Suzuki RG250 1988 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: RG250 Year: 1988 Codes Model Code: RG250Γ (GJ21B) 👋 Introduction Market Position Segment: Lightweight Sportbike / Performance Two-Stroke Target Audience: Enthusiast riders, mechanics,...

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Taper: Motorcycle

Distributeur:

UGS: 370300

Mots clés: 1988 Motorcycle Motorcycles RG Series RG250 Suzuki

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

RG250

Year:

Codes

Model Code:

RG250Γ (GJ21B)

👋 Introduction

Market Position

Segment:

Lightweight Sportbike / Performance Two-Stroke

Target Audience:

Enthusiast riders, mechanics, collectors of classic Japanese motorcycles

Competitive Analysis

Key Competitors:

Yamaha RZ250, Kawasaki KR250, Honda VT250F (though different engine configuration)

Key Features

Engine Configuration:

High-revving, liquid-cooled (often), parallel-twin two-stroke

Handling:

Agile, sporty handling characteristics due to lightweight chassis and suspension design

Performance Focus:

Designed for spirited riding and trackday potential in its era

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical and Electrical Systems, Bodywork, Troubleshooting

Secondary Coverage:

Maintenance Schedules, Wiring Diagrams, Component Specifications

Page Count

Estimated Page Count:

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine:

2-stroke Parallel Twin, Rotary Valve Induction, Cooling System (Air/Liquid - specify based on exact model variant if known)

Fuel System:

Carburetor(s) (Mikuni VM26SS likely), Fuel Tank, Petcock

Ignition System:

CDI (Capacitor Discharge Ignition), Ignition Coils, Spark Plugs, Timing

Transmission:

6-Speed Constant Mesh Sequential Gearbox, Clutch (Wet Multi-plate)

Drivetrain:

Chain Drive, Rear Sprocket, Front Sprocket

Chassis Frame:

Steel Trellis Frame, Subframe

Suspension Front:

Telescopic Forks (likely conventional or possibly upside-down for some variants), Triple Clamps, Steering Stem

Suspension Rear:

Monoshock (likely with linkage system), Swingarm, Rear Shock Absorber Adjustment

Brakes Front:

Dual Disc Brakes, Caliper Type (e.g., 2-piston), Master Cylinder, Brake Lines

Brakes Rear:

Single Disc Brake, Caliper Type (e.g., 1 or 2-piston), Master Cylinder, Brake Lines

Wheels Tires:

Spoked or Cast Wheels, Tire Sizes, Inflation Pressures

Electrical System:

Battery, Charging System (Stator/Alternator), Lighting (Headlight, Taillight, Turn Signals), Instrumentation, Wiring Harness, Fuses

Bodywork Cosmetics:

Fairing, Fuel Tank, Seat, Handlebars, Footpegs, Graphics, Fasteners

Procedures Included

Maintenance:

Oil Changes, Filter Replacements, Chain Adjustment, Spark Plug Replacement, Air Filter Cleaning/Replacement

Engine Overhaul:

Top-end Rebuild (Piston, Rings, Cylinder), Bottom-end Rebuild (Crankshaft, Bearings), Carburetor Rebuild and Synchronization

Transmission Repair:

Clutch Replacement, Gearbox Disassembly and Reassembly

Suspension Service:

Fork Seal Replacement, Fork Oil Change, Rear Shock Rebuild/Replacement

Brake System Service:

Brake Pad Replacement, Brake Fluid Flush and Bleed, Caliper Rebuild

Electrical Diagnostics:

Wiring Harness Testing, Component Diagnosis (Stator, CDI, Lights), Troubleshooting Faults

Troubleshooting:

Diagnostic Flowcharts for Common Issues (e.g., No Start, Poor Running, Electrical Failures)

Specifications Torque:

Torque values for all critical fasteners and components

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine rebuilds and diagnostics)

📊 Manual Specifications

File Format

Digital Format:

PDF (Searchable text, high-resolution scans of original manual pages)

Print Quality

Print Quality Notes:

If printed, expected high-quality reproduction of original diagrams and text

Binding Type

Binding Type Notes:

If printed, typically spiral-bound for lay-flat use in workshop environments

Paper Type

Paper Type Notes:

If printed, typically on durable, workshop-friendly paper stock

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-Stroke, Parallel-Twin, Reed Valve (or Rotary Valve depending on specific GJ21B variant)

Bore X Stroke:

54.0 mm x 54.0 mm (typical for GJ21B)

Displacement:

247 cc

Compression Ratio:

7.2:1 (typical)

Cooling System:

Liquid-Cooled (often with a radiator and fan)

Performance

Horsepower Peak:

Approx. 45-47 PS (approx. 44-46 bhp) at 9,000 rpm (typical for the era and class)

Torque Peak:

Approx. 34 Nm (approx. 25 ft-lbs) at 8,000 rpm (typical)

Fuel System

Carburetor Model:

Mikuni VM26SS x 2 (likely)

Fuel Type:

Unleaded gasoline, Minimum 91 octane (RON+MON)/2 / 87 AKI, mixed with 2-stroke oil

Oil Injection:

Separate Lubrication System (Suzuki Full-Flow Oil System or similar)

🔧 Transmission

Standard

Type:

6-Speed Constant Mesh Sequential

Clutch Type:

Wet, Multi-plate

Features

Gear Ratios:

Specific ratios detailed in manual (e.g., 1st: 2.692, 2nd: 1.882, 3rd: 1.400, 4th: 1.150, 5th: 0.960, 6th: 0.840 - typical values)

Final Drive Ratio:

14/47 (typically 3.357)

📐 Dimensions

Exterior

Length:

Approx. 2,050 mm (2,050 mm)

Width:

Approx. 745 mm (745 mm)

Height:

Approx. 1,150 mm (1,150 mm)

Wheelbase:

Approx. 1,365 mm (1,365 mm)

Weights

Dry Weight:

Approx. 134 kg (134 kg)

Wet Weight:

Approx. 149 kg (149 kg) (with all fluids)

Cargo

Fuel Tank Capacity:

16 Liters (16 L)

🛡️ Safety Features

Ratings

Safety Ratings Era:

Motorcycles of this era did not have standardized crash test ratings like cars. Safety focus was on braking performance, handling, and rider protection equipment.

Active Features

Braking System:

Front and Rear Disc Brakes for effective stopping power.

Handling Stability:

Well-balanced chassis and suspension contributing to stability during cornering.

Passive Features

Lighting:

Adequate headlight, taillight, and turn signal for visibility.

💡 Technology Features

Infotainment

Infotainment System:

N/A - None applicable for this era of sportbike.

Driver Assistance

Driver Assistance Systems:

N/A - None applicable. Focus is on mechanical and electrical systems.

Connectivity

Connectivity Features:

N/A - No digital connectivity features.

🔧 Maintenance

Service Intervals

Oil Change:

Every 3,000-5,000 km or annually (refer to manual for exact intervals and oil type)

Spark Plug Replacement:

Every 5,000-10,000 km, check gap and condition more frequently

Chain Maintenance:

Lubricate and adjust every 500-1000 km or as needed based on wear.

Air Filter Cleaning:

Inspect every 2,500-5,000 km, clean or replace as needed.

Fluid Specifications

Engine Oil Type:

Suzuki recommend specific 2-stroke engine oil for the premix or oil injection system (detailed in manual). Typically, a high-quality API TC or JASO FD rated oil.

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for exact specification)

Fork Oil Type:

Suzuki Fork Oil SS-05 or equivalent SAE 5W (capacity per leg specified in manual)

Coolant Type:

If liquid-cooled, typically a 50/50 mix of ethylene glycol-based antifreeze and distilled water.

Known Issues

Two Stroke Wear:

Typical two-stroke wear on piston rings, cylinder walls, and reed valves over time, requiring rebuilds.

Carburetor Tuning:

Carburetors can be sensitive to altitude, temperature, and fuel quality, requiring regular tuning and cleaning.

Electrical Connections:

Aging wiring and connectors can lead to intermittent electrical issues.

Exhaust Ports:

Carbon buildup in exhaust ports and silencers can affect performance and require cleaning.

📚 Vehicle History

Brand Heritage

Suzuki Motorcycle Legacy:

Suzuki has a long history of producing innovative and high-performance motorcycles, particularly in the two-stroke era.

Model Evolution

Rg Series Predecessors:

The RG250 built upon Suzuki's success with earlier performance two-strokes, incorporating advancements in engine technology and chassis design.

Rg250 Generation:

Part of the RG250 Gamma series, known for its race-inspired styling and performance, closely resembling larger RG500 machines.

Production

Production Years:

1983-1988 (with various iterations and updates within this period, including the GJ21B variant for 1988)

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Historical Acclaim:

The RG250 Gamma was highly acclaimed in its time for its performance, handling, and race-derived technology, often winning comparisons in motorcycle publications.

Ratings

Performance Ratings:

Consistently rated as one of the best 250cc sportbikes of its generation for its acceleration and agility.

Certifications

Certification Notes:

No specific certifications apply in the modern sense; it met the road-legal standards of its time.