Suzuki RV90 RV 90 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Suzuki Model: RV90 Model Variant: RV90 Product Type: Service Repair Workshop Manual Product Format: Digital (Adobe Acrobat PDF) Delivery Method: Instant Download 👋 Introduction Market...

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Taper: Motorcycle

Distributeur:

UGS: 245387

Mots clés: Featured Motorcycle Motorcycles RV 90 RV Series RV90 Suzuki

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

Model Variant:

Product Type:

Service Repair Workshop Manual

Product Format:

Digital (Adobe Acrobat PDF)

Delivery Method:

Instant Download

👋 Introduction

Market Position

Target Audience:

Suzuki RV90 owners, independent repair shops, DIY enthusiasts.

Competitive Analysis

Manual Utility:

Provides dealership-level repair information, enabling comprehensive maintenance and repairs beyond basic owner's manual guidance.

Key Features

Convenience:

Instant download and printable sections offer flexibility and reduced risk of damage compared to traditional paper manuals.

Comprehensiveness:

Covers all major systems and repair procedures, offering a complete resource for the RV90.

📋 Manual Details

Coverage Areas

General Information:

Included

Engine:

Included

Transmission:

Included

Chassis:

Included

Lighting:

Included

Steering:

Included

Seat System:

Included

Clutch:

Included

Suspension:

Included

Locks:

Included

Brakes:

Included

Lubrication:

Included

Electrical System:

Included

Frame:

Included

Fuel System:

Included

Battery:

Included

Page Count

Estimated Page Count:

Variable (Printable as needed)

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English

Format

File Format:

Adobe Acrobat PDF

Operating System Compatibility:

PC or Mac

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed coverage of all internal engine components, including disassembly, inspection, repair, and reassembly procedures.

Engine Electrical:

Ignition system, charging system, starting system diagnostics and repair.

Fuel System Components:

Carburetor adjustment, cleaning, and overhaul; fuel tank and lines; fuel petcock.

Clutch Operation:

Centrifugal clutch inspection, adjustment, and replacement procedures.

Transmission Mechanics:

Gearbox inspection, maintenance, and repair for all gears and associated components.

Brake System:

Drum brake adjustment, shoe replacement, and linkage maintenance.

Suspension System:

Front fork maintenance, rear shock absorber inspection and replacement, and related components.

Steering Mechanism:

Handlebar, steering stem, and bearing maintenance and adjustment.

Electrical Wiring Diagrams:

Comprehensive wiring schematics for all electrical components and systems.

Lighting And Signals:

Headlight, taillight, turn signals, and brake light system troubleshooting and repair.

Frame And Bodywork:

Frame inspection, body panel removal and installation, and seat system components.

Lubrication Points:

Identification and specifications for all lubrication points and fluid types.

Locks And Security:

Ignition switch, steering lock, and seat lock maintenance.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug checks, chain adjustment, and general inspections.

Troubleshooting Guides:

Diagnostic procedures for common issues and malfunctions across all systems.

Disassembly And Reassembly:

Step-by-step instructions for component removal, overhaul, and reinstallation.

Tune Up Procedures:

Detailed instructions for engine tuning and performance optimization.

Major Component Overhaul:

In-depth guides for engine, transmission, and clutch rebuilds.

Electrical Diagnosis:

Testing and troubleshooting of wiring, switches, lights, and charging system.

Technical Depth

Depth Of Coverage:

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

Diagnostic Information:

Includes specifications for component testing, clearances, and tolerances.

Repair Instructions:

Detailed, illustrated steps for all repair and maintenance procedures.

Torque Specifications:

Essential torque values for all fasteners and critical components.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable within PDF reader (depending on original scan quality).

Print Quality

Printability:

High-quality for printing individual sections or entire manuals.

Binding Type

Recommended Binding:

3-Ring Binder (for easy section access)

Paper Type

Storage Recommendation:

Digital storage; printable on durable paper for workshop use.

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, forced air-cooled

Displacement:

89.4 cc (5.45 cu in)

Bore X Stroke:

49.0 mm x 48.0 mm (1.93 in x 1.89 in)

Compression Ratio:

Approx. 6.7:1

Performance

Horsepower:

Approx. 7.5 HP @ 6,000 RPM (Varies by market and specific tune)

Torque:

Approx. 6.5 lb-ft @ 5,000 RPM (Varies by market and specific tune)

Fuel System

Carburetor Model:

Mikuni VM Series (e.g., VM18)

Fuel Type:

Unleaded gasoline (approx. 87 octane)

Fuel Mixture:

20:1 (Gasoline to 2-stroke oil) or as specified in manual.

Lubrication

Transmission Oil Type:

SAE 10W-30 API SE or SF (Capacity typically ~0.6L)

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

Spark Plug Type:

NGK C6HA or equivalent (Gap: 0.7-0.8 mm)

🔧 Transmission

Standard

Transmission Type:

2-speed automatic (Automatic Clutch with 2-speed gearbox, often referred to as Hi/Lo range)

Features

Clutch Type:

Centrifugal automatic clutch

Gear Selection:

Lever operated Hi/Lo range selection

📐 Dimensions

Exterior

Overall Length:

Approx. 1,775 mm (69.9 in)

Overall Width:

Approx. 850 mm (33.5 in)

Overall Height:

Approx. 1,035 mm (40.7 in)

Weights

Dry Weight:

Approx. 76 kg (168 lbs)

Fuel Capacity:

Approx. 4.5 L (1.2 US gal)

Dimensions

Wheelbase:

Approx. 1,165 mm (45.9 in)

Ground Clearance:

Approx. 215 mm (8.5 in)

🛡️ Safety Features

Ratings

Safety Standards:

Adheres to relevant motorcycle safety standards for its production era. (No formal crash test ratings apply to this type of vehicle).

Active Features

Braking System:

Front and rear drum brakes, linked or independent operation.

Lighting:

Headlight, taillight, brake light, and optional turn signals for visibility.

Passive Features

Frame Construction:

Robust steel frame designed for durability and off-road use.

Tire Design:

High-profile, block-pattern tires for enhanced traction on varied terrain.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation: speedometer, neutral indicator, high-beam indicator).

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids).

Connectivity

Connectivity Features:

N/A (No digital connectivity features).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 1,000 km (600 miles) or annually, whichever comes first.

Spark Plug Check Clean:

Every 1,000 km (600 miles).

Air Filter Cleaning:

Every 1,000 km (600 miles) or more frequently in dusty conditions.

Clutch Adjustment:

As needed, check periodically during routine maintenance.

Chain Lubrication Adjustment:

Every 500 km (300 miles) or after riding in wet conditions.

Fluid Specifications

2 Stroke Oil Type:

High-quality 2-stroke motorcycle oil, mixed at 20:1 ratio with gasoline.

Transmission Oil Viscosity:

SAE 10W-30

Transmission Oil Specification:

API SE or SF

Known Issues

Carburetor Issues:

Clogging due to age, gummed-up fuel, or debris. Requires regular cleaning and adjustment.

2 Stroke Engine Wear:

Piston ring wear, cylinder scoring, and carbon buildup in the exhaust port, especially with improper oil mixing or poor maintenance.

Electrical Connections:

Corrosion and loose connections in the aging wiring harness can lead to intermittent electrical faults.

Suspension Leaks:

Front fork seals and rear shock absorbers may develop leaks over time, requiring seal replacement or unit replacement.

Clutch Slippage:

Wear on clutch shoes or springs can lead to reduced acceleration or slippage.

📚 Vehicle History

Brand Heritage

Suzuki History:

Suzuki Motor Corporation, a Japanese multinational corporation, is renowned for its wide range of motorcycles, automobiles, and marine engines, known for innovation and reliability.

Model Evolution

Rv Series Concept:

The 'RV' (Recreational Vehicle) series was designed as a versatile, go-anywhere dual-purpose machine, combining trail capability with street legality in some markets.

Production

Production Years:

Primarily produced from the early 1970s into the late 1970s (specific years vary by market, e.g., ~1972-1978).

Manufacturing Location:

Japan (Suzuki's primary manufacturing facilities)

Model Positioning

Market Niche:

Targeted recreational riders seeking an affordable, easy-to-operate, and capable off-road capable machine.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

The RV90 was a popular and well-regarded recreational and light off-road machine in its era, appreciated for its simplicity and off-road capability.

Ratings

Consumer Reviews Era:

Generally positive for its intended use, offering fun and accessible off-road exploration.