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