Suzuki RGV250L 1990 User manual

99500-12077-01 E

FOREWORD
The SUZUKI RGV250 has been developed as a
new generation motorcycle to the RG
V-models. It
is packed with highly advanced design concepts
including a
SUZUKI 9ft -degree, V-configuration,
a 2-cylinder engine,
an 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 to standardspecifica-
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.
Apprenticemechanics anddo-it-yourselfmechanics,
will also find this manual an extremely usefulrepair
guide. This manual contains the 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
©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·············································· ..... ,- 1
FUEL, OIL AND COOLANT RECOMMENDATION ..................... 1- 1
BREAKING-IN PROCEDURES ················································ .. ·1- 3
CYLINDER IDENTIFICATION ···················································1- 3
SPECIAL MA 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 or V.LN. (Vehicle Identification
Number)
CD is stamped on the steering head pipe. The engine
serial number
<ID is located on the rear side of 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 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 preignition, maximum spark plug life and best lubrication.
If they are not available, a good quality TWO-STROKE OIL (non-diluent type) should be 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 or DOT4
WARNING:
GENERAL INFORMATION 1-2
* Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer,
do
not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling
the system, otherwise serious
damage will result.
* Do not use any brake fluid taken from old or used or unsealed containers.
* Never re-use brake fluid left over from the previous servicing and stored for a long period.
COOLANT
Use an anti-freeze/coolant compatible with an aluminum radiator, mixed with distilled water only, at the
ratio
of 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 as corrosion and rust inhibitor as well as anti-freeze. Therefore, the coolant should
be used at all times even through the atmospheric temperature in your area does not go down to freezing
point.
SUZUKI recommends the
use of SUZUKI GOLDEN CRUISER 1 200 NA (Non-amine type) anti-freeze/
coolant.
If this is not available, use an equivalent which is compatible with an aluminum radiator.
REQUIRED
AMOUNT OF WATER/COOLANT
Solution capacity (total): 1 600 ml (1.711.4 US/Imp qt)
CAUTION:
Mixing of anti-freeze/coolant should not exceed 60%. Mixing beyond it would reduce its efficiency. If the
anti-freeze/coolant mixing ratio
is below 50%, the rust inhibiting performance is greatly reduced. Be sure
to mix the solution at 50%, even though the atmospheric temperature does not go down to freezing point.

1-3 GENERAL INFORMATION
BREAKING-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very
high standard,
but it is still necessary to allow the moving parts to "BREAK-IN" before subjecting the
engine
to maximum stresses. The future performance and reliability of the engine depends on the care and
restraint exercised during its early life. The general rules
are as follows:
• Keep
to these breaking-in engine speed limits:
Initial 800
km
Below 6 000 r/min
Up to 1600 km
Below 8 000 r/min
Over 1600 km
Below 11 500 r/min
• Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle opera-
tion.
However,
do not exceed 11 500 r/min at any time.
CYLINDER IDENTIFICATION
The two cylinders of this engine are identified as Left and
Right cylinder,
as shown in the photograph. (as viewed by the
rider
on the seat)

GENERAL INFORMATION 1-4
SPECIAL MATERIALS
The materials listed below are needed for maintenance work on the RGV250, and should be kept on hand
for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery cloth and the
like. How
to use them and where to use them are described in the text of 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
2- 2
• 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

MATERIAL
...............
--=--
SUZUKI BRAKE FLUID
99000·23110 (0.5L)
~
RUNt
FORK
OIL ~,1I
SUZUKI FORK OIL # 10
99000-99044-10G
SUZUKI GOLDEN CRUISER
1200
NA
Non-Amine type (2.0L)
99000-99032-1
OX
GENERAL INFORMATION 1·6
PART PAGE PART PAGE
• Coolant

1-7 GENERAL INFORMATION
PRECAUTION AND GENERAL INSTRUCTION
Observe the following items without fail when servicing, disassembling and reassembling motorcycles.
o Do not run engine indoors with little or no ventilation.
o
Be sure to replace packings, gaskets, circlips, a-rings and cotter pins with new ones.
CAUTION:
Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new
circlip must
be installed.
When installing a new circlip, care must be taken not to expand the end gap larger than required to slip
the circlip over the shaft.
After installing a circlip, always insure that it is completely seated in its groove and securely fitted.
o Tighten cylinder
head and case bolts and nuts beginning with larger diameter and ending with smaller
diameter, and from inside
to outside diagonally, to the specified tightening torque.
o Use special tools where specified.
o
Use genuine parts and recommended oils.
o
When 2 or more persons work together, pay attention to the safety of each other.
o
After the reassembly, check parts for tightness and operation.
o Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use gasoline
as cleaning solvent.
Warning, Caution
and Note are included in this manual occasionally, describing the following contents.
WARNING .......•.... The personal safety of the rider or bystanders maybe involved. Disregarding
this information could result in personal injury.
CAUTION . . . . . . . . . . . .. These instructions point out special service procedures or precautions that
must be followed to avoid damaging the machine.
NOTE . . . . . . . . . . . . . . .. This provides special information to make maintenance easier or important
instructions clearer.
REPLACEMENT PARTS
When you replace any parts, use only genuine SUZUKI replace-
ment parts,
or their equivalent. Genuine SUZUKI parts are
high quality parts which are designed and built specifically for
SUZUKI vehicles.
CAUTION:
Use of replacement parts which are not equivalent in quality
to genuine SUZUKI parts can lead to performance problems
and damage.

ASBESTOS INFORMATION
Note the following when handling a supply part with the above
WARNING
LABEL or any part in the parts list in this section
which contains
asbestos.
• Operate if possible out of doors in a well ventilated place.
• Preferably
use hand tools or low speed tools equipped, if
necessary, with an appropriate dustextractor facility. If high
speed tools are used, they should always be so equipped.
•
If possible, dampen before cutting or drilling.
• Dampen dust
and place it in a properly closed receptacle
and dispose of it safely.
Any domestic asbestos product to which the above does not
apply, but which is likely to release fibres during use should be
replaced by new one when worn.
1. Clutch cover gasket
2.
Drive shaft bearing retainer gasket
3.
Cylinder cover gasket
4. Exhaust pipe gasket
GENERAL INFORMATION 1-8
WARNING
CONTAINS
ASBESTOS
Breathing asbestos
dust
is dangerous
to heaHh
Follow safety
instructions

1-9 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...... .
Overall
width ....... .
Overall height
...... .
Wheelbase ......... .
Ground clearance
... .
Seat height
........ .
Dry mass .....•.....
ENGINE
2 015 mm (79.3 in)
695 mm (27.4 in)
1 065 mm (41.9 in)
1 375 mm (54.1 in)
120 mm (4.7 in)
755 mm (29.7 in)
128
kg (282 Ibs)
Type. . . . . . . . . . . . .. Two-stroke, water-
cooled, 90°V-twin
Number
of cylinders .. 2
Bore
.............. 56.0 mm (2.205 in)
Stroke. . . . . . . . . . . .. 50.6 mm (1.992 in)
Piston displacement.
.. 249 cm
3 (15.2 cu. in)
Compression ratio . .
.. 7.5: 1
Carburetor. . . . . . . .
.. MI KUNI VM32SS
Air cleaner. . . . . . . . .. Polyurethane foam
element
Starter system . . . . .
.. Primary kick
Lubrication system. .. SUZUKI "CCI"
. TRANSMISSION
Clutch . . . . . . . . . . . .. Wet multi-plate type
Transmission. . . . . .
.. 6-speed constant mesh
Gearshift pattern . . . .. 1-down, 5-up
Primary reduction
.... 2.565 (59/23)
Final reduction
...... 3.066 (46/15)
Gear ratios, Low ... .. 2.454 (27/11)
2nd. . . . .. 1.625 (26/16)
3rd
.. . . .. 1.235 (21/17)
4th .. . . .. 1.045 (23/22)
5th
..... , 0.916 (22/24)
Top
..... 0.840 (21/25)
Drive chain
......... DAIDO: DID 520V2
TAKASAGO:
RK520M06
114 links
CHASSIS
Frontsuspension. . . .. Telescopic, coil spring,
oil damped, spring
5-way, adjustable.
Rear suspension ..... , Full-floating suspension
system, gas/coil spring,
oil damped, spring
7-way, adjustable.
Steering
angle ....... 30° (right & left)
Caster
............. 64°25'
Trail
.............. 98 mm (3.86 in)
Turning radius. . . . .
.. 3.1 m (10.2 ft)
Front brake. . . . . . . .. Disc brake, twin
Rear brake. . . . . . . . .. Disc brake
Fronttiresize ....... 110/70R1753H
Rear tire size . . . . . . .. 140/60 R18 64H
Front
fork stroke .... 120 mm (4.7 in)
Rear wheel travel. . . .. 140 mm (5.5 in)
ELECTRICAL
Ignition type ........ SUZUKI"PEI"
Ignition timing ...... 14° B.T.D.C. below
1 300 r/min
Spark
plug. . . . . . . . .. N.G.K.: BR9ES
Battery
............ 12V 10.8 KC (3Ah)/ .
10HR
Generator .......... Three-phase A.C.
generator
Fuse .............. 20A
CAPACITIES
Fuel tank
including reserve. . .
.. 17L (4.5/3.7 US/Imp gal)
reserve ..... 5.5L (5.8/4.8 US/Imp qt)
Engine oil
.......... 1.1 L (1.2/1.0 US/Imp qt)
Transmission
.. . . . . .. 700 ml
(23.7/24.6 US/Imp
oz)
Coolant ............ 1.6L (1.7/1.4 US/Imp qt)
Front fork oil ....... 429 ml
(14.5/15.1 US/Imp qt)

PERIODIC MAINTENANCE AND
TUNE-UP PROCEDURES
~---------------CONTENTS'----------------~
PERIODIC MAINTENANCE SCHEDULE .................................... 2- 1
PERIODIC MAINTENANCE CHART·································· 2- 1
LUBRICA TION POINTS····················································· 2- 2
MAINTENANCE AND TUNE-UP PROCEDURES ························2- 3
BATTERY ......................................... ,............ ···················2- 3
ENGINE BOL TS AND NUTS···· .. ··· .. · .. ·.... ·· .. ·····....···· .. · .. · .. ·· 2- 3
CYLINDER HEAD, CYLINDER AND MUFFLER .. · .. · .. · .. · .. ·· .. · 2- 4
AIR CLEANER .................................................................. 2- 4
SPARK PLUGS················································· ·················2- 5
CARBURETORS········..·································· ·····················2- 5
FUEL LINES ..................................................................... 2- 7
OIL PUMp········································································· 2- 7
CLUTCH .................................................................... ····· .. 2- 8
TRANSMISSION OIL· .. · .. ·· ......·......· .. · .. ·· ....·· ......·..........· .. · 2- 8
COOLING SYSTEM .......................................................... 2- 8
DRIVE CHAIN .. ·· ....· .. ·;········ .. ····.............. ·· .. · .. ·....· .. ·· .... ··· .. ·2 -10
BRAKES ........................................................................... 2-11
TIRES ................................................................. ·· .. ·· .... ···2-14
STEERING .......................................................... · .. · .. ·· .. ····2-15
FRONT FORK···································································· 2-15
REAR SUSPENSION· .... ·· ......·...... ·· ........··· .. ·....·........· .. ·· .. ·2-15
CHASSIS BOLTS AND NUTS ............ ·· ...... ·· ....· .. ·....· .. ·· .. ·2-16

2·1 PERIODIC MAINTENANCE AND TUNE·UP PROCEDURES
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of
kilometers.
NOTE:
Vehicles operated undersevere conditions may require more frequent servicing.
PERIODIC MAINTENANCE CHART
This interval should be judged by km 1 000
6000 12000
18000
24000
odometer reading or months, whichever months 2 12 24 36 48
comes first.
Battery -I I I I
Engine bolts and nuts T T T T T
Cylinder head, cylinder
and muffler
-C C C C
Air cleaner Clean every 3 000 km
Spark plugs I R R R R
Carburetors I I I I I
I I I I I
Fuel lines Replace every 4 years
Oil pump I I I I I
Clutch I I I I I
Transmission oil R -R -R
I -I -I
Radiator hoses
Replace every 4 years
Coolant
Change every 2 years
I I I I I
Drive chain
Clean and lubricate every 1 000 km
Brakes I I I I I
I I I I I
Brake hoses
Replace every 4 years
Brake
fluid Change every 2 years
Tires I I I I I
Steering I I I I I
Front fork
--I -I
Rear suspention --I -I
Chassis bolts and nuts T T T T T
T: Tighten, I: Inspect and clean, adjust, replace orlubricate as necessary, R: Replace, C: Clean

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-2
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points
are indicated below.
NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil dirt orgrime.
* Lubricate exposedparts which are subject to rust, with motor oil or grease.
mSteering
stem bearing
Exhast valve
control cable m
Clatch lever holder
Speedometer gearbox
Swingarm
pivot
mGrease
mOil

2-3 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the service procedures for each section of Periodic Maintenance.
BATTERY
Inspect Every 6 000 km (12 months)
• Remove the fuel tank. (Refer
to page 3-2.)
• Check the battery voltage
with the SUZUKI pocket tester.
If the voltage reading is below 12.0V, this battery needs
recharging.
Battery voltage: Above
12.0V
• Remove the battery e and E8 lead wires and remove the
battery
from the frame.
CAUTION:
Read the "ELECTRICAL SECTION", for servicing the
battery_
ENGINE BOLTS AND NUTS
Tighten at Initially 1 000 km (2 months) and
Every 6 000
km (12 months)
CYLINDER HEAD NUTS
• Remove the lower fairings. (Refer
to page 7-1.)
• First loosen nuts
by 1/4 turn and tighten the cylinder nuts
to the specified torque in ascending numerical order as
shown in the illustration.
Nut
Tightening torque: 23 -27 N·m (2.3 -2.7 kg-m)
EXHAUST PIPE NUTS
• Tighten the exhaust pipe nuts
to the specified torque.
Tightening torque: 18 -
28 N·m (1.8 -2.8 kg-m)

CYLINDER HEAD, CYLINDER AND
MUFFLER
Clean Every 6 000 km (12 months)
PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-4
• Carbon deposits in the combustion chamber of the cylinder
head and at the piston crown will raise the compression
ratio and may
cause preignition or overheating.
• Carbon deposited at the exhaust
port of the cylinder will
prevent the flow of exhaust gas, reducing the output. Re-
move carbon deposits periodically.
AIR CLEANER
Clean Every 3 000 km
•
Remove the seat. (Refer to page 3-2.)
• Unfasten the hook at
the front part of both right and left
frame covers.
•
Remove the fuel tank. (Refer to page 3-2.)
• Remove the air cleaner cover, then remove the air cleaner
element frame
and air cleaner element from the air cleaner
cover.
• Fill a washing
pan of a proper size with nonflammable clean-
ing solvent. I
mmerse the air cleaner element in the cleaning
solvent
and wash it clean.
•
Squeeze the cleaning solvent out of the washed element by
pressing it between the palms of both hands: do not twist or
wring the element or it will develop tears.
• Immerse
the air cleaner element in motor oil, and squeeze
the oil out of the element leaving it slightly wet with oil.
•
Fit the air cleaner element and its frame to the air cleaner
cover properly.
CAUTION:
* Before and during the cleaning operation, inspect the element for tears. A torn element must be re-
placed.
* Be sure to position the element snugly and correctly, so that no incoming air will bypass it. Remember,
rapid wear
of piston rings and cylinder bore is often caused by a defective or poorly fitted element.
CAUTION:
If driving under dusty conditions, clean the air cleaner element more frequently. Thesurest way to acceler-
ate engine wear
is to use the engine without the element or to use a ruptured element. Make sure that the
air cleaner is in good condition at all times. Life of the engine depends largely on this component!

2-5 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES
SPARK PLUGS
Inspect at Initially 1 000 km (2 months) and
Replace Every 6 000 km (12 months)
• Remove the fuel tank. (Refer
to page 3-2.)
The plug
gap is adjusted to 0.7 -0.8 mm (0.028 -0.031 in).
The
gap is correctly adjusted using a thickness gauge. When
carbon is deposited on the spark plug, remove the carbon with
a spark plug cleaning machine or by carefully using a tool with
a pointed end. If electrodes are extremely worn or burnt,
replace the plug. Also replace the plug
if it has a broken in-
sulator, damaged thread, etc.
NGK BR9ES listed in the table should
be used as the standard
plug. However, the heat
range of the plug should be selected to
meet the requirements of speed, actual load, fuel, etc. If the
plugs
need to be replaced, it is recommended that the standard
plugs listed in the table
be selected. Remove the plugs and in-
spect the insulators. Proper heat
range would be indicated if
both insulators were light brown in color. If they are blacken-
ed by carbon, they should be replaced by a hot type BR8ES if
baked white, by NGK BR10ES.
Plugs with high heat range number are used for hi,gh speed
running. These plugs are designed to be sufficiently cooled to
prevent overheating and are called cold type plugs.
Recommended spark plug
NGK REMARKS
BRBES If
the standard plug is apt to get wet, replace with this plug. Hot type.
BR9ES Standard
BR10ES If
the standard plug is apt to overheat, replace with this plug. Cold type.
NOTE:
0.7 - O.B mm
"R" type spark plug is installed for some specifications. "R" type spark plug has a resistor located at the
center electrode to prevent
radio noise.
CAUTION:
Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be de-
posited on the thread portion of the plug hole and engine damage may result.
CARBURETORS
Inspect at Initially 1 000 km (2 months) and
Every 6 000 km (12 months)
IDLE RPM ADJUSTMENT
NOTE:
Make this adjustment when the engine is hot.