Suzuki RGV250 1989 Manual Download Page 1

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Summary of Contents for RGV250 1989

Page 2: ...SUZUKI standardly grants on motorcycle of its manufacture NOTE The motorcycle on which the HOP UP KIT is installed is not covered by the SUZUKI WARRANTY This HOP UP KIT manual describes only service...

Page 3: ...CARBURETOR SETTING PARTS 14 9 MUFFLER REPLACEMENT 22 10 OIL PUMP REMOVAL AND BLINDING 23 11 SPROCKET REPLACEMENT 25 12 REAR SUSPENSION HEIGHT ADJUSTER BRACKET INSTALLATION 26 13 FRONT FORK 27 14 REAR...

Page 4: ...ate type or Wet multi plate type Transmission 6 speed constant mesh Gearshift pattern 1 down 5 up Primary reduction 2 565 59 23 DRY CLUTCH 2 560 64 25 Final reduction 46 13 3 538 46 15 3 067 STD 37 16...

Page 5: ...70 C considerable power loss will result 3 WARMING UP Always warm up the engine before running in the following manner 1 For 1 2 minutes rev the engine up and down within the range of 5 000 6 000 rpm...

Page 6: ...wear Whenever disassembled Seizure wear Wear scratches Runout seal damage bearing wear Contamination emulsification Stretch kink 2 Other wear items to be replaced ITEM Spark plug Reed valve Clutch spr...

Page 7: ...purpose of decresing the quenching area thereby surpressing abnormal detonation to a minimum D The kit cylinder is different from the normal one in its port timing port shape and height of cylinder T...

Page 8: ...pre vent pitting in case of abnormal detonation A thin 0 8 mm piston ring is used to decrease weight and friction loss The kit piston pin is light in weight yet highly rigid due to its double tapered...

Page 9: ...LOSE RATIO TRANSMISSION Modify the gear ratios for better suitability for competition using the parts listed below Refer to RGV250 Service Manual 99950 12070 01E for details of replacement procedure _...

Page 10: ...0 12C50 24322 12C60 DESCRIPTION COUNTERSHAFT COUNTERSHAFT GEAR 2ND DRIVE GEAR 3RD 4TH DRIVE GEAR 5TH DRIVE GEAR 6TH DRIVE SHAFT DRIVE GEAR 1ST DRIVEN GEAR 2ND DRIVEN GEAR 3RD DRIVEN GEAR 4TH DRIVEN GE...

Page 11: ...low Refer to RGV250 Service Manual 99950 12070 01E for details of replacement procedure REF NO 1 2 3 4 5 PART NUMBER 21441 40A01 21451 40A00 21471 12C50 09164 00006 09440 19013 DESCRIPTION PLATE CLUTC...

Page 12: ...5 CLUTCH FOR DRY TYPE...

Page 13: ...ET DRY OILSEAL INNER COVER GEAR ASSY PRIMARY DRIVEN SPACER DRIVEN GEAR SPACER DRIVEN GEAR BEARING O RING HOUSING CLUTCH OILSEAL HUB CLUTCH SLEEVE THRUST WASHER SLEEVE HUB PLATE CLUTCH DRIVE PLATE CLUT...

Page 14: ...between the bracket and frame 6 Remove the crankcase breather hose from the guide which is fastened together with the 1st muffler mounting on the lower part of chassis right side Route this breather h...

Page 15: ...ose 09408 00074 CLAMP FUEL TANK BREATHER HOSE To fuel tank breather Oil catch tank bracket to be tightened together with carburetor idle adjuster screw bracket using front side of bolt To crankcase Se...

Page 16: ...7 WATER CATCH TANK Install the tank with bands Water catch tank To radiator conduction Make a hole to catch water hose Air bleeding hole 3 mm dia Water catch tank 1 3...

Page 17: ...ions of parts CARBURETOR TYPE MIKUNI TM34SS TWO BORE SIZE 34 mm SETTING PARTS M J Lea 310 320 330 340 350 360 370 380 390 ner 400 Richer HJ Leaner 05 06 07 08 09 P 0 P 1 P 2 i 1 Richer J N Leaner CLIP...

Page 18: ...nge 1 4 3 4 throttle opening Hesitates in range 1 4 3 4 throttle opening and torque is poor Responds to gradual but not to quick throttle opening Responce too sharp to control AJUSTMENT Decrease MJ si...

Page 19: ...range over 9 000 rpm NJ Needle Jet With 15 25 of throttle opening carburetion is affected in entire revolution range with 35 50 of opening over 9 000 rpm and with 75 of opening over 11 000 rpm MJ Main...

Page 20: ...0 5 60 1 Turns back Atmospheric temperature 10 C Barometric pressure For high speed circuit 760mmHg Change with larger MJ 2 3 sizes Change with larger NJ by 1 2 sizes Atmospheric temperature 10 C Bar...

Page 21: ...09491 64002 09491 66002 09491 68002 09491 70011 09491 72011 09491 74003 09491 76003 09491 78001 09491 80010 NEEDLE JET 0 5 0 6 0 7 0 8 0 9 P 0 P 1 P 2 09494 00653 09494 00612 09494 00613 09494 00614...

Page 22: ...dard model is equipped with the air fuel ratio control system which operates according to the engine rpm This system includes an auxiliary main air passage which opens through the air valve as the eng...

Page 23: ...below Air cleaner cap modification Cut the air cleaner cap in half 30 mm Cut at 30 mm from the hook NOTE The net and filter element inside the air cleaner box are no longer used Air cleaner box modif...

Page 24: ...armost the box to take air from the duct Connect the air duct to the air cleaner box as illustrated To prevent loss of air in this area seal the top with a cloth tape To guide air supplied from the ai...

Page 25: ...the exhaust flange using two springs 8 Position the 2nd muffler on the 1st muffler properly referring to the tail pipe direction and hook the two springs 9 Assemble the 1 side muffler in the same mann...

Page 26: ...all the oil pump cap 16432 12C50 in the position from which the oil pump has been removed using the screws 02112 35168 8 Cut the oil hose removed from the system to make a short hose bling one end as...

Page 27: ...1 i W B tftlf 24...

Page 28: ...circlip make sure they are positioned correctly as shown in the illustration NOTE Engine sprockets of 13 16 teeth and rear sprockets of 37 45 teeth are optionally available Select the most suitable nu...

Page 29: ...shock absorber assembly Remove the existing bracket by loosening the bolts 2 Installation Bracket rear shock 41762 1 2C50 Clamp rear shock bracket 41763 12C50 Nut rear shock bracket 09159 14015 Assem...

Page 30: ...ransferred to the cham L 3l Hrff ber The damping adjuster and rebound j f damper valve 0 contribute to damping force Compression damper When the fork is being contracted oil in the oil chamber is forc...

Page 31: ...n the following prodecures Remove the spring adjuster Remove the spring 8 and ball Remove the damping force adjuster Remove the dust seal Detach the spring stopper Loosen the inner tube bolt using the...

Page 32: ...Oil lock piece 5 Inner tube 6 Piston 7 Outer tube D Slide metal 9 Washer Oil seal Q Stopper ring Dust seal Inner rod B o l t Spring Spring washer Spring spacer Spring retainer Spring adjuster Adjuster...

Page 33: ...etal washer and oil seal over the inner tube and the into the outer tube bore Use the special tool to fit them together into the outer tube Specie tool 09940 50112 Oil sea installer NOTE The pjirten s...

Page 34: ...l Also use care so that the spring will not be distorted Turn the lock nut all the way in lightly Have the adjuster protruded by 1 5 mm Turn the spring adjuster all the way in lightly Hold the spring...

Page 35: ...ebound damping can be individually adjusted The compression damping adjuster locates on the top end of fork tube and rebound damping adjuster locates on the bottom part of the fork tube as shown Spiin...

Page 36: ...ing as shown in the illustration Check the oil level of front fork when compressed fully and adjust it to the specification Standard oil level Part No I 5117M2C50 5117M2C60 Oil level measured from inn...

Page 37: ...pension height adjuster bracket installation previously explained remove the shock absorber assembly Slide the stopper rubber upward Compress the spring 2 and remove the spacer then spring guide Remov...

Page 38: ...ype shock absorber In this absorber both the compression damping and rebound damping can be individually ad justed The compression damping adjuster locates on the oil reservoir and rebound damping adj...

Page 39: ...d two each into the piston recesses as shown in the illustration INSULATOR _ Part No 59109 12C50 59109 19C00 Characteristic Small diameter Large diameter 4 4 Piston r i i P v 1 1 Replace the brake pad...

Page 40: ...08310 11087 08310 11067 51750 12C50 51791 15400 07110 06257 07110 08407 09180 08067 51723 12C50 07110 06108 51795 15400 41684 12C50 DESCRIPTION BRACKET STEERING DAMPER BOLT BRACKET FORK CLAMP WASHER B...

Page 41: ...olt Remove the handlebar clamp bolt Remove the steering upper bracket nut Remove the steering upper bracket Remove the left handlebar holder from the fork inner tube8 Slide the bracket of the steering...

Page 42: ...n After completing the adjustment make sure that the steering turns smoothly both to the right and left Mount the steering stopper on the stopper boss formed on the steering lower bracket and tighten...

Page 43: ...nge Other spring constant Optional STANDARD 4 line from top 4 clicks back 3 clicks back 10 mm 0 55 kg mm 103 7 mm Showa SS8 54 mm 8 STAGE I KIT 5 5 line from top 1 click back 4 click back 15 mm 103 7...

Page 44: ...ring with lower spring constant Decrease oi I 1 cc 1mm Decrease 5 cc at a time I ncrease spring preload Change with spring with higher spring constant Increase oil Decrease damping force Review tire s...

Page 45: ...250 38200 32157 12C00 07110 05128 DESCRIPTION HARNESS WIRING SP CONTROL UNIT SP SWITCH ASSY KILL CLAMP PULSER COiL SP SCREW PULSER COIL SP QTY UNIT 1 1 1 1 2 REMARKS 89 89 With the kit installed the a...

Page 46: ...nstallation of magneto pulser coil clamps 32157 12C00 The clamps are installed to surpress vibration which otherwise increases and interferes with the pulse signals due to increased power and revoluti...

Page 47: ...it to be suited for Stage n 1REF NO 2 3 4 5 6 7 8 9 10 11 12 PART NUMBER 94510 12C51 32900 12C70 02112 16206 34161 12C50 09123 06023 09160 06028 09180 06040 08319 21068 32100 12C70 32374 12C50 02122 0...

Page 48: ...y Apply NEJI LOCK Three Bond 1322 Temperature gauge M e t e r _ A m GDI unit Q M Kill switch B G Or B Y No 1 coil No 2 coil d 1 W BI DT I B G j Temperature gauge Magneto 4 5...

Page 49: ...MEMO...

Page 50: ...MEMO...

Page 51: ...Prepared by SUZUKI MOTOR CO fLTD Sales Department II for overseas Spare Parts Accessories Division August 1989 Part No 99000 69445 V Printed in Japan J...

Page 52: ...SUZUKI MOTOR CO LTD...

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