Suzuki RG250 Service Manual Download Page 7

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Summary of Contents for RG250

Page 2: ...s manual an extremely useful guide Model RG250 manufactured to standard specifications is the main subject matter of this manual However the RG250 machines distributed in your country might differ in...

Page 3: ...VIEW OF SUZUKI RG250 FULL COWLING RIGHT SIDE LEFT SIDE...

Page 4: ...GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE UP PROCEDURES I ENGINE r LCOOLING SYSTEM FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION RG250H 87 MODEL...

Page 5: ...VIEW OF SUZUKI RG250 HALF COWLING RIGHT SIDE LEFT SIDE...

Page 6: ...TION CONTENTS SERIAL NUMBER LOCATION 1 1 FUEL OIL AND COOLANT RECOMMENDATION 1 1 BREAKING IN PROCEDURE 1 2 CYLINDER IDENTIFICATION 1 2 SPECIAL MATERIALS 1 3 PRECAUTION AND GENERAL INSTRUCTION 1 5 SPEC...

Page 7: ...on chamber deposits least preignition maximum spark plug life and best lubrication If they are not available a good quality TWO STROKE 01 L non diluent type should be used TRANSMISSION OIL Use a good...

Page 8: ...hibiting performance is greatly reduced Be sure to mix it above 30 even tho ugh the atmospheric temperature does not go down to freezing point Every new unit is filled with anti leakage material Bar s...

Page 9: ...ng il Speedometer cable 7 55 Swing arm bearing and dust seal Tachometer cable Brake pedal shaft Sl J Cushion lever bearing 7 56 SUZUKI Steering stem bearings and races 7 33 Rear shock bearing 7 56 SUP...

Page 10: ...t bearing 3 39 I i1l retainer THREAD LOCK SUPER 13338 99000 32020 To prevent leakage of cooling solution from small hole SUZUKI BAR s LEAK 99000 24240 Cooling solution SUZUKI GOLDEN CRU ISER 1200 2L 9...

Page 11: ...or more persons work together pay attention to the safety of each other o After the reassembly check parts for tightness and operation o Treat gasoline which is extremely flammable and highly explosiv...

Page 12: ...r 130 kg Full cowling Two stroke water cooled 2 54 0 mm 54 0 mm 247 cm3 7 0 1 M IKUNI VM28SS twin Air cleaner Polyurethane foam element Starter system Lubrication system TRANSMISSION Primary kick SUZU...

Page 13: ...Rear wheel travel Front tire pressure Rear tire pressure ELECTRICAL Disc brake 100 90 H16 110 80 H18 130 mm 125 mm 200 kPa 2 00 kg em I Normal solo riding 225 kPa 2 25 kg em I Normal solo riding Igni...

Page 14: ...BATTERy 2 3 ENGINE BOLTS AND NUTS 2 4 CYLINDER HEAD CYLINDER AND MUFFLER 2 5 SPARK PLUG 2 5 AIR CLEANER 2 6 CARBURETOR 2 7 RADIATOR HOSE 2 9 COOLANT 2 9 FUEL LINE 2 10 CLUTCH 2 10 OIL PUMp 2 10 TRANS...

Page 15: ...Battery I I I I Engine bolts and nuts T T T T T Cylinder head cy linder and muffler C C C C Spark plug I R R R R Air cleaner Clean every 3 000 km Carburetor I I I I I I I I Radiator hose Replace ever...

Page 16: ...cle and also for safe riding It is a good practice to lubricate the machine after along rough ride and after getting It wet in the rain or after washing it Major lubrication points are indicated below...

Page 17: ...cessary to keep the surface of the electrolyte above the MIN level line but not above the MAX level line For checking specific gravity use a hydrometer to determine the charged condition 09900 28403 S...

Page 18: ...ve the middle and lower cowling Refer to page 7 2 Remove the radiator Refer to page 4 3 Tighten the cylinder head bolts and nuts to the specified torque with a torque wrench sequen tially in ascending...

Page 19: ...lace 6000 km 12000 km 18 000 km 24000 km 4000 miles 7 500 miles 11 000 miles 15 000 miles Neglect ing the spark plug eventual ly leads to difficu lt starting and poor performance If the spark plug is...

Page 20: ...lug hole and engine damage may result AIR CLEANER Clean Every 3 000 km If the air cleaner is clogged with dust intake resis tance will be increased with a resultant decrease in power output and an inc...

Page 21: ...o that no incoming air will bypass it Remember rapid wear of piston rings and cylinder bore is often caused by a defective or poorly fined element CARBURETOR Inspect 1 000 km 6000 km 12000 k l 18000 k...

Page 22: ...l increase and decrease in accordance with the turning of the screw Find the position where the engine runs regularly and smoothly at the lowest rl min and fix the screw there After adjusting the air...

Page 23: ...e water pump cover and drain the cooling system thoroughly while holding the motorcycle upright WARNING Cooling solution may be harmful if swallowed or if it comes in contact with skin or eyes Contact...

Page 24: ...ap Loosen lock nut and reposition adjuster in place to introduce a necessary amount of play for the clutch lever Loosen lock nut and back adjusting screw away two or three rotations From that position...

Page 25: ...the lock nut CAUTION Oil pump cable adjustment must be done after throttle cable adjustment TRANSMISSION OIL I Change 1 000 km 12000 km 24000 600 miles 7 500 miles 15 000 miles km After a long period...

Page 26: ...ized links 5 Excessive wear 6 Damaged oil seal or 0 ring If any defects are found the drive chain must be replaced CHAIN WEAR CHECKING Loosen axle nut CD Adjust the drive chain carefully by tightening...

Page 27: ...e intervals must be shortened CAUTION Do not use trichlene gasoline or any similar fluids These fluids have too great a dissolving power for this chain and what is more im portant can spoil the 0 ring...

Page 28: ...eaks will interfere with safe running and immediately discolor painted surfaces Check the brake hoses for cracks and hose joint for leakage before riding CAUTION The brake system of this motorcycle is...

Page 29: ...e of air is indicated by spongi ness of the brake lever and also by lack of braking force Considering the damper to whicb such trapped air exposes the machine and rider it is essential that after remo...

Page 30: ...pump and squeeze the lever and open the valve Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles_ NOTE Replenish the brake fluid reservoir as neces sary whi...

Page 31: ...______ l Check that there is no play in the front fork assembly by supporting the machine so that the front wheel is off the ground With wheel straight ahead grasp lower fork tubes near the axle and p...

Page 32: ...pect 12 000 km 24000 km 7500 miles 15000 miles Check air pressure every 6 months_ _ _ 1 Inspect the operation of rear suspension Replace the part when necessary Refer to page 7 471 AIR PRESSURE Remove...

Page 33: ...maintain the correct tire pressure for good roadability or shorter tire life will result CAUTION Cold inflation tire pressure is as follows The standard tire fitted on the motorcycle is 100 90 H16 fo...

Page 34: ...0 25 2 0 2 5 ll Front brake caliper mounting bolt 15 25 1 5 2 5 tIJ Front brake caliper axle bolt 30 36 3 0 3 6 0 Posi damp mounting bolt 6 8 0 6 0 8 Brake pedal bolt 6 10 0 6 1 0 0 Front 18 28 1 8 2...

Page 35: ...2 2 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES...

Page 36: ...CONTENTS ENGINE REMOVAL AND REMOUNTING 3 1 ENGINE DISASSEMBLy 3 11 ENGINE COMPONENTS INSPECT ON AND SERVICING 3 18 ENGINE REASSEMBLy 3 30...

Page 37: ...ep_ Remove the middle and lower cowling See page 7 1 Place the pan under the coolant drain plug hole Remove the drain plug and radiator cap and drain coolant completely Place an oil pan under the engi...

Page 38: ...Ret love the fuel tank mounting bolts Remove the fuel cock mounting screws Disconnect the fuel hose which joints carburetor and fuel cock Disconnect the oil hose and plug the oil outlet ENGINE 3 2...

Page 39: ...nect the oil level lead wire Remove the fuel tank Disconnect the magneto lead wire and actuator lead wire Loosen the exhaust valve cable adjuster after loosening the lock nut Disconnect the cables Rem...

Page 40: ...ostat cover spark plug cap k plug and temperature gauge lead wire Aher disconnecting the lead wire remove the Ignition coil Disconnect the tachometer cable Remove the radiator hose joint Remove the mu...

Page 41: ...procket mounting bolt Remove the engine sprocket Remove the oil pump cover Disconnect oil pump cable NOTE Do not forget the end piece Remove the air cleaner mounting bolt Loosen the carburetor clamp s...

Page 42: ...Loosen and remove the engine mounting bracket bolt Loosen the engine mounting bolts Remove the engine ENGINE 3 6...

Page 43: ...r mounting bolt with bracket Tighten the engine mounting bracket bolts Tighten the engine mounting bolts NOTE Two rear engine mounting nuts and are self lock nuts Once the nut has been removed it is n...

Page 44: ...ve chain If it is difficult to install the engine sprocket loosen the axle nut and chain adjuster bolt Move the wheel assembly and give the drive chain play TIGHTENING TORQUE hem N m kg m Engine sproc...

Page 45: ...hten the muffler mounting bolts and exhaust clamp nut to specified torque TIGHTENING TORQUE Item N m kg m Exhaust pipe clamp 18 28 1 8 2 8 nut Muffler lOmm 40 60 4 0 6 0 mounting bolt 8mm 18 28 1 8 2...

Page 46: ...the each exhaust valve control cable to the respective positions of the actuator No 1 cable is connected to 1 position of the actuator NOTE The exhaust valves should be in open position when connecti...

Page 47: ...e kick starter lever and joint hose Loosen the cylinder head nuts and bolts and then remove the cylinder head Loosen the cylinder nuts and disconnect the oil hoses Remove the cylinders Mark the R righ...

Page 48: ...ip from dropping into crank case and then remove the piston pin circJip with long nose pliers Draw out piston pin by using special tool and take off piston 09910 34510 Piston pin puller Remove conrad...

Page 49: ...ate drive plate driven plate damper washer bearing and push piece Remove the push rod Loosen the clutch sleeve hub nut by using the special tool 09920 53710 Clutch sleeve hub holder Remove the tachome...

Page 50: ...earing retainer Loosen the primary drive gear nut by using the stlecial tool and then remove the primary drive ear Remove the oil pump Disconnect the neutral lead wire Remove the neutral switch contac...

Page 51: ...pecial tool 09930 40113 Rotor holder Remove the rotor by using the special tool 09930 30102 Sliding shaft 09930 30190 Attachment F Remove the startor and pick up coil Loosen the lower crankcase bolts...

Page 52: ...crankcase bolts SepJrate the upper and lower crankcase Remove the crankshaft CD countershaft driveshaft kick starter shaft and oil pump drive gear Remove the C rings and oil seal j from the crankcase...

Page 53: ...03 Impact driver set Remove gear shift arm stopper l Pull out the No 1 gearshift fork shaft j remove No 1 and No 2 gearshift forks INoTE not forget the spring Unhook the cam stopper spring ill from th...

Page 54: ...NDER HEAD oeCARBON Decarbonize the combustion chamber DISTORTI ON The cylinder head is of the 2 cylinder mono block type Check the gasketed surface of the cylinder head for distortion with a straighte...

Page 55: ...laid flat on the surface plate in a lapping manner The gasketed surface must be smooth and perfectly flat in order to secure a tight joint a leaky joint can be the cause of reduced power output and i...

Page 56: ...amage the cyl inder wall surface Check the oil seal for any signs of exhaust gas leakage Inspect the exhaust valve and cylinder sliding surface for nicks scratches wear or other damage Distortion Ct e...

Page 57: ...e sure to chamfer the edges of ports and smooth the chamfered edges with emery paper To chamfer use a scraper taking care not to nick the wall surface r NOTE Minor surface flaws on the cylinder wall d...

Page 58: ...Thread tock 1342 De carbon the crown of the piston and piston ring grooves After cleaning the grooves fit the rings and rotate them in their respective grooves to be sure that they move smoothly Carbo...

Page 59: ...ton to cylinder clearance exceeds the limit shown in the table below overhaul the cylinder and use an oversize piston or replace both cylinder and piston Service Limit 0 120 mm PISTON PIN BORE Using a...

Page 60: ...er output because of the resultant blowby through the enlarged gap Here lies the importance of using piston rings with end gaps within the limit Measure the piston right free end gap Mark RN 1st 2nd S...

Page 61: ...the lip Q of the oil seal may result in leakage of the fuel air mixture or oil Inspect for damage and be sure to replace if there are any CON ROD SMA LL END BORE Using a caliper gauge measure the con...

Page 62: ...ced Service Limit CRANKSHAFT CRANKSHAFT RUNOUT 3 0mm Support crankshaft by V blocks Q with the dial gauge rigged to read the runoutasshown Service Limit 0 05 mm Excessive crankshaft runout is often re...

Page 63: ...mechanism for smooth operation If any worn parts are found replace it with a new one When reinstalling clutch release assembly to the engine sprocket cover apply Suzuki Moly Paste to the sliding surfa...

Page 64: ...clutch is operated These plates are expandable they are meant to Ie replaced when found worn down or distorted to the respective limit use a caliper to check thickness and claw width and a thickness...

Page 65: ...uge check the shift fork clearance in the groove of its gear 09900 20803 J Thitkn ess gauge This clearance for each of the three shift forks plays an important role in the smoothness and positiveness...

Page 66: ...part before reinstalling Instal l the gearshift cam to the lower crankcase IOstall washer CD 8ild gearshift cam stopper plate on the positioning pin Three kinds of gearshift forks are used They resem...

Page 67: ...ift shaft to crankcase Seat the washer and install the gearshift shaft stopper with applying Thread Lock Super 1303 99000 32030 Thread Lock Super 1303 GEARSHIFT CAM The shape of each gearshift pawl is...

Page 68: ...r on the gearshift cam nstall both gearshift cam guide screws CD and gearshift pawl screws with applying Thread Lock Super 1333B 99000 32020 IThread Lock Super 13338 Install the kick starter gear reta...

Page 69: ...ploded view given here will serve as a reference for correctty mounting the gears washers and circl ips CAUTION Never reuse a circlip After a circlip has been removed f rom a shaft it should be discar...

Page 70: ...ure with the rounded side against the gear surface CAUTION Always use new circlip when reassembling Install the 5th drive gear and 3rd 4th drive gear on the countershaft Temporarily position the circl...

Page 71: ...3 35 ENGINE Fit the circlip CD in the groove on the counter shaft Install the wave washers washer and bearing CRANKSHAFT...

Page 72: ...rank web to web width 50 0 0 1 mm Apply Thread Lock 322 to the outer surface of the left crankshaft oil seal 99000 32110 Thread Lock 1322 CRANKCASE Clean the mating surfaces of crankcase Install the f...

Page 73: ...TE Use of Suzuki Bond No 12078 is as follows II Make surface free from moisture oil dust and other foreign materials II Spread on surfaces thinly to form and even layer and assemble the cases within f...

Page 74: ...e 6 mm bolt 9 13N m 10 9 1 3 kg ml Final 8 mm bolt 20 24 N m 12 0 2 4 kg ml STATOR AND PICK UP COIL Install the stator after applying the thread lock 1342 to the securing screws 99000 32050 Thread loc...

Page 75: ...CD of primary drive gear faces outside Tighten the primary drive gear nut using the special tool to the specified torque 09910 20115 Tightening torque Conrod holder 60 80 N m 16_0 8_0 kg mJ Be sure t...

Page 76: ...k starter lever so that the mark ing on the kick starter shaft is on top Fix the kick starter so that the marking on the kick starter matches the marking on the kick starter shaft Free the kick starte...

Page 77: ...shifting gear mounted on the gearshift shaft Be sure to mesh gears CD and with their center lines coinciding with each other or the mechanism will shift poorly or wil l not sh ift at all CLUTCH Insta...

Page 78: ...the nut by firmly bending the tongue of the washer The round edge side of the short clutch push rod must be faced inside Install the push rods Install push piece CD thrust bearing and thrust washer p...

Page 79: ...piston It is extremely important that when the piston is fed into the cylinder each ring in place should be so positioned as to hug the locating pin as shown in the Fig PISTON The arrow mark of the pi...

Page 80: ...akage NOTE Be sure to identify that Top marked sur face is cylinder head side Mount the cylinder head on the cylinder block Tighten the 8 mm nuts and 6 rnm bolts to specification with a torque wrench...

Page 81: ...COOLING SYSTEM CONTENTS COOLING SySTEM 4 1 RADIATOR AND WATER HOSE 4 2 THERMOSTAT 4 4 WATER PUMp 4 6 WATER TEMPERATURE GAUGE 4 10...

Page 82: ...trol over the flow of water through the radiator The valve is actuated by the temperature sensitive wax con tained in the peliet Referring to the following illustration the thermostat is in closed con...

Page 83: ...HOSES Tightening torque Item N m kg m 7 9 0 7 0 9 10 13 1 0 1 3 COOLING SYSTEM 4 2 D Reservoir tank assembly Reservoir tank hose Radiator inlet hose Radiator assembly Radiator cap Radiator outlet hos...

Page 84: ...ure for 10 seconds If the pressure should fall during this 10 second interval it means that there is a leaking point in the system in such a case inspect the entire system and replace the leaking comp...

Page 85: ...n cracked condition or flattened must be replaced INSTALLATION The radiator is reinstalled in the reverse order of the removal procedure After installing the radiator be sure to add cooling water refe...

Page 86: ...when the thermo stat drops to the bottom of the jar This reading which is the temperature level at which the thermostat varve begins to open should be anywhere between 63 5 and 66 5 C Thermostat valve...

Page 87: ...e transmission oil and coolant Loosen and remove the inlet connector bolt Take off the inlet connector Disconnect the tachometer cable Remove the kick starter lever and clutch cover Remove the water p...

Page 88: ...the water pump cover Loosen the water pump bolt by holding the water pump shaft with vise Remove the water pump impeller Remove the water pump shaft by tapping with plastic hummer Remove the oil seal...

Page 89: ...assembly and removal and also carry out the following steps When installing the mechanical seal apply the SUZUKI BOND No 1207B to the matching surface 99000 31140 SUZUKI BOND No 1 207B When installing...

Page 90: ...he new a ring and dowell pin when installing the water pump cover WATER PUMP IDLE GEAR Measure the thrust clearance of water pump idle gear Standard thrust clearance 0 35 1 10 mm Reassemble shim as sh...

Page 91: ...LING SYSTEM 4 10 The following circuit diagram shows the electrical wiring for the thermometer The major components are temperature gauge in contact with cooling water and temperature indicator water...

Page 92: ...er A temper ature gauge whose ohmic value does not change in the proportion indicated in the next page must be replaced Temperature gauge specification Water temp fO CI Standard resistance U 50 Approx...

Page 93: ...FUEL AND LUBRICATION SYSTEM CONTENTS FUEL TANK AND FUEL COCK 5 1 CARBURETOR 5 2 OIL PUMp 5 7...

Page 94: ...l the main passage opens With the valve OFF both holes close ON position RES position CLEAN The fuel cock filter will collect impurities and therefore must be periodically checked and cleaned The fuel...

Page 95: ...EM E 01 30 The others Carburetor type MIKUNI VM28SS 1 0 Number 40AOO 40AlO 1 In Fuel level 4 0 1 0 mm Float height 23 5 1 0 mm Main jet M J 160 needle 5DP5 3rd 5DP5 2nd Needle jet N J p O Pilot jet P...

Page 96: ...Loosen the carburetor clamp screws Remove the fuel tank Refer to page 3 1 Loosen and remove the air cleaner mounting bolt and actuator Slide the air cleaner backward Take off the carburetor Loosen an...

Page 97: ...ontinue flowing and cause it to overflow If the seat and needle are worn beyond the permissible limits similar trouble wi II occur Conversely if the needle sticks the gasoline will not flow into the f...

Page 98: ...too rich or too lean When replacing the spark plug consult the page 2 5 MIXTURE ADJUSTMENT This adjustment is effected mainly by main jet and jet needle Before doing so check to be sure that the floa...

Page 99: ...riginal and the positions of adjustable parts should not be changed except when compensating for the mixture ratio due to a titude differences or other climatic conditions When adjustment is necessary...

Page 100: ...peed at the same 2000 r min move the lever up to the fully open position and let the pump draw for 2 minutes For this operation the reading taken on the device should be 2 9 3 5 ml 09900 21602 CCI oil...

Page 101: ...ECTRICAL SYSTEM CON1ENTS CHARGING SySTEM 6 1 IGNITION SySTEM 6 5 AUTOMATIC EXHAUST CONTROL UNIT AND ACTUATOR 6 7 COMBINATION METER 6 11 WATER TEMPERATURE METER 6 13 LAMPS 6 14 SWITCHES 6 15 BAT1ERY 6...

Page 102: ...Generator r yC y YE 3JY yE 3JY L _________J Function of Regulator Regulalor Rectifier o r f I seR I 0 0 L _ _ ______ _ 8M IG SW f l ghtlOg Switch 0 S c c 0 Whife the engine r min is low and the gener...

Page 103: ...int to point Namely at the state of this the current generated from the AC generator gets through SeR without charging the battery and returns to AC generator again At the end of this state since the...

Page 104: ...test be sure that the battery is fully charged condition STD charging output 09900 25002 13 5 15 5V DC at 5 000 r min Pocket tester AC GENERATOR NO LOAD PERFORMANCE Remove the left frame cover seat an...

Page 105: ...ket tester X kn range measure the resistance between the lead wires in the following table If the resistance checked is incorrect replace the regu lator rectifier 09900 25002 Pocket tester Unit kn Ell...

Page 106: ...dings of the ignition coil resulting in strong spark between the spark plug gap Magneto STATOR CO IL C D 1 Unit Spark plug R Using the pocket tester measure the resistance between the lead wires in th...

Page 107: ...ster 09900 25002 Pocket tester Ignition coil resistance Primary Secondary SlY S W 0 1 0 n Plug cap Plug cap 20 35 kn Check the gap wit h a thickness gauge Spark plug gap 0_6 0_8 mm NOTE If not sparkin...

Page 108: ...E OPERATION Remove the right middle cowling Remove the exhaust valve pulley cover Install the exhaust valve pu lley holder with the spacer Start the engine and increase the engine rimin to check the e...

Page 109: ...onnect the positive termi nal of the battery to the Green lead and e negative terminal to the White lead of the actuator Using a pocket tester x kn range check the continuity between White and Yellow...

Page 110: ...xhaust valves should be opened EXHAUST VALVE CONTROL UNIT Remove the seat and pillion seat Remove the seat tail cover Disconnect the couplers and remove the control unit CD Use a SUZUKI pocket tester...

Page 111: ...r G W P OFF OFF ON 101 OFF OFF BI ON 13 21 ON 17 51 ON 13 21 ON 191 ON 13 21 0 y ON 13 21 ON 17 51 ON 13 21 ON 19 51 ON 13 21 Gr ON 101 OFF OFF OFF OFF G ON 1401 ON 1201 ON 1201 ON 1321 ON 1141 0 r W...

Page 112: ...ombination meter as follows INSPECTION Using pocket tester check the continuity between lead wires in the following diagram If the continuity measured is incorrect replace the respective part 09900 25...

Page 113: ...er tight c f B R EB High beam BM e Ground Item Ef Probe e Probe of tester of tester Speedometer light B Gr B W Tachometer light B Gr B w Temperature B Gr B W meter light Turn signal B B W indicator li...

Page 114: ...eter from the water temperature gauge Connect a jamper wire be tween BIG wires coming from the main wiring harness and engine ground With the ignition switch turned on the water temperature meter shou...

Page 115: ...ELECTRICAL SYSTEM 6 14 LAMPS HEAD LIGHT TURN SIGNAL LIGHT TYPE I TYPE D...

Page 116: ...spect each switch for continuity with the pocket tester referring to the chart If it is found any abnormality replace the respec tive switch assembly with a new one 09900 25002 Pocket tester IGNITION...

Page 117: ...H DIMMER SWITCH Y W Y HI LO PASS TURN SIGNAL SWITCH B R L u HORN SWITCH OFF ON Lbl B w o W 6 RIGHT HANDLE SWITCH LIGHTING SWITCH 0 Gr S v ON ENGINE STOP SWITCH OIR L9 G o Y W B Y B W OFF o o RUN ELECT...

Page 118: ...6 17 ELECTRICAL SYSTEM FRONT BRAKE SWITCH a W B I OFF ON a o NEUTRAL SWITCH BI Ground ON o o REAR BRAKE SWITCH OFF ON o W B o o OIL LEVEL SWITCH BI w B W ON o o...

Page 119: ...rrent Charging time 0 5 A The charging time for a new battery is determined by the number of months that have elapsed since the date of manufacture Date of manufacture is indicated by a three part num...

Page 120: ...up portion of electrolyte surface as shown in figure Check the reading as corrected to 20 C with chart to determine the recharging time in hours by constant current charging at a charging rate of 0 5...

Page 121: ...full of sediment the battery cannot be used any more If the battery is not charged for a long time lead sulfate is generated on the surface of the pole plates and will deteriorate the per formance 5ul...

Page 122: ...CONTENTS COWLING 7 1 FRONT BRAKE 7 3 FRONT WHEEL 7 11 TIRE AND WHEEL 7 16 FRONT FORK 7 22 STEERING 7 29 REAR BRAKE 7 34 REAR WHEEL AND REAR SPROCKET 7 42 REAR SUSPENSiON 7 47...

Page 123: ...7 1 CHASSIS COWLING CONSTRUCTION...

Page 124: ...Remove the lower cowling by loosening 5 screws left and right Remove the middle cowling by loosening 4 screws left and right Remove the upper cowling by loosening 2 screws and mirror mounting nuts CHA...

Page 125: ...ke off brake pads NOTE 00 not operate the brake lever while taking off the brake pads CAUTION Replace the brake pad with a set otherwise braking performance will be adversely af fected CAUTION Fit the...

Page 126: ...from the last servicing and stored for long periods WARNING Brake fluid if it leaks will interfere with safe running and discolor painted surfaces Check the brake hose for cracks and hose joint for l...

Page 127: ...the caliper by loosening the caliper axle bolts Push out the piston by using air gun CAUTION Do not use high pressure air to prevent piston damage Remove the piston CD dust seal and oil seal from the...

Page 128: ...ng a micrometer check the disc for wear Its thickness can be checked with disc and wheel in place The service limit for the thickness of the disc are shown below 0990 20205 Micrometer 0 25 mm Service...

Page 129: ...mbly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the caliper bore and piston to be inserted into the bore NOTE When assembling the caliper install the new seals Tightening...

Page 130: ...catch spilled drops of brake fluid Unscrew the union bolt and disconnect the brake hose master cylinder joint CAUTION Completely wipe off any brake fluid adhering to any part of motorcycle The fluid...

Page 131: ...rvoir cap and diaphragm Drain brake fluid Remove the brake lever Pull off dust boot Remove circlip by using the special tool Remove piston primary cup and spring 09900 06108 CD Circlip Piston Snap rin...

Page 132: ...t the fol lowing steps I CAUTION Wash the master cylinder components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Apply brake flu id to the cylinder bor...

Page 133: ...WHEEL CONSTRUCTION REMOVAL Support the machine by side stand and jack Loosen the front axle nut Loosen the ax Ie clamp nut Remove the right brake caliper Disconnect the speedometer cable Remove the l...

Page 134: ...eel bearings by using the special tool in the fol lowing procedures Insert the adapter into the wheel bearing After inserting the wedge bar from the opposite side lock the wedge bar in the slit of the...

Page 135: ...r runcut and replace it if the runout exceeds the limit 09900 20606 Dial gauge 1 100 09900 20701 Magnetic stand Service Limit 0 25 mm WHEEL Make sure that the wheel runout checked as shown does not ex...

Page 136: ...earing before installing the bearings 99000 25010 SUZUKI Super grease A Install the wheel bearings by using the special tool CAUTION First install the wheel bearing for left side 09924 84520 Bearing i...

Page 137: ...CD to the two recesses of the wheel hub and attach the speedometer gearbox to the wheel hub When tightening the front axle check to be sure that the speedometer gearbox is in the position so that the...

Page 138: ...tire removal the following tools are required ff 2 3 c n I Remove the valve core from the valve stem and deflate the tire completely NOTE Mark tire with chalk to note the position CD of the tire on th...

Page 139: ...r Attach the operation arm to the center shaft Attach the bead breaker to the operation arm and dismount the bead from the rim Turn the wheel over and dismount the other bead from the rim Install the...

Page 140: ...S 7 18 Thoroughly inspect the removed tire and if anyone of the following items is observed do not repair the tire Replace with a new one A puncture or a split whose total length or diameter exceeds 6...

Page 141: ...with a new one if seal rubber is abnormally deformed or worn INSTALLATION Any dust or rust around the valve hole must be cleaned off Then install the valve in the rim CAUTION When installing the valve...

Page 142: ...on of wheel rotation and align the balancing dot of the tire with the valve stem as shown CAUTION There is not directional arrow on the front tire so mount the tire so that 1 0 number faces to the lef...

Page 143: ...tly over the tire while inflating it NOTE Check the rim line cast on the tire side walls It must be equidistant from the wheel rim all the way around If the distance bet ween the rim line and the whee...

Page 144: ...e 7 11 Remove the stabilizer and front fender Loosen the upper lower clamp bolts right and left and handlebar bracket bolt NOTE Loosen the front fork cap bolt before loosen ing the front fork lower cl...

Page 145: ...cap bolt Q and draw out seat spacer spring seat and spring Hold the fork inverted for a few minutes to drain the oil Invert the fork and stroke it several times to remove the oil from inside Remove d...

Page 146: ...ing the caliper mounting portion of the outer tube by vise separate the inner tube from the outer tube as shown CAUTION The outer tube and inner tube anti friction metal or metal slide rings must be r...

Page 147: ...0401 INSPECTION DAMPER ROD RING L type hexagon wrench set I Inspect damper rod ring for wear and damage OIL LOCK PIECE Inspect the oil lock piece and wave washers for wear and damage FORK SPRING Measu...

Page 148: ...y available as a replacement unit Inspect the O rings located between unit and front fork outer tube for wear or damage FRONT FORK CAP Inspec O ring for wear or damage REASSEMBLY AND REMOUNTING Reasse...

Page 149: ...ool CAUTION Use special care to prevent damage to the Teflon coated surface of the anti friction metal when mounting it 09940 50112 Oil seal installer POSI DAMP UN IT Apply thread lock 1342 to the sec...

Page 150: ...m FORK SPRING When installing the fork spring small pitch end should position in top When reinstalling the front fork assembly it must be 5 mm in height between upper surface CD of the inner tube and...

Page 151: ...ce adjuster to same position S T D position 2 Tighten the following bolt to specified torque Tightening torque Upper clamp bolt Lower clamp bolt Handlebar bracket bolt STEERING CONSTRUCTION N m kg m 2...

Page 152: ...Refer to page 7 11 Remove the front fork Refer to page 7 22 Remove the headlight and disconnect the wire harness Disconnect the combination lead wire and tachometer cable Remove the combination meter...

Page 153: ...n switch Loosen the steering stem head bolt and remove the upper bracket Loosen the steering stem nut by using the special tool while holding the steering stem with hand 09940 14911 Steering stem nut...

Page 154: ...over Steering bearing installer Inspect and check the removed parts for the following abnormalities Bearing race wear and brinelling Worn or damaged teel balls Distortion of steering stem and steering...

Page 155: ...SUZUKI super grease A STEM NUT Fit the dust seal to the stem nut Tighten the steering stem nut to 40 50 N m 4 0 5 0 kg mi 09940 14911 I Steering stem nut wrench I Turn the steering stem bracket about...

Page 156: ...he pro cedure was accomplished correctly Finally check to be sure that the steering stem moves freely from left to right with own weight If play of stiffness is noticeable re adjust the steering stem...

Page 157: ...eceptacle Pull out the cotter pin and remove the torque link bolt and nut Remove the caliper mounting bolts and take off the caliper NOTE Slightly loosen the caliper housing bolts to facilitate later...

Page 158: ...h and separate the cal iper halves Place a rag over the piston to prevent it from popping out Push out the piston by using air gun CAUTION Do not use high pressure air for preventing piston damag Remo...

Page 159: ...ston seal Inspect the each rubber part for damage and wear Disc Measure the disc thickness by using the micro meter 09900 20205 Micrometer 0 25 mm Service Limit 5 3 mrn With the disc mounted on the wh...

Page 160: ...nt or gasoline to wash them Apply brake fluid to the caliper bore and piston to be inserted into the bore Bleed the air after reassembling the caliper See page 2 15 L _ _ ________________ TIGHTENING T...

Page 161: ...7 1 Loosen the reservoir tank securing boh Remove the second muffler Remove the brake pedal Remove the footrest bracket and master cylinder by loosening the securing bolts Disconnect the brake light...

Page 162: ...emove the circlip by using the special tool 09900 06105 D Circlip Piston Primary cap Return spring INSPECTION Snap ring pliers Inspect the cylinder wall and piston surface for nicks scratches or other...

Page 163: ...y Never use cleaning solvent or gasoline to wash them Apply brake fluid to the cylinder bore and all the internals to be inserted into the bore Rear brake pedal When installing the rear brake pedal al...

Page 164: ...REAR WHEEl AND REAR SPROCKET CONSTRUCTION CHASSIS 7 42...

Page 165: ...ional stand r stand Loosen the caliper mounting bolt and torque link bolt Loosen the rear axle nut and draw out the axle shaft Remove the rear wheel DISASSEMBLY Remove the rear sprocket Remove the dis...

Page 166: ...e occurs or rotating smoothly Replace the bearing if there is something unusual A X LE SHAFT Using a dial gauge check the axle shaft for runcut and replace it if the runout exceeds the limit 09900 206...

Page 167: ...ND REMOUNTING Reassemble and remount the rear wheel in the reverse order of disassembly and removal and also carry out the following steps WHEEL BEARING Apply grease to the wheel bearings 99000 25010...

Page 168: ...Grease A REAR SPROCKET Install the rear sprocket to the mounting drum T ightening torque I 20 35 N m 12_0 3_5 kg ml Install the disc to the wheel After applying the thread lock 1360 to the bolt tighte...

Page 169: ...7 47 CHASSIS SUSPENSION REAR SWINGARM HOCK ABSORBER...

Page 170: ...Aeferto REMOVAL middle and lower cowling Remove the page 7 1 d frame cover eve the seat an Rem chain cover Remove the Aemove the m ge 3 41 uffler Refer to pa CHASSIS 7 48...

Page 171: ...side of fuel tank Remove the battery case Disconnect the brake hose Remove the rear brake caliper Rear to page 7 35 Support the machine by side stand and jack Remove the rear wheel Refer to page 7 42...

Page 172: ...bolts Remove the swingarm DISASSEMBLY Loosen the rear shock lower nut and cushion lever center nut Separate the swingarm rear shock and cushion lever SWINGARM Remove the torque link and chain buffer...

Page 173: ...ve the dust covers and spacers Remove the bearing and bush by using the special tool 09923 73210 Bearing remover 09930 30102 Sliding shaft CUSHION LEVER Remove the eccentric spacer Remove the dust cov...

Page 174: ...CHASSIS 7 52 Remove the bearing from the spacer Remove the oil seal I Remove the bearing by using the special tool 09913 75810 Bearing installer Remove the spacer and dust seal...

Page 175: ...ION SWING ARM PIVOT SHAFT Using a dial guage check the pivot shaft for runout and replace it if the runout exceeds the limit 09900 20606 Dial gauge 1 100 Service Limit O 3mm BEARINGS NEEDLE ROLLER BEA...

Page 176: ...t the mounting bolt to the bearing and check the play be moving the bolt If an excessive play is noted replace the bearing with a new one REASSEMBLY AND REMOUNT Reassemble the rear suspension in the r...

Page 177: ...s outside Apply grease to the bearings and dust seal cover 99000 25010 SUZUK I Super Grease A I CUSHION LEVER Install the bearing and dust seal by using special tool 09913 75810 Bearing installer Remo...

Page 178: ...kg m 40 60Nm 4 0 6 0 kg m ij r L l CHASSIS 56 Apply grease to the tip of dust seal and bearing Apply grease to the lip of dust seal and bearing Apply grease to the lip of dust seal and I Apply grease...

Page 179: ...ERVICING INFORMATION CONTENTS TROUBLESHOOTING 8 1 WIRING DIAGRAM 8 7 CABLE WIRE AND HOSE ROUTING 8 8 HANDLE AND KICK LEVER INSTALLATION 8 11 SPECIAL TOOLS 8 12 TIGHTENING TORQUE 8 16 SERVICE DATA 8 19...

Page 180: ...ton ring groove worn Replace 5 Piston pin bearing worn Replace Noise seems to come from clutch 1 Worn splines of countershaft or hub Replace 2 Worn teeth of clutch plates Replace 3 Distorted clutch pl...

Page 181: ...ean 7 Clogged fuel pipe resulting in inadequate fuel Clean and prime supply to carburetors 8 Defective exhaust valve control unit actuator or Replace exhaust valve Dirty or heavy 1 Oil pump out of adj...

Page 182: ...d clean speed trouble 2 Needle jet is clogged Check and clean 3 Throttle valve is not operating properly Check throttle valve for operation 4_ Air cleaner element is clogged Check and clean Overflow a...

Page 183: ...es or loose lead Repair or replace or not charge connections retighten 2_ Shorted grounded or open generator coils Replace 3 Shorted or panctured regulator rectifier Replace Generator does 1 Lead wire...

Page 184: ...m 3 A short circuit condition exists within the Replace the battery battery due to excessive accumulation of sediments caused by the high electrolyte S G 4 Electrolyte S G is too low Recharge the batt...

Page 185: ...fy pad fitting 3 Damaged wheel bearing Replace 4 Loose front wheel ade or rear wheel axle T ighten to specified torque 5 Worn pads Replace 6 Foreign material in brake fluid Replace brake fluid 7 Clogg...

Page 186: ...8 7 SERVICING INFORMATION WIRING DIAGRAM l I irr H Fiji f lll i...

Page 187: ...witch lead wire left handle Ignition switch lead wire Right and Left Clamp switch lead wire left handle turn signal lead wire Clamp Boot Main harness Clamp Clamp Clamp Regulator Rectifier lead wire Cl...

Page 188: ...B 9 SERVICING INFORMATION Clutch cable o c Throttle cable I Throttle cable calmp Clutch cable Fuel cock Throttle cable Clutch cable i C Radiator reservoir tank...

Page 189: ...ON Oil tank Clamp iI Fuel tank To carburetor SERVICING INFORMATION 8 10 ON RES Fuel cock Air vern hose Over flow pipe...

Page 190: ...8 11 SERVICING INFORMAnON HANDLE AND KICK LEVER INSTALLATION 44 Front fork Upper bracket 44...

Page 191: ...5 Tire depth gauge 14 09900 21101 Torque wrench 0 5 4 5 kg m 21102 Torque wrench 0 1 2 kg m 21103 Torque wrench 1 0 9 0 kg m 15 09900 21304 V block set 16 09900 21602 eel oil gauge 17 09900 25002 Pock...

Page 192: ...g outer race installer 38 09941 50110 Bearing remover 39 09941 54911 Bearing outer race remover 40 09941 74910 Steering bearing installer 41 09941 84510 Bearing inner race remover 42 09941 94510 Rim p...

Page 193: ...SERVICING INFORMATION 8 14...

Page 194: ...8 15 SERVICING INFORMATION c...

Page 195: ...at cover screw 10mm Engine mounting bolt 8mm Engine mounting bracket bolt Exhaust pipe clamp nut 10mm Muffler mounting bolt 8mm Engine sprocket bolt 6mm Crankcase bolt 8mm Spark plug SERVICING INFORMA...

Page 196: ...nion bolt 20 25 2 0 2 5 Front brake caliper mounting bolt 15 25 1 5 2 5 Front brake caliper axle bolt I 30 36 3 0 3 6 Posi damp mounting bolt 6 8 0 6 0 8 Brake pedal bolt 6 10 0 6 1 0 Front 18 28 1 8...

Page 197: ...lt 7 marked bolt mm N m kg m N m kg m 4 1 2 0 1 0 2 1 5 3 0 15 0 3 5 2 4 0 2 0 4 3 6 0 3 0 6 6 4 7 0 4 0 7 8 12 0 8 1 2 8 10 16 1 0 1 6 18 28 1 8 2 8 10 22 35 2 2 3 5 40 60 4 0 6 0 12 35 55 3 5 5 5 70...

Page 198: ...5 14 000 13 980 CONROD CRANKSHAFT Unit mm ITEM STANDARD LIMIT Conrad small end LD 18 003 18 011 18 040 Conrad deflection 3 0 Crank web to web width 50 0 1 Crankshaft runout 0 05 OIL PUMP ITEM SPECIFIC...

Page 199: ...No 3 Shift fork groove width No 1 No 2 5 5 5 6 No 3 Shift fork thickness No 1 No 2 5 3 5 4 No 3 DRIVE CHAIN Unit mm ITEM STANDARD LIMIT Drive chain Type 0 1 0 D I D S20V S TAKASAGO RK520SMO Z2 links 1...

Page 200: ...il resistance 0 1 1 0 Q Y Y Magneto coil resistance Pick up 40 70 Q R W B W Pulser 150 300 Q G B W Exciter 5 15 Q B R G Generator no load voltage More than 34 V AC at 5 000 r min Regulated voltage 13...

Page 201: ...38 098 38 148 Wheel runout Axial 2 0 Radial 2 0 Wheel axle runout Front 0 25 Rear 0 25 Tire size Front 100 90H 16 Rear 1 lO 80H 18 Tire tread depth Front 1 6 Rear 2 0 SUSPENSION Unit mm ITEM STANDARD...

Page 202: ...gine oil type SUZUKI eel oil or eel super oil Engine oil tank capacity lo2l Transmission oil type SAE 20W 40 Transmission oil capacity Change 850ml Overhaul 900 ml Front fork oil type Fork oil 10 Fron...

Page 203: ...RG250H 87 MODEL Please refer tD the sections 1 through 8 except for the items discribed in this section SERVICE DATA 9 1 1...

Page 204: ...14 000 13 980 CONROD CRANKSHAFT Unit mm ITEM STANDARD LIMIT Conrad small end 1 0 18 003 18 01 1 18 040 Conrad deflection 3 0 Crank web to web width 50 0 1 Crankshaft runout 0 05 OIL PUMP ITEM SPECIFI...

Page 205: ...35 DRIVE CHAIN Unit mm ITEM STANDARD LIMIT Drive chain Type 0 1 0 OI0520V S TAKASAGO RK 520 SMO Z2 links 110 20 pitch length I 319 4 Drive chain slack 15 20 CARBURETOR SPECIFICATION ITEM E 01 06 22 2...

Page 206: ...Secondary 20 35 kQ Plug cap Plug cap Generator no load voltage More than 34 V fAC at 5 000 r min Regulated voltage 13 5 1S 5Vat 5 000 r min Battery Type designation 12N5 3BISI Capacity 12V 1B O kC 15A...

Page 207: ...xial 2 0 Radial 2 0 Wheel axle unout Front 0 25 Rear 0 25 Tire size Front 100 90 16 54H Rear 110 80 1858H Tire tread depth Front 1 6 Rear 2 0 SUSPENSION Unit mm ITEM STANDARD LIMIT Front fork stroke 1...

Page 208: ...ngine oil type eel or eel super Engine oil tank capacity 2 l Transmission oil type SAE 20W 40 Transmission oil capacity Change 850ml Overhaul 900ml Front fork oil type Fork oil 10 Front tork oil capac...

Page 209: ...Prepared by SUZUKI MOTOR CORPORATION MOlOrcyc1e Technical Service Departmcm 2nd Ed October 1990 1st Ed October 1985 Part No 99500 12061 0IE Primed in Japan 212...

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Suzuki RG250, Service Manual

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Summary of Contents for RG250

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