Suzuki RF900R (RF900RR RF900RS RF900RT RF900RV) Motorcycle Workshop Service Repair Manual 1994-1997

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🏷️ Basic Information Identification Make: Suzuki Model: RF900R Model Variants: RF900RR, RF900RS, RF900RT, RF900RV Production Years: 1994-1997 Codes Engine Code: G528 👋 Introduction Market Position Category: Sportbike / Sport-Touring Motorcycle...

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Typ: Motorcycle

Anbieter:

Art.-Nr: 39937

Stichworte: 1994 1995 1996 1997 450 Case Construction Motorcycle RF900R RF900RR RF900RS RF900RT RF900RV Skid Steer Loaders Suzuki

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

RF900R

Model Variants:

RF900RR, RF900RS, RF900RT, RF900RV

Production Years:

1994-1997

Codes

Engine Code:

👋 Introduction

Market Position

Category:

Sportbike / Sport-Touring Motorcycle

Target Audience:

Suzuki RF900R owners, mechanics, DIY enthusiasts

Competitive Analysis

Competitors:

Kawasaki ZZ-R1100, Yamaha FZR1000, Honda CBR1000F (during its era)

Key Features

Manual Value:

Comprehensive, dealer-level repair information, detailed illustrations, step-by-step procedures, troubleshooting guidance.

Vehicle Appeal:

Powerful inline-four engine, comfortable riding position for a sportbike, capable for both spirited riding and touring.

📋 Manual Details

Coverage Areas

Vehicle Models:

Suzuki RF900R (RF900RR, RF900RS, RF900RT, RF900RV)

Production Years Covered:

1994, 1995, 1996, 1997

Page Count

Total Pages:

More than 450

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

File Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine Mechanical, Engine Coolant, Engine Control System, Charging System, Starting System, Ignition System, Fuel System, Clutch System, Transmission System (Manual Transaxle System)

Chassis:

Brake System, Suspension System (Front and Rear), Steering System, Wheel and Tire System, Drive Shaft/Chain System

Electrical:

Lighting System, Combination Meter, Electrical System Diagnosis, Wiring Diagrams, Wiper and Washer System, Power Window System, Power Door Lock System

Body:

Body Repair, Interior Components, Exterior Components, Sun Roof System

Engine Mechanical:

Cylinder block, cylinder head, crankshaft, pistons, connecting rods, valves, camshafts, timing chain, lubrication system (oil pump, oil filter).

Fuel System:

Carburetors (disassembly, cleaning, adjustment), fuel pump (if applicable), fuel lines, fuel tank.

Cooling System:

Radiator, cooling fan, water pump, thermostat, coolant hoses, expansion tank.

Ignition System:

Ignition coils, spark plugs, CDI unit, pickup coils, wiring.

Electrical System:

Wiring diagrams, charging system (stator, regulator/rectifier, battery), starting system (starter motor, starter clutch), lighting, instruments, switches.

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, lubrication

Repair:

Engine disassembly and reassembly, transmission overhaul, brake component replacement, suspension work, electrical component repair

Troubleshooting:

Diagnostic procedures for common and complex issues across all systems, including electrical and engine performance problems

Technical Data:

Specifications, torque values, clearances, fluid capacities, electrical schematics

Engine Rebuild:

Complete engine overhaul, including piston replacement, ring installation, bearing checks, valve seat grinding, and seal replacement.

Suspension Service:

Fork seal replacement, fork oil change and level adjustment, rear shock absorber inspection and replacement.

Brake Service:

Brake pad replacement, caliper overhaul, master cylinder service, brake fluid flush and bleeding.

Chassis Maintenance:

Steering head bearing inspection and adjustment, swingarm bearing lubrication and check, wheel bearing service.

Technical Depth

Depth:

Complete workshop level, covering detailed disassembly, repair, and reassembly procedures, suitable for both DIY enthusiasts and professional mechanics.

Diagnostic Tools:

Guidance on using basic tools for diagnosis and repair, emphasis on understanding electrical schematics.

Manual Content Quality

Illustrations:

Detailed illustrations, drawings, and photos throughout for visual guidance.

Instructions:

Numbered instructions with sub-steps, notes, cautions, and warnings for critical information.

📊 Manual Specifications

File Format

Format:

Compatibility:

Windows, Mac, Linux

Print Quality

Printability:

Yes, all pages are printable

Binding Type

Binding:

Digital Download (PDF)

Paper Type

Paper Type:

N/A (Digital)

Protection

Digital Rights Management:

DRM-free

⚙️ Engine Specifications

Primary Engine

Type:

937cc, Liquid-cooled, 4-stroke, DOHC, 16-valve, Inline-4

Bore X Stroke:

73.0 mm x 55.0 mm

Performance

Horsepower:

Approximately 125-135 HP (varies by market and specific year)

Torque:

Approximately 97 Nm (71.5 lb-ft) @ 9,000 RPM (approximate)

Fuel System

Induction:

Mikuni BST40 flat-slide carburetors (4 x 40mm)

Fuel Type:

Unleaded gasoline, 91+ octane

Lubrication

Oil Type:

API SG or SH, SAE 10W-40 motorcycle specific oil recommended

Oil Capacity:

Approx. 3.8 L (4.0 US qt) without filter change, 4.1 L (4.3 US qt) with filter change

🔧 Transmission

Standard

Type:

6-speed constant mesh

Clutch Type:

Wet, multi-plate

Features

Drive System:

Chain drive

📐 Dimensions

Exterior

Overall Length:

Approx. 2,170 mm (85.4 in)

Overall Width:

Approx. 760 mm (29.9 in)

Overall Height:

Approx. 1,220 mm (48.0 in)

Weights

Dry Weight:

Approx. 215 kg (474 lbs)

Wet Weight:

Approx. 240 kg (529 lbs) (fully fueled)

Wheels Tires

Front Tire Size:

120/70ZR17M/C (58W)

Rear Tire Size:

170/60ZR17M/C (72W)

Front Wheel Size:

MT3.50 x 17

Rear Wheel Size:

MT5.00 x 17

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (Motorcycle safety is primarily assessed through rider skill and protective gear, not standardized vehicle crash tests like cars.)

Active Features

Braking System:

Dual 320mm discs with 4-piston calipers (front), Single 270mm disc with 2-piston caliper (rear).

Passive Features

Lighting:

Halogen headlamp, LED taillight, standard turn signals.

💡 Technology Features

Infotainment

Display:

Analog speedometer and tachometer, with LCD display for odometer, trip meters, and warning lights.

Driver Assistance

Not typically available on this model, check specific market variants.

Connectivity

Features:

N/A (basic motorcycle electronics)

🔧 Maintenance

Service Intervals

Oil Change:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Air Filter:

Inspect every 6,000 km (3,700 miles), replace as needed or every 12,000 km (7,500 miles).

Spark Plugs:

Replace every 12,000 km (7,500 miles) or as per manual recommendation.

Valve Clearance:

Inspect every 12,000 km (7,500 miles).

Fluid Specifications

Coolant:

Suzuki Coolant (or equivalent mixture of ethylene glycol and distilled water, typically 50/50).

Brake Fluid:

DOT 4

Clutch Fluid:

DOT 4 (if hydraulic clutch)

Transmission Oil:

Suzuki Gear Oil (or equivalent API GL-4, SAE 75W-90)

Known Issues

Common Problems:

Carburetor synchronization issues, potential for stator failure (common on many bikes of this era), fuel petcock diaphragm wear.

Maintenance Focus:

Regular oil changes, maintaining proper carb synchronization, checking and maintaining the cooling system, and ensuring the electrical charging system is functioning optimally.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation, Japan

Model Evolution

Development:

Developed as a successor to the GSX-R750 in some markets and as a more sport-touring focused alternative to pure superbikes. Known for its potent engine and comfortable ergonomics for its class.

Production

Production Run:

1994-1997, with minor updates across the years. Later models were superseded by other Suzuki offerings.

🏆 Awards & Recognition

Recognitions

Industry Awards:

While specific awards for the RF900R are not widely documented, it was well-regarded in motorcycle press for its performance and handling for a sport-touring machine of its era.