RGVe50 SERVICE MANUAL sy AEFOREWORD The SUZUKI RGV250 has boon developed 2s a new generation motoreycle to the RGV-models. It is packed with highly advanced design concepts including # SUZUKI 90°-degree, V-configuration, a 2eylinder engine, an Automatic Exhaust Timing Control (A.E.T.C.). a SUZUKI Boron Composit (S.8.C.), @ Slingshot carburetor, # New air induc- tion system, @ Radial Flow Radiator, @ Dual-cell configuration, highly rigid frame tank rails (DC- ALBOX type), 9 High rigidity iront fork and rear suspension. The RGV260, manufactured to standard specifica- tions, is the main subject matter of this manual. However, the RGV250 machines distributed in your country might differ in minor respects from the standard-specification and, if they do, it is because some minor modifications (which are of no consequence in most cases as far as servicing is concerned) had to be made to comply with the statutory requirements of your country. This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service SUZUKI motorcycles. Apprentice mechanics and do-it-yourself mechanics, will azo find this manual an extremely useful repair guide. This manual contains th most up-to-date information at the time of publication. The rights are reserved to update or make corrections to this manual at any time. SUZUKI MOTOR CORPORATION Overseas Service Department ©COPYRIGHT SUZUKI MOTOR CORPORATION 1990, GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES ENGINE FUEL AND LUBRICATION SYSTEM COOLING SYSTEM 6 | ELECTRICAL SYSTEM Gi CHASSIS EA SERVICING INFORMATION RGV2501L('90-MODEL) RGV250M (‘9 7-MODEL) RGV250N (’92-MODEL) 77 RGV250P ('93-MODEL) RGV250R ('94-MODEL) RGV250T (’96-MODEL)GENERAL INFORMATION CONTENTS- SERIAL NUMBER LOCATION ++ FUEL, OIL AND COOLANT RECOMMENDATION -....- BREAKING-IN PROCEDURES ~~» CYLINDER IDENTIFICATION SPECIAL MATERIALS PRECAUTION AND GENERAL INSTRUCTION ---0------0--rr Ie SPECIFICATIONS ova owrwsGENERAL INFOAMATION SUZUKI RGV250 RIGHT SIDE SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) © is stamped on the steering head pipe. The engine serial number @ Is located on the rear side of the crankcase. ‘These numbers are required especially for registering the ma: chine and ordering spare parts. FUEL, OIL AND COOLANT RECOMMENDATION FUEL Gesoline used should be graded 85 ~ 95 octane or higher. An unleaded or low-lead gasoline type is recommended. ENGINE OIL Use SUZUKI “CCI” oil or SUZUKI CCI Super oil. They are formulated to give best engine performance with least combustion chamber deposits, least preigniticn, maximum spark plug life and best lubrication. If they are not available, a good quality TWO-STROKE OIL (non-difuent type} should be usec. eeGENERAL INFORMATION 1.2 —$ A _ SEE RAL INFORMATION 1:2 TRANSMISSION OIL Use a good quality SAE 10/40 MOTOR OIL. FRONT FORK OIL Uso fark oil # 70, ‘g9000.99044.106: SUZUKI Fork oil # 10 BRAKE FLUID Specification and classtfiestion: SAE J1708, DOTS or DOT WARNING: * Since the brake system of this motorcycie is filled with a glyeal-hated brake fluid by the manufacturer, do not use or mix different types of fluid such 2s silicone-based and petraleum-based fluid for refilling the system, otherwise sorious damage will result. * Do not use any brake fluid taken from old or used or unsealed containers. © Never re-use brake fluid lett over from the previous servicing and stored for a lang period. COOLANT Use an onti-freeze/conlant compatible with an atuminum radiator, mixed with distilied wator only, at the ratio of 5D : 50, WATER FOR MIXING Use distilled water only. Water othar than distilled wizter ean corrode and clog the alun ANTI-FREEZE/COOLANT The coolant performs as corrosion and rust inhibitor as welt as anti-freeze, ‘Therefore, the coolant should ‘be Used at

Turning radius - 3.1m (10.240) cooled, 90° V-twin Front brake 1 Dise brake, twin Nuiiber oC ayitaders es 2 Rear brake . + Dise brake Bore +++ 86.0 mm (2.208 in) Front tira size ....... 110/70 R17 53H Stroke .. ++. 50.6 mm (1,992 in) fpouriire size yao/e0 R18 64H Piston displacement... 249 em? (15.2 cu. in} Front fork stroke... 120 mmn (47 in) Compression ratio .... 7.8 +1 Rear wheel travel... 140. mm (65 in) Carburetor. MIKUNI VM32sS Air cleaner . Polyurethane foam element ELECTRICAL Starter system Primary kick Ignition type ee. SUZUKI “PEI” Lubrication system SUZUKI "CCI" Ignition timing ...... 14° B.T.D.C. below 1.300 rimin Spark plu » N.G.K.: BROES TRANSMISSION Baty nso, AV 108 KC (BAN Clutch... Wot multi-plate type j0aR Transmission ..... 6-speed constant mesh Generator ... ‘Three-phase A.C. Gearshift pattern... t-down, Sup generator Primary reduction ..., 2.565 (59/29) Fuse vecesececessee 208 Final reduction ...... 3.065 (46/15) Gear ratios, Low ..... 2.454 (27/11) and 1.625 (28/16) CAPACITIES aed 1.235 (21/17) Fuel tank Ath oo... 1.045 (23/22) including reserve ..... 17L (4.5/3.7 US/Imp gal) 5th 0.916 (22/24) reserve ..... 5.5L (5.8/4.8 US/Imp at) Top ..... 0.840 (21/25) Engine oil .....s.... 1e1L (1.2/1.0 US/Imp at) Drivechain ......,.. DAIDO : DID 520V, Transmission ........ 700 ml TAKASAGO (23.7/24.6 US/imp 02) RK520MOB——Goolant.... 2.22. 1.6L (1.7/1.4 US/Imp gt) 114 links Front fork oil 428 mi 2 (14.5/18.1 US/Imp at) ne