Suzuki RGV250L 1990 Bedienungsanleitung

99500-12077-01

FOREWORD

The

SUZUKI

RGV250

has

been developed

new generation motorcycle to the RG

V-models.

packed with highly advanced design concepts

including a

SUZUKI

9ft

-degree,

V-configuration,

a 2-cylinder engine,

Automatic Exhaust Timing

Control (A.E. T.C.), a

SUZUKI

Boron Composit

(S.B.C.), a Slingshot carburetor, a New

air

induc-

tion system, a Radial

Flow

Radiator, a Dual-cell

configuration, highly rigid frame tank rails (DC-

ALBOX

type), a High

rigidity

front

fork

and rear

suspension.

The

RGV250, manufactured

standardspecifica-

tions,

the main subject matter

this manual.

However, the RGV250 machines distributed

your

country

might

differ

minor

respects

from

the standard-specification and,

they do,

because

some

minor

modifications (which

are

consequence

in most

cases

far

servicing

concerned) had

made

comply

with the

statutory requirements

your

country.

This service manual

has

been

produced

primarily

for

experienced mechanics

whose

job

to inspect,

adjust, repair and service

SUZUKI

motorcycles.

Apprenticemechanics anddo-it-yourselfmechanics,

will

also find this manual

extremely usefulrepair

guide. This manual contains the most up-to-date

information

the time

publication.

The

rights

are

reserved

update

make corrections to this

manual

any time.

SUZUKI MOTOR CORPORATION

Overseas Service

Department

©COPYRIGHTSUZUKI

MOTOR CORPORATION 1990

GROUP INDEX

GENERAL

INFORMATION

PERIODIC

MAINTENANCE

AND

TUNE-UP PROCEDURES

ENGINE

FUEL

AND

LUBRICATION

SYSTEM

COOLING SYSTEM

ELECTRICAL

SYSTEM

CHASSIS

SERVICING

INFORMATION

RGV250L('90-MODEL)

RGV250M

('9T-MODEL)

RGV250N

('92-MODEL)

RGV250P

('93-MODEL)

RGV250R

('94-MODEL)

RGV250T

('96-MODEL)

GENERAL

INFORMA

TION

~---------------CONTENTS'----------------~

SERIAL

NUMBER

LOCATION··············································

.....

FUEL, OIL

AND

COOLANT

RECOMMENDATION

..................... 1- 1

BREAKING-IN PROCEDURES ················································

·1-

CYLINDER

IDENTIFICATION

···················································1- 3

SPECIAL

TERIALS .............................................................. 1- 4

PRECAUTION

AND

GENERAL

INSTRUCTION···············""""'"

1- 7

SPECIFICATIONS····································································· 1- 9

1·1

GENERAL

INFORMATION

SUZUKI

RGV250

RIGHT SIDE

SERIAL

NUMBER

LOCATION

The frame

serial

number

V.LN.

(Vehicle Identification

Number)

stamped on the steering

head

pipe. The engine

serial number

<ID

located on the rear

side

the crankcase.

These

numbers

are

required especially

for

registering the ma·

chine and ordering

spare

parts.

LEFT SIDE

FUEL,

OIL

AND

COOLANT

RECOMMENDATION

FUEL

Gasoline

used

should

graded 85 -95 octane

higher. An unleaded

low-lead gasoline type

recommended.

ENGINE OIL

Use

SUZUKI

"CCI"

oil

SUZUKI CCI Super oil. They

are

formulated

give

best engine performance

with

least combustion chamber deposits,

least

preignition, maximum spark plug life and best lubrication.

they

are

not

available, a good

quality

TWO-STROKE

OIL

(non-diluent type) should

used.

TRANSMISSION

OIL

Use

a good quality SAE 10W/40 MOTOR

OIL.

FRONT FORK OIL

Use

fork

oil # 10.

99000-99044-10G:

SUZUKI

Fork

oil

# 10

BRAKE FLUID

Specification and classification: SAE J1703, DOT3

DOT4

WARNING:

GENERAL

INFORMATION

1-2

* Since the brake system

this motorcycle

filled

with

a glycol-based brake

fluid

the manufacturer,

not

use

mix

different types

fluid

such

silicone-based and petroleum-based

fluid

for

refilling

the system, otherwise serious

damage

will

result.

* Do

not

use

any brake

fluid

taken

from

old

used

unsealed containers.

* Never

re-use

brake

fluid

left

over

from

the previous servicing and stored

for

a long period.

COOLANT

Use

anti-freeze/coolant compatible

with

aluminum radiator, mixed

with

distilled water

only,

at the

ratio

50 : 50.

WATER FOR

MIXING

Use

distilled water only. Water other than distilled water

can

corrode

and

clog the aluminum radiator.

ANTI-FREEZE/COOLANT

The coolant performs

corrosion and rust

inhibitor

well

anti-freeze. Therefore, the coolant should

used

all times

even

through the atmospheric temperature in

your

area

does

not

go down

freezing

point.

SUZUKI recommends the

use

SUZUKI GOLDEN CRUISER 1 200

(Non-amine type) anti-freeze/

coolant.

this

not

available,

use

equivalent which

compatible

with

aluminum radiator.

REQUIRED

AMOUNT

WATER/COOLANT

Solution capacity (total): 1 600 ml (1.711.4 US/Imp qt)

CAUTION:

Mixing

anti-freeze/coolant should

not

exceed 60%. Mixing beyond

would reduce its efficiency.

the

anti-freeze/coolant mixing ratio

below 50%, the rust inhibiting performance

greatly reduced.

sure

mix

the

solution at

50%,

even

though the atmospheric temperature

does

not

down

freezing point.

1-3

GENERAL

INFORMATION

BREAKING-IN

PROCEDURES

During manufacture

only

the best possible materials

are

used

and all machined parts

are

finished

a very

high standard,

but

still

necessary

allow

the moving parts

"BREAK-IN"

before subjecting the

engine

maximum

stresses.

The future performance and reliability

the engine depends on the

care

and

restraint exercised during its early life. The general rules

are

follows:

• Keep

these breaking-in engine

speed

limits:

Initial 800

Below 6 000

r/min

1600

Below 8 000

r/min

Over

1600

Below

500

r/min

• Upon reaching

odometer reading

600

km you

can

subject the motorcycle

full

throttle

opera-

tion.

However,

not

exceed

500

r/min

at any time.

CYLINDER

IDENTIFICATION

The

two

cylinders

this engine

are

identified

Left

and

Right cylinder,

shown in the photograph.

(as

viewed

the

rider

the seat)

GENERAL

INFORMATION

1-4

SPECIAL

MATERIALS

The materials listed below

are

needed

for

maintenance

work

on the RGV250,

and

should

kept

hand

for

ready

use.

They supplement

such

standard materials

cleaning fluids, lubricants, emery

cloth

and the

like. How

use

them

and

where

use

them

are

described in the

text

this manual.

MATERIAL

SUZUKI SUPER GREASE

"A"

99000-25010

THREAD

LOCK SUPER

"1322"

99000-32110

SUZUKI BOND No. 1215

99000-31110

THREAD

LOCK SUPER

"1333B"

99000-32020

PART

PAGE

• Side stand

pivot

• Brake pedal

pivot

and

brake rod

link

• Gearshift lever mounting

boss

• Oil

seals

3-37

• Actuator pulley

bolt

3-11

• Driveshaft bearing retainer 3-37

• Crankcase upper 3-38

• Water pump mechanical

seal

3-46

housing

• Gearshift pole I

ifter

plate screw

3-41

• Gearshift

cam

guide 3-41

PART

PAGE

• Wheel bearing 7- 3

• Steering stem bearing 7-18

•

Rear

sprocket mounting

7-31

drum

bearing

• Swingarm, cushion lever 7-44

bearing

• Cushion lever and 7-46

cush

ion lever rod

'·5

GENERAL

INFORMATION

MATERIAL

THREAD

LOCK

SUPER

"1303"

99000-32110

THREAD

LOCK

SUPER

"1324"

99000-32120

THREAD

LOCK

SUPER

"1360"

99000-32130

~.:':

}'.

THREAD

LOCK

"1342"

99000-32050

PART PAGE

• Kick starter shaft stopper 3-43

• Cylinder lock

bolt

7-13

• Magneto

rotor

nut

• Disc plate

bolt

3-50

7- 3

7-28

• Counter bearing shaft retainer

3-41

• Shifting

cam

shaft

3-41

•

Cam

stopper arm support

bolt

3-41

•

Cam

stopper

arm

support

nut

3-41

• Gearshift pole Iifter plate screw

3-41

• Gearshift

cam

guide

screw

3-41

• Magneto stator

and

signal

3-50

generator screw

• Exhaust

valve

arm

bolt

3-52

PART PAGE

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