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1994-2002 Suzuki RF900R Werkstatt-Reparaturhandbuch

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🏷️ Basic Information Identification Make: Suzuki Model: RF900R Model Years Covered: 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002 Codes Chassis Code: Often referred to by its engine prefix...
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Art.-Nr: 604523
1994-2002 Suzuki RF900R Werkstatt-Reparaturhandbuch1994-2002 Suzuki RF900R Werkstatt-Reparaturhandbuch1994-2002 Suzuki RF900R Werkstatt-Reparaturhandbuch1994-2002 Suzuki RF900R Werkstatt-Reparaturhandbuch
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
RF900R
Model Years Covered:
1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002
Codes
Chassis Code:
Often referred to by its engine prefix and general model designation, specific chassis codes may vary by region but typically relate to the NCV model series.
👋 Introduction
Market Position
Motorcycle Segment:
Sport-touring / Hypersport
Key Selling Points:
Powerful inline-four engine, aerodynamic fairing, comfortable riding position for longer distances.
Competitive Analysis
Direct Competitors:
Honda CBR1000F, Yamaha FZR1000, Kawasaki ZX-9R (later models).
Key Features
Engine Configuration:
Liquid-cooled, DOHC, 16-valve, inline-four cylinder.
Frame Type:
Aluminum twin-spar frame.
Braking System:
Dual front disc brakes, single rear disc brake.
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive repair, maintenance, and troubleshooting for the Suzuki RF900R motorcycle.
Page Count
Estimated Page Count:
400+
Manual Type
Manual Type:
Workshop Repair Manual / Service Manual
Language
Language:
English
Format
Format:
Digital (likely PDF or similar electronic format)
📖 Manual Coverage
Systems Covered
Engine:
Engine assembly, disassembly, component inspection, tuning, oil system, cooling system.
Fuel System:
Carburetor service, fuel pump, fuel lines, fuel tank.
Transmission:
Gearbox assembly, disassembly, clutch operation, shift mechanism.
Electrical System:
Wiring diagrams, ignition system, charging system (alternator, regulator/rectifier), starting system, lighting, instrumentation.
Suspension:
Front forks (telescopic), rear shock absorber, linkage, swingarm.
Brakes:
Front and rear brake systems (hydraulic disc brakes), calipers, master cylinders, brake lines, bleeding procedures.
Wheel And Tire:
Wheel bearing service, tire mounting and balancing, rim specifications.
Frame And Bodywork:
Chassis inspection, fairing removal/installation, seat, fuel tank mounting.
Cooling System:
Radiator service, coolant type and capacity, thermostat.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, brake pad inspection/replacement, coolant checks.
Troubleshooting:
Diagnostic charts for common issues related to starting, running, electrical faults.
Engine Rebuild:
Detailed steps for engine disassembly, piston/ring replacement, valve adjustments, gasket replacement.
Carburetor Tuning:
Jetting specifications, idle speed adjustment, mixture control.
Electrical Diagnostics:
Testing of ignition coils, starter motor, charging system components.
Suspension Service:
Fork seal replacement, oil level adjustments, rear shock service.
Brake System Repair:
Caliber rebuild, master cylinder replacement, bleeding procedure.
Technical Depth
Depth Level:
Comprehensive, suitable for professional mechanics and experienced DIY enthusiasts. Covers from basic maintenance to complete engine and chassis overhauls.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable, allowing for quick location of specific terms.
Print Quality
Print Readability:
Designed for clear viewing on screen and printable for workshop use.
Binding Type
Binding Type:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, DOHC, inline-four
Displacement:
937 cc (57.2 cu in)
Bore X Stroke:
74.0 mm x 54.5 mm (2.91 in x 2.15 in)
Compression Ratio:
10.7:1
Performance
Horsepower Peak:
Approx. 125-130 hp (93-97 kW) at 10,000 rpm (varies by market and tuning)
Torque Peak:
Approx. 97 Nm (71.5 lb-ft) at 8,500 rpm (varies by market and tuning)
Fuel System
Carburetors:
Four Mikuni BSF36 constant-velocity carburetors
Fuel Capacity:
20 Liters (5.3 US gal)
Engine Components
Valve Train:
DOHC, 4 valves per cylinder
Ignition System:
Electronic ignition (CDI)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch:
Wet multi-plate
Features
Gear Ratios:
Specific ratios detailed within the manual.
Fluid Specifications
Transmission Oil Type:
API GL-4, SAE 80W-90 hypoid gear oil (refer to manual for exact specifications and change intervals).
📐 Dimensions
Exterior
Length:
Approx. 2,155 mm (84.8 in)
Width:
Approx. 760 mm (30.0 in)
Height:
Approx. 1,200 mm (47.2 in)
Wheelbase:
Approx. 1,460 mm (57.5 in)
Weights
Dry Weight:
Approx. 210 kg (463 lbs)
Wet Weight:
Approx. 230 kg (507 lbs)
Load Capacity:
Refer to manual for specific rider and luggage weight limits.
🛡️ Safety Features
Ratings
Safety Features Overview:
As a motorcycle of its era, safety features are primarily passive and inherent to its design and components.
Active Features
Braking Performance:
Dual front discs with 4-piston calipers and single rear disc offer strong stopping power for its class.
Passive Features
Chassis Integrity:
Aluminum twin-spar frame provides rigidity and stability.
Lighting:
Adequate headlight, taillight, and turn signals for visibility.
💡 Technology Features
Infotainment
Infotainment Features:
N/A (Motorcycle of this era typically does not feature integrated infotainment systems.)
Driver Assistance
Rider Assistance:
Basic electronic ignition system.
Connectivity
Connectivity Features:
N/A (No integrated connectivity features.)
Instrumentation
Gauge Cluster:
Analog tachometer, speedometer, fuel gauge, temperature gauge, and warning lights.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 4,000-6,000 km (2,500-3,700 miles) or 6 months, whichever comes first.
Valve Clearance Check:
Every 12,000-16,000 km (7,500-10,000 miles).
Spark Plug Replacement:
Every 12,000-16,000 km (7,500-10,000 miles).
Fluid Specifications
Engine Oil Type:
SAE 10W-40, API SG or higher (check manual for specific viscosity based on ambient temperature).
Engine Oil Capacity:
Approx. 3.5 Liters (3.7 US qt) with filter change, 3.2 Liters (3.4 US qt) without.
Coolant Type:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water.
Coolant Capacity:
Approx. 1.9 Liters (2.0 US qt)
Known Issues
Common Wear Items:
Clutch plates, brake pads, fork seals, regulator/rectifier (known to fail on some models), carburetor synchronization.
Potential Problems:
Stalling due to carburetor issues, charging system failures, cam chain noise if not maintained.
Part Numbers
Oil Filter Part Number:
Common aftermarket equivalents exist; Suzuki OEM part number would be specified in a parts catalog, often starting with '16510-...' for filters.
Spark Plug Part Number:
NGK CR9E or equivalent is a common fitment, but specific recommendation should be confirmed with the manual.
📚 Vehicle History
Brand Heritage
Suzuki Motorcycle History:
Suzuki has a long-standing reputation for producing innovative and performance-oriented motorcycles across various categories, from small commuters to powerful sportbikes and off-road machines.
Model Evolution
Rf Series Development:
The RF series evolved from Suzuki's earlier GSX-R sportbikes, aiming to offer a blend of high performance with greater comfort and touring capability. The RF900R was a significant iteration in this lineage.
Production
Production Period:
Launched in 1994 and produced through to 2002, with updates and minor revisions over its lifespan.
Manufacturing Location:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
Generally well-received upon release for its blend of performance and practicality, though some reviews noted its weight compared to more focused sportbikes.
Ratings
Reliability Perception:
Suzuki is generally considered a reliable brand; however, maintenance is key, especially for the charging system and carburetors on this model.
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