1989-1996 Suzuki Gamma RGV250 (RGV250K-L-M-N-P-R-T) Motorcycle Workshop Repair Service Manual Best Download PDF

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Basic Information Identification Make: Suzuki Model: RGV250 Gamma Model Codes: RGV250K, RGV250L, RGV250M, RGV250N, RGV250P, RGV250R, RGV250T Generation Generation: RGV250 (VJ22A) Production Years Covered: 1989, 1990, 1991, 1992, 1993, 1994,...

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Taper: Motorcycle

Distributeur:

UGS: 43128

Mots clés: 1989 1990 1991 1992 1993 1994 1995 1996 Gamma RGV250 Motorcycle Motorcycles RGV250 RGV250K RGV250L RGV250M RGV250N RGV250P RGV250R RGV250T Suzuki

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Description

Basic Information
Identification
Make:	Suzuki
Model:	RGV250 Gamma
Model Codes:	RGV250K, RGV250L, RGV250M, RGV250N, RGV250P, RGV250R, RGV250T
Generation
Generation:	RGV250 (VJ22A)
Production Years Covered:	1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996

Introduction
Market Position
Market Position:	The Suzuki RGV250 Gamma was a highly regarded 250cc two-stroke sportbike, renowned for its performance and handling, directly competing with models like the Yamaha TZR250 and Honda NSR250R. This manual targets owners and mechanics focused on maintaining and restoring these iconic machines.
Competitive Analysis
Competitive Analysis:	As a comprehensive workshop manual, it offers an equivalent level of detail to factory service manuals, providing crucial diagnostic and repair information that is essential for preserving the performance and longevity of a high-strung, technologically advanced two-stroke sportbike.
Key Features
Key Features:	Extensive coverage of all major vehicle systems, detailed illustrations and diagrams, step-by-step repair procedures, diagnostic flowcharts, torque specifications, and maintenance schedules.
Documentation Quality:	The manual is presented as containing the same information as professional technician manuals, ensuring accuracy and completeness.

Manual Details
Coverage Areas
Coverage Areas:	Full service, repair, maintenance, rebuilding, refurbishment, restoration
Page Count
Page Count:	Not specified, assumed comprehensive
Manual Type
Manual Type:	Workshop Repair Service Manual
Language
Language:	English
Format
Format:	Digital PDF Download

Manual Coverage
Systems Covered
Systems Covered:	Engine Mechanical, Engine Lubrication, Engine Cooling, Engine Control, Fuel System, Exhaust System, Clutch, Manual Transaxle, Driveline, Front Axle, Rear Axle, Front Suspension, Rear Suspension, Road Wheels & Tyres, Brake System, Parking Brake, Brake Control, Steering System, Body, Lock & Security, Glasses, Window System, Mirrors, Roof, Exterior & Interior, Instrument Panel, Seats, Air Conditioner System, Wiring Diagrams, Starting & Charging System, Lighting System, Driver Information System, Wiper, Washer & Horn, Body Control System, LAN System, Audio Visual, Navigation & Telephone, Auto Cruise Control, Power Supply, Ground & Circuit Elements, Maintenance Procedures
Index Coverage:	Includes an alphabetical index for quick access to specific topics and repair procedures.
Bodywork Coverage:	Includes detailed procedures for fairing removal and installation, body panel alignment, and cosmetic component replacement.
Procedures Included
Procedures Included:	Diagnosis, Repair, Maintenance, Rebuild, Refurbishment, Restoration, Troubleshooting, Component Inspection, Adjustment, Replacement, Overhaul
Diagnostic Procedures:	Detailed diagnostic flowcharts and troubleshooting guides for electrical and mechanical issues.
Electrical Diagnostics:	Extensive wiring diagrams and component testing procedures for diagnosing electrical faults.
Technical Depth
Technical Depth:	Comprehensive, detailed procedures covering all aspects from basic maintenance to full engine and chassis rebuilds, suitable for professional technicians and experienced enthusiasts.
Torque Specifications:	Comprehensive listing of all critical torque specifications for engine, chassis, and component fasteners.

Manual Specifications
File Format
File Format:	PDF
Compatibility:	Compatible with all versions of Windows, Mac, and Linux operating systems, requiring only a standard PDF reader.
Print Quality
Print Quality:	High quality photos, illustrations, and diagrams, designed for clear printing.
Binding Type
Binding Type:	Digital Download (No physical binding)
Paper Type
Paper Type:	N/A (Digital Format)

Engine Specifications
Primary Engine
Engine Type:	90-degree V-twin, liquid-cooled, two-stroke, Reed Valve Induction, Rotary Valve Induction (later models)
Displacement:	247 cc
Bore X Stroke:	54.0 mm x 54.5 mm
Compression Ratio:	7.2:1 - 7.5:1 (depending on model year)
Cylinder Arrangement:	90-degree V-twin
Performance
Horsepower:	Approximately 60-65 PS (44-48 kW) at 11,000 rpm (varies by market and year)
Torque:	Approximately 3.9 kgf-m (38 Nm; 28 lb-ft) at 10,000 rpm (varies by market and year)
Fuel System
Carburetion:	Twin Mikuni VM28SS carburetors (typical)
Fuel Type:	Unleaded Gasoline (95 RON or higher recommended)
Oil System:	Suzuki C.C.S. (Crankcase Cooling System) or separate oil injection system for two-stroke oil
Engine Control System
Ignition:	CDI (Capacitor Discharge Ignition), potentially with electronic timing advance
Emission Control:	Reed valve induction, crankcase scavenging, exhaust power valves (Suzuki SAEC - Suzuki Advanced Engine Control)
Power Valves:	Electronically controlled exhaust powervalves (SAEC system) for improved torque across the rev range and reduced emissions.

Transmission
Standard
Transmission Type:	6-speed constant mesh, sequential return
Clutch Type:	Wet, multi-plate, cable-operated
Features
Gear Ratios:	Detailed in manual (specific ratios vary by year/model)
Final Drive:	Sealed O-ring chain drive
Fluid Requirements
Transmission Oil:	Suzuki Gear Oil SAE 80W API GL-4 (or equivalent, capacity specified in manual)

Dimensions
Exterior
Length:	Approx. 1965 mm (77.4 in)
Width:	Approx. 680 mm (26.8 in)
Height:	Approx. 1125 mm (44.3 in)
Wheelbase:	Approx. 1375 mm (54.1 in)
Ground Clearance:	Approx. 130 mm (5.1 in) (typical)
Weights
Dry Weight:	Approx. 136 kg (299.8 lbs)
Wet Weight:	Approx. 156 kg (343.9 lbs) (fully fueled)
Fuel Capacity:	16 Liters (4.2 US gal)
Oil Capacity:	1.3 Liters (1.4 US qt) for two-stroke oil reservoir

Safety Features
Active Features
Brakes Front:	Dual hydraulic disc brakes, typically 290 mm (11.4 in) discs with twin-piston calipers
Brakes Rear:	Single hydraulic disc brake, typically 230 mm (9.1 in) disc with twin-piston caliper
Passive Features
Frame Type:	Aluminum twin-spar frame (SLEC - Suzuki Lightweight Frame Construction)
Suspension Front:	Telescopic forks, typically 41mm diameter, with adjustable preload and rebound damping (later models introduced USD forks)
Suspension Rear:	Monoshock (Pro-Link or similar linkage system), with adjustable preload and rebound damping
Wheels Tires Front:	17-inch alloy wheel, typically 110/70-17 tire
Wheels Tires Rear:	17-inch alloy wheel, typically 150/70-17 tire
Steering Head Angle:	Approx. 24.5 degrees (typical)
Trail:	Approx. 94 mm (3.7 in) (typical)

Technology Features
Infotainment
Infotainment Features:	Basic instrumentation: speedometer, tachometer, coolant temperature gauge, odometer, trip meter, neutral indicator, turn signal indicators, high beam indicator. No advanced infotainment features typical of modern motorcycles.
Driver Assistance
Driver Assistance Features:	Suzuki SAEC (Suzuki Advanced Engine Control) for optimized power delivery and emissions via electronically controlled exhaust powervalves.
Connectivity
Connectivity Features:	None

Maintenance
Service Intervals
Oil Change Interval:	Recommended every 3,000-5,000 km (1,800-3,000 miles) or annually, depending on usage. Refer to manual for specific intervals.
Spark Plug Replacement:	Typically every 5,000-10,000 km (3,000-6,000 miles). Specific plug types and gap settings are critical and found in the manual.
Air Filter Cleaning:	Recommended every 3,000-6,000 km (1,800-3,000 miles), or more frequently in dusty conditions.
Chain Lubrication:	Recommended every 500-1,000 km (300-600 miles) and after washing or riding in rain.
Coolant Flush Interval:	Recommended every 2 years or 20,000 km (12,000 miles) for optimal cooling system performance.
Fluid Specifications
Coolant:	Suzuki recommends a 50/50 mixture of distilled water and Suzuki Super Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors).
Brake Fluid:	DOT 4 or DOT 5.1 brake fluid (refer to manual for exact specification).
Two Stroke Oil:	Suzuki recommends a high-quality 100% synthetic two-stroke oil, JASO FD or higher performance rating, for the oil injection system. Refer to manual for specific part numbers or recommendations.
Known Issues
Known Issues:	Exhaust power valve operation (carbon buildup, seizure), carburetor synchronization and cleaning, reed valve wear, crank seals, ignition coil failure, general two-stroke engine wear (piston rings, cylinder wear). The manual provides diagnostic steps for these common issues.
Carburetor Issues:	Mikuni VM28SS carburetors require precise setup. Issues often stem from clogged jets, worn needle valves, or improper synchronization, all of which are addressed in detail within the manual.
Engine Tune Up
Engine Tune Up Procedures:	Includes checking and adjusting ignition timing, carburetor jetting and synchronization, idle speed, and checking compression. The manual details the specific tools and procedures required.

Vehicle History
Brand Heritage
Brand Heritage:	Suzuki has a strong legacy in sportbike manufacturing, particularly with its two-stroke technology, exemplified by the legendary RG500 Grand Prix racer. The RGV250 Gamma is a direct descendant of this racing heritage.
Model Evolution
Model Evolution:	The RGV250 Gamma saw significant evolution from its introduction, particularly in chassis design (from steel to aluminum), engine technology (introduction of RCV for variable exhaust port timing, different carburetion and ignition systems), and suspension components. The VJ22A chassis (1990-1995) represented a major update from the initial VJ21A. The K-T designation signifies various model year updates and variations within this generation.
Production
Production Location:	Japan

Awards & Recognition
Recognitions
Recognitions:	The RGV250 Gamma itself was highly acclaimed during its production run for its class-leading performance and handling, often winning comparisons in motorcycle magazines of the era. While specific awards are not listed for the manual, its comprehensive nature implies it's a valuable resource for maintaining a highly regarded machine.