Shifting Gears and Speed Ranges

How to Shift Gear

Procedure for engaging gears and clutch operation.

Recommended Speed Ranges for Gears

Speed ranges for optimal gear usage.

Riding Tips: Driving Techniques for Hills and Speed

High Speed Riding Considerations

Adjustments for riding at high speeds.

Riding on Hills

Techniques for ascending and descending hills.

Riding Tips: Stopping and Parking Procedures

Stopping and Parking Procedure

How to safely stop and park the motorcycle.

Steering Lock for Theft Prevention

How to use the steering lock when parking.

Inspection and Maintenance Schedule

Item Checklist for Inspection

List of items to inspect at various intervals.

Lubrication Schedule

Parts requiring periodic lubrication and intervals.

Air Cleaner and Carburetor Maintenance

Cleaning Air Cleaner Element

Procedure for cleaning the air filter.

Adjusting Carburetor Idle Speed

How to adjust idle speed and synchronizing.

Clutch and Throttle Cable Adjustments

Synchronizing Throttle Valves

Ensuring throttle valves open simultaneously.

Adjusting Clutch

Procedure for adjusting clutch cable and release screw.

Ignition Timing and Drive Chain Maintenance

Adjusting Ignition Timing

Checking and adjusting ignition timing.

Adjusting Drive Chain Play

How to adjust drive chain tension.

Drive Chain Lubrication and Muffler Cleaning

Lubricating Drive Chain

Frequency and method for lubricating the drive chain.

Cleaning Muffler Baffle Pipe

Procedure for removing carbon deposits from the muffler.

Oil Pump and Battery Maintenance

Adjusting Oil Pump Cable

Aligning marks for oil pump cable adjustment.

Battery Solution Level Check

Checking and maintaining battery electrolyte level.

Spark Plug and Tire Maintenance

Spark Plug Type and Gap

Recommended spark plugs and gap settings.

Tire Tread Condition

Importance of tire tread and replacement guidelines.

Transmission Oil and Fuel Strainer Maintenance

Changing Transmission Oil

Procedure for changing transmission oil.

Cleaning Fuel Strainer

How to clean the fuel strainer.

Headlamp Beam and Front Fork Oil Maintenance

Headlamp Beam Adjustment

How to adjust the headlamp beam horizontally and vertically.

Changing Front Fork Oil

Procedure for changing front fork oil.

Tightening Bolts and Nuts Procedures

Points to be Tightened

List of critical bolts and nuts requiring regular tightening.

Troubleshooting: Engine Starting Issues

Fuel and Spark Plug Checks

Checks for fuel, spark plug condition, and spark presence.

Troubleshooting: Engine Power and Stoppages

Engine Fails to Develop Power

Causes of power loss and checking exhaust.

Engine Stops Suddenly

Checks for fuel, ignition, and spark plug issues.

Troubleshooting: Stability and Steering Issues

Bad Stability and Steering

Checks for tire pressure, fork play, and wheel alignment.

Motorcycle Wiring Diagram

Manual Index

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