Segment:
Lightweight sportbike, performance two-stroke category.
Rivals:
Yamaha TZR250, Kawasaki KR-1/KR-1S, Honda NSR250R.
Selling Points:
Lightweight chassis, potent two-stroke V-twin engine, aggressive styling, advanced RSU (Rain Suction Unit) engine cooling system (on some variants/years), sharp handling.
Systems Covered:
Engine, Transmission, Fuel System, Ignition System, Cooling System, Electrical System, Chassis, Suspension, Brakes, Bodywork, Troubleshooting, Maintenance
Type:
Service and Repair Manual
Engine Mechanical:
Complete disassembly and reassembly of the 2-stroke V-twin engine, including cylinder head, pistons, connecting rods, crankshaft, crankcase, and all associated components.
Fuel System:
Carburetor adjustment and overhaul (Mikuni VM28SS), fuel pump, fuel lines, and fuel tank maintenance.
Ignition System:
CDI ignition system, spark plugs, ignition coils, and timing adjustments.
Cooling System:
Liquid cooling system, radiator, water pump, hoses, and thermostat service.
Transmission And Drivetrain:
Clutch operation and adjustment, gearbox disassembly and reassembly, gear ratios, chain maintenance, and sprocket replacement.
Electrical System:
Wiring diagrams, lighting, charging system (alternator, rectifier/regulator), starting system (starter motor, battery), indicators, and horn troubleshooting.
Chassis And Suspension:
Frame inspection, front fork (conventional telescopic, RSU - Rain Suction Unit system) service and adjustment, rear shock absorber service, steering head bearing maintenance.
Brakes:
Front and rear disc brake systems, brake caliper overhaul, master cylinder service, brake fluid replacement, and bleeding procedures.
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank, and minor body panel repairs and maintenance.
Maintenance Tasks:
Regular servicing, oil changes (premix or oil injection system), filter replacements, chain lubrication and adjustment, spark plug replacement, brake pad replacement, and coolant flushes.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, fault finding charts, and solutions for performance issues, starting problems, and electrical faults.
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly for all major systems.
Depth:
Comprehensive coverage suitable for both home mechanics and professional technicians, from basic maintenance to full engine rebuilds and advanced diagnostics.
Type:
Liquid-cooled, 2-stroke, 90-degree V-twin
Bore X Stroke:
54.0 mm x 54.4 mm
Power Output:
Approx. 60-65 PS (44-48 kW) @ 11,000 rpm (varies by market and specific tuning)
Torque:
Approx. 37 Nm (27 lb-ft) @ 10,500 rpm
Top Speed:
Approx. 120-130 mph (193-209 km/h)
Carburetors:
Dual Mikuni VM28SS constant velocity carburetors
Fuel Type:
Unleaded gasoline (min. 95 octane recommended)
Oil Delivery:
Oil injection system (Suzuki Posi-Force) or Premix
Type:
6-speed constant mesh, claw-shift
Gear Ratios:
1st: 2.538 (33/13), 2nd: 1.812 (29/16), 3rd: 1.400 (28/20), 4th: 1.150 (23/20), 5th: 1.000 (22/22), 6th: 0.875 (21/24)
Final Drive:
O-ring sealed chain, 520 size
Classification:
Sportbike
Braking System:
Dual front hydraulic disc brakes, Single rear hydraulic disc brake.
Suspension Features:
Anti-dive front suspension (often referred to as SEPF - Suzuki Electronic Performance Suspension or similar marketing terms, actual mechanism is mechanical anti-dive), adjustable rear monoshock.
Lighting:
Halogen headlight, LED taillight.
Oil Change:
Every 5,000 km (3,000 miles) or annually. Engine oil (for gearbox): Check level monthly, change every 10,000 km (6,000 miles).
Spark Plugs:
Inspect every 2,500 km (1,500 miles), replace as needed. Recommended: NGK BR9ES or equivalent.
Air Filter:
Clean every 5,000 km (3,000 miles), replace as needed.
Chain Maintenance:
Lubricate and adjust every 1,000 km (600 miles) or after washing/wet riding.
Engine Oil:
Suzuki recommends Castrol MTX Full Synthetic 2-stroke oil or equivalent high-quality 2-stroke racing oil for the oil injection system. Gearbox oil: SAE 10W-40 API GL-4.
Coolant:
Ethylene glycol-based antifreeze/coolant, mixed 50/50 with distilled water.
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid.
Common Problems:
Carburetor synchronization and jetting issues, wear in the power valve system, crankcase seals leaking, exhaust power valve sticking, front fork seal leaks, aging electrical connectors.
Maintenance Tips:
Regularly clean and rebuild carburetors, ensure proper operation of the exhaust power valves, keep the cooling system in good order, and inspect electrical connections for corrosion.
Legacy:
Suzuki has a long history of success in Grand Prix racing, particularly with its two-stroke machines, which heavily influenced the design and performance of the RGV series.
Rgv250 Generations:
The RGV250 evolved through several generations, starting with the RG250 Gamma. The RGV250M represents the third generation, building on the success of the M and V models, with key updates focusing on aerodynamics, chassis rigidity, and engine tuning. The 'M' designation typically indicates specific market variations or updates from the preceding 'V' model.
Production Period:
The RGV250 was produced from 1987 to 1996. The 1991 model falls within the second major generation (GJ21/VJ22) which was produced from 1990-1995.
