Market Position:
The Suzuki RGV250 was a highly regarded, high-performance 250cc two-stroke sportbike, competing in the popular lightweight sportbike class of the late 1980s and 1990s. It was known for its sophisticated V-twin engine and racing-derived technology.
Key Competitors:
Honda VFR400/RVF400 (though larger displacement), Kawasaki ZXR250, Yamaha TZR250, Aprilia RS250 (later models).
Key Features Vehicle:
Liquid-cooled 2-stroke V-twin engine, Suzuki's 'At The Power Band' (ATPB) engine management, aggressive styling, capable chassis, strong performance for its class.
Key Features Manual:
Authoritative and detailed guide for owners and technicians, essential for maintaining peak performance and reliability of the RGV250.
Engine Mechanical:
Engine assembly, disassembly, lubrication, cooling, fuel injection (SDTV), ignition, exhaust, engine management (ECU).
Transmission:
Gearbox operation, clutch system, gear shifting mechanism, maintenance and repair.
Chassis And Suspension:
Front fork (Telescopic, conventional or upside-down depending on year/model), rear shock absorber (Monoshock), swingarm, steering system, wheel bearings, alignment.
Brakes:
Front and rear hydraulic disc brakes, master cylinders, calipers, brake lines, fluid specifications, bleeding procedures.
Electrical System:
Wiring diagrams, lighting, charging system (stator, regulator/rectifier), battery, ignition system components, sensors, fuses, horn, starter motor.
Fuel System:
Carburetor (Mikuni TMX or similar), fuel tank, fuel pump (if applicable), fuel lines, fuel filter.
Cooling System:
Radiator, fan, coolant hoses, coolant specifications, water pump.
Bodywork And Fairings:
Fairing removal and installation, seat, fuel tank cover, tail section, fender, graphics.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake pad inspection, tire pressure checks.
Troubleshooting:
Diagnostic charts for common starting problems, engine performance issues, electrical faults, braking system malfunctions.
Engine Rebuild:
Detailed steps for top-end rebuild (piston, rings, cylinder), bottom-end overhaul (crankshaft, bearings, seals), cylinder head service.
Carburetor Rebuilding:
Disassembly, cleaning, reassembly, jetting information, synchronization procedures.
Suspension Servicing:
Fork oil change, seal replacement, rear shock adjustments and servicing.
Electrical Component Testing:
Testing of stator, CDI unit, ignition coils, battery, regulator/rectifier using multimeters.
Torque Specifications:
Critical torque values for engine components, fasteners, suspension linkages, and chassis bolts.
Technical Depth:
Comprehensive. Covers basic maintenance to full engine and chassis rebuilds, including electrical system diagnostics and troubleshooting.
Engine Type:
Liquid-cooled, 2-stroke, 90-degree V-twin
Bore X Stroke:
54.0 mm x 54.5 mm (typical, variations may exist by specific model code)
Compression Ratio:
7.2:1 to 7.8:1 (varies by model year)
Valves Per Cylinder:
2 (Reed valve induction)
Power Delivery System:
Suzuki Computer Controlled Capacitor Discharge Ignition (CDI)
Horsepower:
Approx. 55-60 PS (40-44 kW) at 11,000 rpm (depending on market and specific model)
Torque:
Approx. 3.8-4.1 kgf-m (37-40 Nm) at 10,500 rpm (depending on market and specific model)
Fuel Delivery:
Dual Mikuni TMX30 (or similar) carburetors (specific model year dependent)
Fuel Type Recommendation:
Unleaded gasoline, 95-98 RON (Octane Rating)
Oil Mixing:
Automatic oil injection (separate oil reservoir)
Safety Ratings:
N/A (Motorcycle safety is primarily based on design, rider skill, and regulatory compliance, not standardized crash test ratings like cars).
Active Safety Features:
Powerful dual front disc brakes, single rear disc brake, responsive chassis and suspension, strong engine braking.
Passive Safety Features:
Reinforced frame structure, protective fairings, rider ergonomics designed for control.
Infotainment Features:
N/A (Focus is on performance and mechanicals, not modern infotainment systems).
Driver Assistance Features:
N/A (No electronic rider aids like ABS or traction control in this era).
Engine Management System:
Suzuki's groundbreaking 'At The Power Band' (ATPB) system and Suzuki Dual Throttle Valve (SDTV) system (on later models) for improved power delivery and efficiency.
Exhaust Power Valve:
Mechanical or electronic exhaust powervalve system (SET - Suzuki Exhaust Tuning) to optimize torque across the rev range.
Oil Change Interval:
Every 3,000-5,000 km or annually, whichever comes first.
Spark Plug Replacement:
Every 6,000-10,000 km, depending on plug type and usage.
Chain And Sprocket Inspection:
Check and lubricate every 500-1,000 km, adjust tension as needed.
Brake Fluid Replacement:
Every 2 years or as recommended by the manual, due to moisture absorption.
Engine Oil Type:
2-stroke motorcycle oil specifically designed for high-performance, liquid-cooled engines (e.g., JASO FD or FC rated). Manual specifies Suzuki's own or equivalent.
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Manual specifies Suzuki Long Life Coolant or equivalent.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Transmission Oil Type:
GL-4 hypoid gear oil (specific viscosity, e.g., 80W/90, detailed in manual).
Known Issues Engine:
Cylinder scoring, piston ring wear, exhaust power valve sticking or failure, crank seal leaks, reed valve wear, carburetor jetting sensitivity.
Known Issues Electrical:
Regulator/rectifier failure, stator coil degradation, CDI unit issues, wiring harness chafing.
Known Issues Chassis:
Steering head bearing wear, swingarm bearing wear, fork seal leaks, general wear and tear on suspension components due to performance usage.
Brand Heritage:
Suzuki has a rich history in motorcycle racing, particularly in Grand Prix, with strong expertise in 2-stroke engine technology. This heritage directly influenced the development of the RGV250.
Model Evolution Rgv250:
The RGV250 evolved from earlier Suzuki 250cc two-stroke models like the RG250 Gamma. Key developments included the adoption of the V-twin engine configuration, improved chassis design (often featuring aluminum frames), and advanced electronic engine management for its era.
Generations Covered:
The manual covers the VJ21A (early 90s), VJ22A (mid-90s, often with improved suspension like upside-down forks), and VJ23A (later models, often considered the most refined) generations.
Production Period:
1988-1996 (manual covers the majority of this significant period)
