Category:
Lightweight Sportbike / Two-Stroke Performance Motorcycle
Competitors:
Yamaha RZ250/TZR250, Kawasaki KR-1/KR-1S, Honda NSR250R.
Performance Focus:
Renowned for its sharp handling, potent two-stroke power delivery, and aggressive styling.
Two Stroke Technology:
Embodied Suzuki's expertise in high-performance two-stroke engine design, including advanced exhaust powervalve systems (SET-A).
Maintenance Importance:
Essential for owners seeking to maintain the peak performance and longevity of these high-strung, high-revving engines.
Applicable Model Years:
1990, 1991, 1992, 1993, 1994, 1995, 1996
Engine Variants Covered:
V-twin 2-stroke, liquid-cooled, 247cc (specific variants may differ slightly by year, e.g., VJ21A, VJ22A, VJ23A)
Trim Levels Covered:
All production models, including standard and sport variants.
Estimated Pages:
300-500 (typical for comprehensive workshop manuals of this era, exact count varies by edition)
Type:
Workshop Service Repair Manual
Delivery Method:
Instant download after purchase.
Engine:
Detailed diagnostics, overhaul, top-end, bottom-end, cooling system, lubrication, fuel injection/carburetion (depending on specific year's system), exhaust system, ignition system.
Transmission:
Clutch, gearbox (6-speed sequential), final drive, lubrication, troubleshooting and repair.
Brakes:
Front and rear brake systems (hydraulic disc), master cylinders, calipers, fluid replacement, bleeding, servicing.
Suspension:
Front telescopic forks (including adjustable models), rear monoshock suspension, swingarm, bearing maintenance, tuning.
Electrical:
Wiring diagrams, battery, charging system (stator, regulator/rectifier), lighting, ignition, starter motor, instrumentation, troubleshooting common electrical faults.
Frame And Bodywork:
Frame inspection, fairing removal and installation, seat, fuel tank, handlebars, footpegs, general body panel repair and maintenance.
Routine Maintenance:
Oil changes, chain adjustment and lubrication, spark plug replacement, air filter cleaning/replacement, brake pad inspection, coolant checks.
Engine Rebuild:
Piston replacement, cylinder honing, crankshaft service, sealing and gasket replacement, engine assembly torque specifications.
Suspension Service:
Fork seal replacement, fork oil change and level setting, rear shock absorber service.
Electrical Troubleshooting:
Diagnostic charts, component testing, wiring harness repair.
Carburetor Tuning:
Synchronization, jetting, idle speed adjustment (for models with carburetors).
Troubleshooting Guides:
Systematic guides for diagnosing and resolving common and complex mechanical and electrical issues.
Depth:
Comprehensive; covers from basic maintenance to complete engine and gearbox overhauls, including detailed specifications and diagnostic procedures.
Searchability:
Searchable text for quick information retrieval.
Compatibility:
Compatible with Adobe Reader or any PDF viewer.
Image Resolution:
High-resolution scans suitable for clear viewing of diagrams and text.
Digital Format:
PDF (Portable Document Format)
Digital Accessibility:
Accessible on computers, tablets, and smartphones.
Engine Type:
Liquid-cooled, 2-stroke, V-twin
Bore X Stroke:
54.0 mm x 54.5 mm (typical, check specific year)
Compression Ratio:
7.2:1 to 7.4:1 (depending on model year and tuning)
Valvetrain:
Reed valve induction, Suzuki Exhaust Control (SET-A) powervalve system.
Horsepower:
Approx. 60-65 PS (44-48 kW) at 11,000 rpm (factory figures, often modified)
Torque:
Approx. 38-40 Nm (28-30 lb-ft) at 10,000 rpm (factory figures)
Engine Speed Range:
Designed for high-revving operation, typically redlining above 11,500 rpm.
Fuel Delivery:
Carbureted (dual Mikuni VM28SS for earlier models, later models may feature Suzuki's ECCS electronic carburetor control system, VJ23A used different carb setup).
Fuel Type:
Unleaded gasoline (minimum 91 octane recommended)
Oil System:
Premix or separate oil injection system (Suzuki's PEM - Premix Electronic Mixture system).
Type:
6-speed constant mesh, sequential manual
Type:
N/A (all were manual)
Clutch:
Wet, multi-plate, cable-actuated.
Final Drive:
Chain drive (520 pitch typical).
Gear Ratios:
Specific ratios vary by year but are optimized for sportbike performance; refer to manual for exact figures.
Length:
Approx. 2,030 mm (79.9 in) (varies by year)
Width:
Approx. 670 mm (26.4 in) (varies by year)
Height:
Approx. 1,080 mm (42.5 in) (varies by year)
Wheelbase:
Approx. 1,370 mm (53.9 in) (varies by year)
Dry Weight:
Approx. 135-140 kg (297-309 lbs) (varies by year and equipment)
Wet Weight:
Approx. 155-160 kg (342-353 lbs)
Fuel Capacity:
16.0 L (4.2 US gal)
Motorcycle Safety Standards:
Designed and manufactured to meet Japanese and international motorcycle safety standards of the era.
Braking System:
Dual front disc brakes, single rear disc brake (caliper types vary by year, e.g., twin-piston front).
Suspension Performance:
Advanced adjustable front forks and rear monoshock for optimized handling and stability.
Frame Construction:
Lightweight aluminum twin-spar frame for rigidity and agile handling.
Tire Sizes:
Front: 110/70-17, Rear: 150/60-17 (typical, check manual for variations)
Instrumentation:
Analog tachometer, speedometer, odometer, trip meter, coolant temperature gauge, indicator lights (turn signal, neutral, oil pressure, high beam).
Electronic Aids:
Limited by era; primary focus on mechanical performance. Some models may feature basic electronic ignition or carburetor control systems.
Connectivity Features:
N/A (no modern connectivity features).
Oil Change Interval:
Every 3,000-5,000 km (1,800-3,000 miles) or annually, check manual for specific grade.
Spark Plug Replacement:
Every 6,000-10,000 km (3,700-6,200 miles), depending on plug type and usage.
Chain Adjustment:
Every 1,000-1,500 km (600-900 miles) or as needed.
Engine Oil Type:
2-stroke motorcycle oil, API TC, JASO FD rated (or higher). Specific grade recommended in manual.
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4 (preferred for consistent performance)
Transmission Oil Type:
Gear oil, SAE 80W-90 API GL-4 or GL-5.
Engine Wear:
High-performance 2-stroke engines require diligent maintenance; potential for piston/ring wear if not properly maintained or if pre-mix is incorrect.
Powervalve Carbon Buildup:
Carbon deposits can affect powervalve operation, requiring periodic cleaning as detailed in the manual.
Electrical Gremlins:
As with many bikes of this era, wiring harness integrity and connections can be a source of issues; manual's wiring diagrams are crucial.
Carburetor Maintenance:
Carburetors may require periodic cleaning, synchronization, and jetting adjustments, especially if using different fuel or exhaust systems.
Suzuki Two Stroke Legacy:
Built on Suzuki's rich history in Grand Prix racing, particularly with the legendary RG500 Gamma and RGV500 machines.
Rgv250 Generations:
Evolved through several key generations (e.g., VJ21A '88-'89, VJ22A '90-'95, VJ23A '96-'98 - this manual covers up to '96 models).
Technological Advancements:
Introduced and refined technologies like the 'RG-gamma' engine, powervalves, and advanced chassis designs for its class.
Production Period:
The RGV250 was produced from 1988 to 1998, with this manual specifically covering the 1990-1996 iterations.
Manufacturing Location:
Japan
