Classification:
High-performance two-stroke sportbike, revered for its racing heritage and handling.
Competitors:
Honda NSR250R, Yamaha TZR250, Kawasaki KR-1/KR-1S
Engine Layout:
Liquid-cooled, 90-degree V-twin, two-stroke
Performance Emphasis:
Lightweight chassis, powerful engine for its class, agile handling.
Technological Advancements:
Suzuki's ATAC (Automatic Torsional Angle Control) exhaust system for improved powerband.
Engine Mechanical:
Complete disassembly, inspection, assembly, troubleshooting of the two-stroke V-twin engine.
Engine Electrical:
Ignition system, CDI unit, charging system, starter motor, wiring diagrams.
Fuel System:
Carburetor tuning, float bowl servicing, jetting information, fuel pump, fuel lines.
Cooling System:
Radiator, water pump, thermostat, coolant flow, bleed procedures.
Transmission:
Gearbox disassembly, inspection, assembly, clutch operation, lubrication.
Chassis Frame:
Frame inspection, steering head bearings, swingarm bearings.
Suspension Front:
Front fork disassembly, oil specifications, seal replacement, damping adjustments.
Brakes Front:
Brake caliper service, master cylinder overhaul, pad replacement, fluid bleeding, disc specifications.
Wheels Tires:
Wheel bearing inspection and replacement, tire pressure recommendations, wheel balancing.
Electrical System:
Headlight, taillight, turn signals, horn, battery, fuses, wiring harness routing.
Bodywork Trim:
Fairing removal and installation, seat, tank, minor cosmetic components.
Suspension Rear:
Rear shock absorber service, linkage adjustments, spring preload, damping.
Brakes Rear:
Rear brake caliper service, master cylinder, pad replacement, fluid bleeding, disc specifications.
Maintenance:
Regular scheduled maintenance, fluid changes, filter replacements, spark plug service.
Troubleshooting:
Diagnosis of common performance issues, starting problems, electrical faults.
Repair Overhaul:
Complete step-by-step guides for major component rebuilds and repairs.
Disassembly Assembly:
Detailed procedures for removing and reinstalling all major and minor components.
Adjustments:
Carburetor synchronization, chain tension, brake lever play, clutch free play.
Wiring Diagrams:
Comprehensive electrical schematics for fault finding and component identification.
Depth:
Comprehensive: Covers basic maintenance to full engine and component rebuilds.
Illustrations:
Detailed pictorial diagrams, exploded views, and photographs guiding each procedure.
Special Tools:
Identification and usage instructions for specific service tools required for repairs.
Specifications:
Includes critical service data, torque values, wear limits, and measurement guidelines.
Engine Type:
Two-stroke, V-twin, liquid-cooled
Displacement:
247cc (for most RGV250 models)
Bore X Stroke:
Typically around 54.0 mm x 54.5 mm (verify with manual for specific year)
Compression Ratio:
Varies by year and model, often in the 7.0:1 to 7.5:1 range (check manual)
Horsepower:
Typically around 60-65 HP (at crank, power output varied by market restrictions)
Torque:
Typically around 27-30 lb-ft (verify with manual)
Carburetion:
Twin Mikuni VM28SS carburetors (or similar, depending on year/market)
Fuel Type:
Unleaded gasoline (premium recommended)
Fuel Mixture:
Pre-mix or oil injection system (Suzuki PEM - Pilot Educated Mixture)
Oil Change Interval:
As per periodic maintenance chart (typically every 3,000-5,000 km or annually).
Spark Plug Service:
Every 6,000-8,000 km or as specified.
Chain Adjustment Lubrication:
Every 1,000 km or as needed.
Engine Oil Type:
2-stroke engine oil for high-performance motorcycles (TCW-3 rated or equivalent).
Fork Oil Grade:
Typically SAE 10W or 15W (verify exact specification in manual).
Brake Fluid Type:
DOT 4 recommended.
Coolant Type:
Ethylene glycol based antifreeze (50/50 mix with distilled water recommended).
Common Problems:
Carburetor synchronization issues, reed valve wear, exhaust valve (RVE) cleaning/maintenance, ignition system components.
Specific Component Wear:
Power valves can become carboned up, requiring periodic cleaning for optimal performance. Crankshaft seals can degrade over time.
