Suzuki RGV250 1989 User manual

SUZUKI
RGV250

MANUFACTURE'S EXEMPTION
SUZUKI RGV250 HOP-UP KIT is a special-purpose designed for exclusive usein competition only on racing
course as distinguished from public road and highways. RGV250 HOP-UP KIT is not equipped for con-
formity with traffic law and regulations, and is not accorded with the benefit of product which SUZUKI
standardly grants on motorcycle of its manufacture.
NOTE:
*The motorcycle on which the HOP-UP KIT isinstalled, is not covered by the SUZUKI WARRANTY.
*This HOP-UP KIT manual describes only service specifications and servicing procedures which
differ from those of the RG V250 service manual,
*Specification will be changed without pre-notice.
* Please refer to the RG V250 service manual for details.
S&Z&m MOTOR C0.fLTD.
Sales Department E (for overseas)
Spare Parts & Accessories Division
©COPYRIGHTSUZUKIMOTORCO.,LTD.1989

CONTENTS
SPECIFICATIONS1
GENERALINFORMATION2
KITPARTSINSTALLATION PROCEDURES4
1. CYLINDERHEAD, CYLINDER,HEADGASKET4
2. PISTONANDPISTONRING5
3.CLOSERATIOTRANSMISSION6
4.CLUTCH(FORWETTYPE)8
5.CLUTCH(FORDRYTYPE)9
6.OILCATCHTANK11
7.WATERCATCHTANK13
8.CARBURETORSETTINGPARTS14
9. MUFFLERREPLACEMENT22
10. OILPUMPREMOVALANDBLINDING23
11. SPROCKETREPLACEMENT25
12. REARSUSPENSIONHEIGHTADJUSTERBRACKETINSTALLATION26
13. FRONTFORK27
14. REARSHOCKABSORBERSPRINGREPLACEMENT34
15. FRONTBRAKECALIPERPADMODIFICATION36
16. STEERINGDAMPERINSTALLATION 37
17. SUSPENSIONSETTING40
18. SUSPENSIONSETTINGGUIDE41
19. STAGEI KIT PARTSELECTRICAL42
20. STAGEIIKIT PARTSELECTRICAL44
21. OTHERRECONSTRUCTION47

SPECIFICATIONS
ENGINE
Type.......Two-stroke,liquid-cooled
Numberofcylinders2
Bore. . . . 56.0mm
Stroke. . . . 50.6mm
Pistondisplacement249cm3
Compressionratio8.8: 1
CarburetorMiKUNITM34SS,Two
Sparkplug. . N.G.K.: R5184-9.5,10,10.5
TRANSMISSION
ClutchDrymulti-platetypeor
Wetmulti-platetype
Transmission6-speedconstantmesh
Gearshiftpattern1-down,5-up
Primaryreduction2.565(59/23)[DRYCLUTCH2.560(64/25)]
Finalreduction46/13(3.538)
46/15(3.067STD)
37/16(2.313)
STANDARDOPTION
Gearratios,Low2.454(27/11)1.875(30/16)
2nd1.625(26/16)1.471(25/17)
3rd1.235(21/17)1.222(22/18)
4th1.045(23/22)1.040(26/25)
5th0.916(22/24)0.926(25/27)
Top0.840(21/25)0.840(21/25)
DrivechainTAKASAGO:RK520TR-Z
D.I.D.:520ERS
-1-

GENERALINFORMATION
DFUEL
Theengineisoftwo-stroketype,designedtorunonoil~premixedfuel(whentheoilpumpisremoved).
Fuelspecification:Racinggasolineoraviationgasolinemixedwithoilintheratioof30: 1.
Oilspecification: Motul700E,ShellSportsSX(synthetic).
2)COOLANT
Coolantspecification:Softdrinkablewater
Whenfillingthecoolingsystemwithwater,followtheproceduresbelow.
(1) Removetheradiatorcapandpourwaterthroughthefillerneck.
(2)Bleedairfromthewaterpump.
(3)Holdingthehandlebars,leanthemotorcycletwoorthreetimestoexpelairtrappedinthesystem.
(4)Squeezeeachradiatorhosetodriveairaway.
(5)Loosentheairbleedboltonthesideofradiatortoremoveair.
(6)Repeattheprocedures(1)through(5)aboveuntilthewaterleverbecomesconstant.
(7)Fittheradiatorcapsecurely.
Aftertheaboveproceduresarecompleted,startandwarmuptheengine,thencheckthatthereisno
waterisnowaterleakage.Stoptheengine,allowtocoolandcheckthewaterlevelagain.
•Duringtheraceinterval,drainthesystemcompletelytoavoidcorrosionorotherharmfulproblemsin
theradiatorandenginewaterjacket.
•Thewatertemperatureforbestengineoperationis55 — 65°C.
Whenmorethan70°C,considerablepowerlosswillresult.
3)WARMINGUP
Alwayswarmuptheenginebeforerunninginthefollowingmanner:
(1) For 1 — 2 minutes,revtheengineupanddownwithintherangeof5,000 — 6,000rpm.
(2) Foranother1 — 2 minutes,revtheengineupanddownlimitingthehighestrevolutionto8,000rpm.
(3)Whenthewatertemperaturereachesapproximately65°C,testdriveforapproximately50m and
checktheoperationofgearshifting,clutch,brakeetcifanappropriatewarmingupsiteisavailable.
(Ifthewatertemperaturerisestomorethan90°C,checkthesystemimmediatelybecausetheremay
beproblemslikeleakage,insufficientwateretc.)
4)BREAKIN
(1)Newmachine
Keeptheenginespeedasconstantaspossibleduringrunning.Toshiftupordown,keeptothefollowing
rpmlimits.Useashighgearasispracticallypossible.
a.First,run2 — 3 timesinthetracklimitingtheenginespeedbelow8,000rpm.
b.Stopandcheckforpartslooseness,leakageetc.
c.Runapproximately30kmlimitingtheenginespeedbelow8,000rpm.
d. Runapproximately20kmlimitingtheenginespeedbelow9,000rpm.
e.Runapproximately20kmlimitingtheenginespeedbelow10,000rpm.
Thetotalofrunningdistanceisapproximately75km.
CAUTION:
Duringbreakinginperiod,runtheengineonslightlyrichcarburetion.
(2)Whenpartsreplaced
•Ifthecylinderorcrankshaftisreplaced,thesamebreakinasnewmachineisrequired(approximately
75km).
_2-

•Ifthepartssuchaspiston,piston ring, transmissiongeararereplaced,breakinasfollows:
For20kmbelow8,000rpm
For10kmbelow9,000rpm
For10kmbelow10,000rpm
Totaldistance — 40km
5)REPLACEMENT
(1)Scheduledreplacement
PARTSORITEM
Piston
Pistonring
Pistonpin
Pistonpincirclip
Pistonpinbearing
Pistonpinbearingwasher
Crankshaft
Transmissionoil
Drivechain
Forkoil
Brakeoil
RECOMMENDEDCHECK
Every500km
Every500km
Every1,000km
Every300km
(Eachtimeremoved)
Every500km
Every1,000km
Every2,000km
Initial100kmandevery1,000km
Every500km
Initial100kmandevery3 races
Every3 monthsorafterrain
REPLACEINFOUND
Wear,pitting
Wear,sticking
Seizure,steppedwear
Wheneverdisassembled
Seizure,wear|
Wear,scratches
Runout,sealdamage,bearingwear
Contamination,emulsification
Stretch, kink
(2)Otherwearitemstobereplaced
ITEM
Sparkplug
Reedvalve
Clutchspring
Drivesprocket
IDrivensprocket
Expansionchamberspring
Exhaustsilencer
REPLACEIFFOUND
Electrodewear,insulatordamage
Damagedordeformedreed(Affectslowrpmperformance)
Fatigue
Wear,crack,break
Wear,crack,break
Fatigue,otherdamage
Noiseleveloverpermittedlimit
6)TRANSMISSIONOIL
Transmissionoilcapacity:700ccwhenrefilling
800ccwhenoverhauled
Standardoilspecification:10W-4QMotor
7)SPARKPLUG
Specification:NGKR5184# 10(STD);# 9=5(Opt);# 10.5(Opt)
Sparkgap: 0,5 — 0,6mm
8)SPARKPLUGCAP
From'89model,theignitionsystemisdigitallycontrolled.Thedigitalcontrolsystemissusceptibleto
radiointerference.Therefore,makesuretousethesparkplugcapofstandardspecification.

KITPARTSINSTALLATIONPROCEDURES
Thismanualexplainstheinstallation,handling,settingandotherimportantproceduresforeachcomponent
ofthekitparts.Formorefundamentalworksnotcontainedinthismanual,refertoRGV250Service
Manual.
1. CYLINDERHEAD,CYLINDER,HEADGASKET
0Thecombustionchamberofkitcylinderheadis
finishedwitha specialplatingso-calleda BN
platingtopreventpittingincaseofabnormal
detonation.
(DA thincylinderheadgasket(thickness= 0.7mm)
isusedforthiskittocontributetocompression
increase.Also,thedimensionofgasketboreis
madeascloseaspossibletothatofcylinderfor
thepurposeofdecresingthequenchingarea,
therebysurpressingabnormaldetonationtoa
minimum.
(DThekitcylinderisdifferentfromthenormal
oneinitsporttiming,portshapeandheightof
cylinder.
®Thedowelpinsareusedbecauseofclosertole-
ranceofcylinderheadgasketboreoff-center.
Thedowelholesareprovidedonthecylinder,
cylinderheadandgasket.
(5)Tohavethecompressionadjusted,a thinner
cylinderbasegasketisused(thickness= 0.6mm).
^tp
NOTE:
Exhausttimingofthekitcylinderisfasterthanisstandardone.Therefore,ifthestandardexhaust
valveisinstalledwithoutmodification,thevalvewillprotrudeinsidetheexhaustportresultingin
decreasedpower.
Therefore,grindofftheexhaustvalveendsoastobeflashwiththeexhaustportwiththevalvefully
opened.
Cylinderexhaust
portupperedge
Grindoff

REF. NO.
1.
2.
3.
4.
5.
PARTNUMBER
11111-12C60
11141-12C50
11200-12C60
04211-11129
11241-12C50
DESCRIPTION
HEAD, CYLINDER
GASKET,CYLINDERHEAD
CYLINDERASSY
PIN, CYLINDERHEAD
KNOCK
GASKET,CYLINDER
QTY/UNIT
2
2
2
4
2
REMARKS
t= 0.7
t= 0.6
2. PISTONANDPISTONRING
®A forged,lightweightpistonisusedinthiskit.
Aswithcylinderheadcombustionchamber,the
pistoncrownisfinishedwithBNplatingtopre-
ventpittingincaseofabnormaldetonation.
©A thin, 0.8mmpistonringisusedtodecrease
weightandfrictionloss.
@Thekitpistonpinislightinweightyethighly
rigidduetoitsdoubletaperedshapebore.
®&®Withthechangeofpistonpin,thecirclip
andthrustwasherarealsomodified.
NOTE:
When installingthepiston, position
1,7mmholesfacingexhaustside. its two
[REF. NO.
1.
2.
3.
4.
5.
PARTNUMBER
12110-12C53
12140-12C51
12151-12C50
12153-12C50
12152-12C51
DESCRIPTION
PISTONCOMP
RINGSET,PISTON
PIN, PISTON
CIRCLIP,PISTONPIN
WASHER,PISTONPIN
BEARING
Q'TY/UNIT
2
2
2
4
4
REMARKS
«5_

3,CLOSERATIOTRANSMISSION
Modifythegearratiosforbettersuitabilityforcompetitionusingthepartslistedbelow.RefertoRGV250
ServiceManual(99950-12070-01E)fordetailsofreplacementprocedure.
_6-

|REF. NO.
1-1
1-2
*2
*3
*4
5
6
7
*8
*9
*10
*11
12
*13
14
*15
PARTNUMBER
24121-12C50
24121-12C60
24221-12C60
24231-12C60
24251-12C60
24261-12C50
24130-12C51
24311-12C52
24321-12C60
24331-12C60
24341-12C60
24351-12C60
24361-12C50
08211-25321
16320-12C50
24322-12C60
DESCRIPTION
COUNTERSHAFT
COUNTERSHAFT
GEAR,2NDDRIVE
GEAR,3RD/4THDRIVE
GEAR,5THDRIVE
GEAR,6THDRIVE
SHAFT,DRIVE
GEAR,1STDRIVEN
GEAR,2NDDRIVEN
GEAR,3RDDRIVEN
GEAR,4THDRIVEN
GEAR,5THDRIVEN
GEAR,6THDRIVEN
SHIM, 2NDDRIVENGEAR
GEAR,OILPUMPDRIVE
BUSH, 2NDDRIVENGEAR
Q'TY/UNIT
REMARKS
FORWETCLUTCH
FORDRYCLUTCH
NT: 17
NT: 18/25
NT: 27
NT: 25
NT: 30
NT: 25
NT: 22
NT: 26
NT: 25
NT: 21
NT: 28
NOTEMARK*:NEWLYDEVELOPED.

4.CLUTCH(FORWETTYPE)
Toreinforcetheclutchforcompetitioncapability,replacethepartswiththoselistedbelow.Referto
RGV250ServiceManual(99950-12070-01E)fordetailsofreplacementprocedure.
|^REF.NO.
1
2
3
4
5
PARTNUMBER
21441-40A01
21451-40A00
21471-12C50
09164-00006
09440-19013
DESCRIPTION
PLATE, CLUTCHDRIVE
PLATE, CLUTCHDRIVEN
SEAT,WAVEWASHER
WAVEWASHER
SPRING
QTY/UNIT
8
7
1
1
6
REMARKS
T:3 mm
T:1.6mm
™g_

5.CLUTCH(FORDRYTYPE)

IREF.NO.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
PARTNUMBER
21000-12850
09282-58001
21211-12C50
21251-12C50
21252-12C50
09263-25033
09280-20001
21220-12C50
09283-35023
21411-12C50
09160-20051
21441-12C50
21451-20A01
21471-12C60
21472-12C50
21462-12C51
21463-15400
09440-18017
22522-12C50
01107-06405
21481-17C50
23165-12C50
23261-20A00
08322-21068
23271-14101
09135-06009
21111-12C50
DESCRIPTION
CLUTCHSET(DRY)
OILSEAL,INNERCOVER
GEARASSY.PRIMARY
DRIVEN
SPACER,DRIVENGEAR
SPACER,DRIVENGEAR
BEARING
O-RING
HOUSING,CLUTCH
OILSEAL
HUB, CLUTCHSLEEVE
THRUSTWASHER,
SLEEVEHUB
PLATE, CLUTCHDRIVE
PLATE, CLUTCHDRIVEN
SEAT,WAVEWASHER
WAVEWASHER,CLUTCH
SLEEVEHUB
DISC, CLUTCHPRESSURE
BEARING,PRESSUREDISC
SPRING, CLUTCH
SPACER,CLUTCHSPRING
BOLT
WASHER
PACK,CLUTCHRELEASE
PINION, CLUTCHRELEASE
WASHER,CLUTCH
RELEASEPINION
ARM,CLUTCHRELEASE
BOLT,PINION
GEAR,PRIMARYDRIVE
QTY/UNIT
5
6
1
1
1
1
5
5
5
5
REMARKS
INC..REF.N0.1'
58x 78x 7
NT:64/20
25x30x19.8
35x 45x 6
20x 50x 2
T:3 mm
T:1.6mm
6.5x 13x25.6
6x40
6.2x 18.8x 1.6
-33
-10-

REF. NO.
27.
28.
29.
30.
31.
32.
33.
34.
PARTNUMBER
11341-12C50
11370-12C50
11482-12C00
11342-12C50
11971-12C50
07120-06252
11972-12C50
24121-12C60
DISCRIPTION
COVER,CLUTCHINNER
COVER,CLUTCHOUTER
GASKET,CLUTCHCOVER
PLUG, KICKSHAFT
PLUG, OILFILLER
BOLT
PLUG, OILDRAIN
COUNTERSHAFTFOR
DRYTYPE
Q'TY/UNIT
1
1
1
1
1
4
1
1
REMARKS
6x25
NT: 16(Notshown)
6.OILCATCHTANK
1. Removetheundercowl.
2. Removethefrontseat.
3.Removethefueltank.
4. Removetheaircleaner.
5.InstalltheoilcatchtankonthechassisasshowninFig.2.
•Removethefrontboltsecuringthecarburetoridleadjusterscrewbracket.Refitthisbolttosecure
therearsideofoilcatchtankbrackettogetherwiththeidleadjusterscrewbracket.
•Passtheclamp(selt-lockingtiestrap)throughthefrontbracketofoilcatchtankandfastenthe
clampontheframedowntube.Usecareatthistimenottopinchthewiringharnessbetweenthe
bracketandframe.
6.Removethecrankcasebreatherhosefromtheguidewhichisfastenedtogetherwiththe1stmuffler
mountingonthelowerpartofchassisrightside.Routethisbreatherhosetotheoilcatchtankas
showninFig.1.
7.Insertoneendoftheoutletpipe(overalllength2 m)intotheoilcatchtankandroutethepipetothe
rearofthemachine.Ifthepipeisfoundtoo long, cutittotheproperlength.Whenclampingthepipe
ontheframetogetherwiththewiringharness,usecarenottopinchit.
8.Installtheaircleaner.
9.Installthefueltank.
10. Attachtheself-adhesiveclampontheframe(tankrail)asshowninFig.1 andFig.2.
11. Replacethefueltankbreatherhosewitha longerone(length790mm).
•Insertoneendofthefueltankbreatherhoseintotheoilcatchtankandsecurethepipeonthe
framebyusingtheclamppreviouslyinstalled.Ifthepipeisfoundtoo long, cutittotheproper
length.
12. Installtheseatandundercowl.
13. Finally,checkthatthesteeringdoesnotinterferewiththefueltankbreatherhosewhenfullyturned
rightandleft.
-11-

Lengthofhose
inserted
Tofueltankbreather
/
(Fig. 1)
Toenginecrankcase
VIEWC
09352-50823-00B
HOSE, OILCATCHTANK
OUTLET
Enginebreatherhose
09408-00074
CLAMP,FUELTANK
BREATHERHOSE
Tofueltankbreather
Oilcatchtankbrackettobe
tightenedtogetherwith
carburetoridleadjusterscrew
bracketusingfrontsideofbolt.
Tocrankcase
Securefrontbracketonframedowntubebyaclamp.
(Atthistime,donotpinchthesidestandswitchwiring
betweenthebracketandframe.)
-12-

7.WATERCATCHTANK
^
Installthetank
withbands.
Watercatchtank
Toradiatorconduction
Makeaholetocatchwaterhose.
Airbleedinghole(3mmdia.)
Watercatchtank
-13-

8.CARBURETORSETTINGPARTS
Setthecarburetorinaccodancewiththeconditionsoftheracecoursetemperature,altitude(atmospheric
pressure),etc.Varioustypesofsettingarepossiblebyvariouscombinationsofparts.
CARBURETORTYPE
MIKUNITM34SS,TWO
BORESIZE,34mm
SETTINGPARTS
M.J.
Lea
#310\
#320
#330
#340
#350
#360
#370
#380
#390
ner
#400 Richer
HJ.
Leaner
05
06
07
08
09
P-0
P-1
P-2
i
1
Richer
J.N.
Leaner
CLIPPOSITION
1"tf
1ri
5th—'
1
1
i
'
JRicher
P.W.J.
#50
#60
(IS)-
P.J.
#35
#37.5
#40
M.A.J.
#0.5
(#1.0)STD
A.S.
TURNINGIN
I
TURNINGBAG
Leaner
ii
TI
Richer
Leaner
4
Rich
i
ler
Richer
4
\
r
Leaner
Ric
i
her
KV
Leaner
14-

CARBURETIONWITHDIFFERENTCLIMATICCONDITIONS
Condition
Cold
Hot
Dry
Wethot
Highaltitude
Result
Lean
Rich
Lean
Rich
Rich
Requiredadjustment
Tomakericher
Tomakeleaner
Tomakericher
Tomakeleaner
Tomakeleaner
Partstouse
MJorNJ
it
a
ii
a
CARBURETORTUNINGBYBIFFEREWTFAILURESYMPTOM
SYMPTOM
Withfullthrottle;
•Revpeaktoolow
•Doesn'trevupquickly
•Poorpoweroutput(Rich)
Withfullthrottle;
1• Hesitates
•Pingsorknocks
•Revsupoutpowernot
sufficient.
Performsdullorinter-
jmittentinrange1/4 — 3/4
throttleopening.
Hesitatesinrange1/4 — 3/4
throttleopeningandtorque
ispoor.
Respondstogradualbutnot
toquickthrottleopening.
Responcetoosharpto
control
AJUSTMENT
•DecreaseMJsize.
•Decreasegraduallyby1 —
2sizeswhileobserving
pistoncrowncolor.
©DecreasePWJsize.
®IncreaseMJsize.
«increasegraduallyby1 —
2sizeswhileobserving
pistoncrowncolor.
•IncreasePWJsize.
DecreaseNJsizetomake
mixtureleaner.
IncreaseNJsizetomake
mixturericher.
DecreaseMJsizebecauseof
toorichmainsystem.
IncreasePJsizeorlowerJN
position*
REMARKS
•Checkifchokeison.
•Checkifnotoverflowing.
•Checkifairnotleakingin.
•Checkifignitiontimingnottoo
fast.
(Richata partialopening)
-15-

DESCRIPTIONOF'89RGV250CARBURETORTUNING
Throttleopening
01525355075100%
PJ
<
^
y
>
NJ \
<
<
>
MJ
PWJ
Thisdiagramindicateswhereeachjetaffectsthecarburetionthroughoutthethrottleopeningrange.
•PJ(PilotJet):With15%ofthrottleopening,carburetionisaffectedinentirerevolutionrangeandwith
25% ofthrottleopening,intherangeover9,000rpm.
•NJ(NeedleJet):With15—25%ofthrottleopening,carburetionisaffectedinentirerevolutionrange;
with35- 50%ofopening,over9,000rpm;andwith75%ofopening,over11,000rpm.
•MJ(MainJet):With75%ofthrottleopening,carburetionisaffectedintherevolutionrangeover9,000
rpm, andwith100%ofthrottleopening,intherangeover9,000rpm,
•PWJ(PowerJet):With75%ofthrottleopening,carburetionisaffectedintherevolutionrangeover
10,000rpm,andwith100%ofthrottleopening,intherangeover8,000rpm.
-16-

CARBURETORJETTINGEXAMPLE(#1 indicatestheleftcylinderand# 2 theright.)
FORSTAGEI
MJ
NJ
JN
PJ
MAJ
PWJ
AS
#1
#320
0-9
6FL-76-52-3
35
0.5
60
1% Turnsback
#2
#320
0-9
6FL-76-52-3
35
0.5
60
1% Turnsback
FORSTAGEH
MJ
NJ
JN
PJ
MAJ
PWJ
|AS
#1
#340
P-1
6FL-76-52-3
35
0.5
60
1% Turnsback
#2
#350
P-1
6FL-76-52-3
35
0.5
60
1% Turnsback
Atmospherictemperature:10°C;
Barometricpressure
Forhighspeedcircuit :760mmHg.
:Changewithlarger
MJ2 - 3 sizes.
Changewithlarger
NJby1 -2sizes.
Atmospherictemperature:10°C;
Barometricpressure: 755mmHg
Forhighspeedcircuit Changewithlarger
MJ2 - 3 sizes.
Changewithlarger
NJby1size.
Ifaviationgasolineismixed,thejettingmay
bealteredfromtheabovechartsasindicated
below:
With50%ofmixtureIfwithMJ,smallerby1 size
100% avgasIfwithMJ,smallerby2 sizes
-17™