Positioning:
High-performance 250cc two-stroke sportbike, popular for its racing heritage and agile handling.
Competitors:
Yamaha TZR250, Honda NSR250R, Kawasaki KR-1/KR-1S.
Design Philosophy:
Lightweight chassis, potent V-twin two-stroke engine, and advanced suspension for its class.
Performance Focus:
Engineered for spirited riding and track-day performance.
Engine Coverage:
Complete engine disassembly, assembly, troubleshooting, and repair for all RGV250 variants within the specified years.
Chassis Coverage:
Frame, suspension (front forks, rear shock), steering, wheels, brakes, and exhaust system.
Electrical Coverage:
Wiring diagrams, ignition system, lighting, charging system, starting system, and instrument cluster.
Bodywork Coverage:
Fairings, body panels, seat, fuel tank, and cosmetic components.
Estimated Pages:
300-400 pages (typical for comprehensive service manuals of this era).
Type:
Factory Service Manual / Workshop Manual
Engine Systems:
V-twin two-stroke engine, Suzuki Control Exhaust Valve (SCEV) system, cooling system (liquid-cooled), fuel and oil injection systems, lubrication, ignition timing, and tuning.
Transmission Systems:
Six-speed sequential gearbox, clutch operation and adjustment, gear shift mechanism, and lubrication.
Braking Systems:
Front and rear disc brakes, hydraulic system, brake pad replacement, caliper service, and bleeding procedures.
Suspension Steering:
Front telescopic forks (SACS - Suzuki Advanced Cooling System on some models), rear monoshock suspension, fork seal replacement, oil levels and changes, steering head bearing service.
Maintenance Procedures:
Routine checks, oil changes, filter replacements, spark plug service, chain adjustment, and lubrication.
Troubleshooting Procedures:
Diagnostic charts for common performance issues, starting problems, electrical faults, and engine noise.
Repair Procedures:
Complete engine rebuilds, carburetor overhaul, suspension component replacement, electrical component repair, and body panel repair.
Special Tool Requirements:
Identification and usage of specialized tools required for specific repair tasks (e.g., flywheel puller, clutch holding tool).
Depth:
Comprehensive, from basic owner maintenance to full engine and transmission rebuilds, including torque specifications and clearances.
Engine Type:
Liquid-cooled, 49-degree V-twin, two-stroke
Bore X Stroke:
54.0 mm x 54.5 mm (VJ21A/VJ22A), 55.0 mm x 52.4 mm (VJ23A)
Compression Ratio:
7.4:1 to 7.8:1 (depending on model year and variant)
Power Delivery:
Strong mid-range and top-end power band characteristic of high-performance two-strokes.
Horsepower:
Approx. 55-60 PS (40-44 kW) at 11,000 rpm (factory figures, often higher in practice).
Torque:
Approx. 3.9-4.1 kgf·m (38-40 Nm) at 10,500 rpm.
Carburetion:
Twin Mikuni VM28SS flat-slide carburetors (VJ21A/VJ22A), Twin Mikuni TM32 flat-slide carburetors (VJ23A).
Fuel Type:
Unleaded gasoline (95-98 RON recommended)
Oil Injection:
Automatic oil injection system for two-stroke oil.
Transmission Type:
6-speed constant mesh, sequential
Clutch Type:
Wet, multi-plate, cable-actuated
Gear Ratios:
Specific gear ratios vary by model year and can be found in the manual (e.g., 1st: 2.500, 2nd: 1.857, 3rd: 1.450, 4th: 1.217, 5th: 1.045, 6th: 0.923).
Length:
Approx. 2000 mm (varies slightly by model year).
Width:
Approx. 700 mm (varies slightly by model year).
Height:
Approx. 1130 mm (varies slightly by model year).
Dry Weight:
Approx. 136-141 kg (depending on model year and equipment).
Wet Weight:
Approx. 154-159 kg (fully fueled and ready to ride).
Front Tire Size:
110/70-17 M/C 54H
Rear Tire Size:
150/70-17 M/C 69H
Wheel Type:
Cast aluminum alloy wheels
Safety Standards:
Designed to meet then-current motorcycle safety standards for road use.
Braking System:
Dual front disc brakes, single rear disc brake for strong stopping power.
Lighting:
Halogen headlight, taillight, and turn signals for visibility.
Instrument Cluster:
Analog tachometer, speedometer, coolant temperature gauge, and indicator lights. Basic but functional.
ABS:
Not typically equipped with Anti-lock Braking System (ABS).
Electronics Era:
Reflects the technology of the early to mid-1990s, with mechanical controls and simpler electrical systems.
Oil Change Frequency:
Every 3,000-5,000 km or annually (engine oil and gearbox oil).
Spark Plug Replacement:
Every 6,000-10,000 km (depending on plug type and usage).
Chain Maintenance:
Lubricate and adjust chain every 500-1000 km.
Engine Oil:
Suzuki 2-stroke oil or equivalent JASO FD certified oil.
Gearbox Oil:
SAE 80W-90 API GL-4 or GL-5 gear oil.
Coolant:
Ethylene glycol-based coolant, 50/50 mix with distilled water.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Piston rings, reed valves, clutch plates, crankcase seals, and suspension bushings.
Scev System:
The Suzuki Control Exhaust Valve (SCEV) system can accumulate carbon deposits, leading to sticking and performance issues if not regularly serviced.
Carburetor Tuning:
Carburetors require precise tuning, especially after engine work or modifications. Synchronization is critical.
Two Stroke Care:
Proper oil-to-fuel mixture or reliable oil injection is crucial for longevity. Avoid prolonged idling.
Suzuki Performance:
Suzuki has a strong heritage in racing, particularly in the 500cc Grand Prix series, which influenced the RGV250's design and performance.
Rgv250 Development:
Evolved from the RG250 Gamma, incorporating advancements in engine technology (V-twin, SCEV) and chassis design for improved performance and handling.
Manufacturing Location:
Japan
Popularity:
Highly sought after by enthusiasts for its performance and collectibility.
