🏷️ Basic Information

Make:

Suzuki

Model:

RGV250 Gamma

Covered Model Designations:

RGV250K, RGV250L, RGV250M, RGV250N, RGV250P, RGV250R, RGV250T

Production Years:

1989-1996

👋 Introduction

Market Position:

The Suzuki RGV250 Gamma was a highly regarded two-stroke sportbike, known for its performance and handling in its era. This manual caters to owners and mechanics looking to maintain and repair these iconic motorcycles.

Competitive Analysis:

Competed directly with other 250cc two-stroke performance motorcycles of the late 80s and 90s, such as the Yamaha TZR250 and Kawasaki KR-1. Its V-twin engine and advanced features set it apart.

Key Features:

Comprehensive coverage of all models from 1989-1996, detailed troubleshooting guides, clear step-by-step instructions, hundreds of photos and diagrams, essential for DIY repairs and professional servicing.

📋 Manual Details

Coverage Areas:

General Information, Body, Frame & Mounting, Engine, Suspension, Driveline, Brake System, Transmission, Clutch, Chains, Exhaust, Fuel System, Steering, Shocks, Instrumentation & Warning Systems, Battery & Charging Systems, Audio, Lighting, Electrical Distribution, Wiring Diagrams, Emission Control, Cooling System, Lubrication System, Ignition System, Manual Transmission, Drive Shaft, Differential, Axle, Tire & Wheel, Parking Brake, Steering Column, Power Steering, Climate Control, Seat Belt Systems, Engine Immobilizer, Cruise Control, Wiper & Washer Systems, Door Locks, Meter Systems, Horn, Windshield/Glass/Mirrors, Instrument Panel, Seats, Engine Hood/Doors, Exterior & Interior components

File Format:

PDF

System Compatibility:

All Versions of Windows, Mac, iOS, Blackberry, Android

Printable:

Yes

Drm Protection:

Complete Free

Language:

English

Preview Availability:

Yes (Free Download Available)

Estimated Page Count:

Hundreds of pages (specific number not provided, but characteristic of a full factory workshop manual).

Download Speed:

Speed Download

📖 Manual Coverage

Technical Depth:

Professional Quality, In-depth Factory Workshop Service and Repair Manual, covering all repair procedures A-Z. Includes step-by-step instructions and pictures for all areas of repair.

Procedures Included:

Maintenance, Engine Rebuilding, Carburetor Tuning, Suspension Overhaul, Brake System Service, Transmission Overhaul, Clutch Replacement, Electrical System Diagnosis and Repair, Wiring Harness Repair, Troubleshooting, Component Replacement, General Repairs.

Systems Covered:

Engine Mechanical, Engine Control System, Emission Control, Fuel System (including Carburetors), Intake & Exhaust Systems, Cooling System, Lubrication System, Ignition System, Charging System, Starting System, Clutch System, Manual Transmission, Drive Shaft, Differential, Axle, Suspension System (Front & Rear), Steering System, Brake System (Front & Rear, Parking Brake), Electrical Systems (Lighting, Instrumentation, Audio, Wiring), Body & Frame, Frame Mounting, Climate Control, Restraint Systems (Seat Belts), Security Systems (Immobilizer), Cruise Control, Wiper & Washer Systems, Door Locks, Audio/Visual Systems, Instruments, Exterior & Interior Trim, Wheels & Tires.

Manual Type:

Workshop Service and Repair Manual

Repair Focus:

DIY repairs and professional servicing, enabling users to perform any repair job with step-by-step instructions and pictures.

Parts List Included:

While primarily a service and repair manual, it implies detailed component information and diagrams that aid in identifying and replacing parts.

Illustrations Quality:

Includes hundreds of photos and diagrams to illustrate repair procedures, making them easy to follow for novice mechanics.

📊 Manual Specifications

File Quality:

High Quality

Print Quality:

Printable pages for workshop use.

Binding Type:

Digital (PDF)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Liquid-cooled, 2-stroke, V-twin (90°)

Displacement:

247 cc

Horsepower:

Approx. 55-60 HP (depending on model and market restrictions)

Torque:

Approx. 38 Nm (depending on model)

Fuel System:

Carburetor (typically dual Mikuni VM28SS or similar)

Ignition System:

Digital CDI

Cooling System Type:

Liquid-cooled

Lubrication System:

Oil injection system (Suzuki Super Oil Injection - SSOI)

Engine Layout:

V-twin configuration

Intake System:

Reed valve induction with dual carburetors

Performance Enhancements Covered:

While not a tuning manual, it covers maintenance procedures critical for maintaining peak performance, such as cleaning reed valves and ensuring proper carburetor function.

🔧 Transmission

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-plate

Final Drive:

Chain

📐 Dimensions

Dry Weight:

Approx. 130-140 kg (depending on model)

Fuel Tank Capacity:

Approx. 16 Liters

Wheelbase:

Approx. 1375 mm

Seat Height:

Approx. 780 mm

Ground Clearance:

Approx. 135 mm

🛡️ Safety Features

Braking System:

Front: Dual hydraulic disc; Rear: Hydraulic disc

Suspension Front:

Telescopic, USD (Upside-Down forks on later models)

Suspension Rear:

Monoshock (Suzuki Full-Floater or similar linkage system)

Frame Type:

Aluminum twin-spar frame

Front Brake Details:

Dual 300mm discs with 4-piston calipers (later models may have improved caliper designs)

Rear Brake Details:

Single 210mm disc with 2-piston caliper

💡 Technology Features

Infotainment Features:

Basic analog instrumentation (tachometer, speedometer, temperature gauge, warning lights). No advanced infotainment systems.

Driver Assistance Features:

The RGV250 did not feature electronic rider aids like traction control or ABS. Its performance was managed through rider skill and advanced chassis design.

Engine Management System:

Early models utilized mechanical power-valve systems (e.g., ATAC), while later models incorporated electronically controlled power valves (RGV-Gamma Engine Control System - ECS) for improved power delivery across the rev range.

🔧 Maintenance

Typical Service Intervals:

Frequent checks of chain lubrication, tire pressure, brake fluid, and coolant are recommended. Engine decarbonization and carburetor cleaning are typically suggested every 5,000-10,000 km or annually, depending on usage. Refer to the manual for specific intervals.

Engine Oil Type:

2-stroke premix oil (specific Suzuki recommendations should be followed, e.g., Suzuki Super Oil Injection compatible)

Coolant Type:

Ethylene glycol-based antifreeze (e.g., Yamalube Coolant or equivalent, typically 50/50 mix with distilled water)

Brake Fluid Type:

DOT 4

Transmission Oil Type:

Gear oil (e.g., SAE 80W-90 GL-4)

Common Issues:

Common issues can include wear on the power-valves (ATAC system), carburetor synchronization issues, wear in the engine's reed valves, and general wear and tear on aging two-stroke components. Clutch wear is also common with hard use. Electrical connectors can sometimes corrode.

Recommended Parts Replacement:

Regular replacement of spark plugs, air filters, and fuel filters is standard. Power valve cleaning and inspection, as well as crank seals, are critical for engine longevity.

Troubleshooting Coverage:

Extensive troubleshooting sections for common problems, including engine performance issues, electrical faults, and chassis/suspension problems. The manual provides diagnostic flowcharts and potential causes.

Technical Data Availability:

Includes detailed technical data, specifications, diagrams, and a complete list of parts for repair and maintenance.

Maintenance Schedule:

The manual provides guidance for routine maintenance, covering inspections, adjustments, and replacements at specified intervals to ensure optimal performance and longevity.

📚 Vehicle History

Brand Heritage:

Suzuki has a strong legacy in racing and performance motorcycles, particularly with their two-stroke technology.

Model Evolution:

The RGV250 Gamma evolved significantly over its production run, with major updates including changes to the engine (e.g., introduction of the 'RGV-Gamma' engine with different cylinder porting and RGV-Gamma Engine Control System), chassis, suspension (USD forks), and electronics. Different model designations (K, L, M, N, P, R, T) represent these year-to-year updates and variations.

Production Period:

1989-1996

Notable Model Changes:

Key changes include the adoption of the electronically controlled RGV-Gamma Engine Control System (ECS) for improved performance, introduction of upside-down front forks, revised chassis geometry, and cosmetic updates across the model years.

🏆 Awards & Recognition

Recognitions:

Widely recognized by enthusiasts and motorcycle publications of its time for its exceptional handling, performance, and styling, often considered a benchmark in the 250cc sportbike class.