Suzuki RGV250L 1990 Service Manual Download Page 1

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Summary of Contents for RGV250L 1990

Page 1: ...99500 12077 01 E...

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Page 3: ...ations which are of no consequence in most cases as far as servicing is concerned had to be made to comply with the statutory requirements of your country This service manual has been produced primari...

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Page 5: ...TION CONTENTS SERIAL NUMBER LOCATION 1 FUEL OIL AND COOLANT RECOMMENDATION 1 1 BREAKING IN PROCEDURES 1 3 CYLINDER IDENTIFICATION 1 3 SPECIAL MA TERIALS 1 4 PRECAUTION AND GENERAL INSTRUCTION 1 7 SPEC...

Page 6: ...ring the ma chine and ordering spare parts LEFT SIDE FUEL OIL AND COOLANT RECOMMENDATION FUEL Gasoline used should be graded 85 95 octane or higher An unleaded or low lead gasoline type is recommended...

Page 7: ...he ratio of 50 50 WATER FOR MIXING Use distilled water only Water other than distilled water can corrode and clog the aluminum radiator ANTI FREEZE COOLANT The coolant performs as corrosion and rust i...

Page 8: ...the care and restraint exercised during its early life The general rules are as follows Keep to these breaking in engine speed limits Initial 800 km Below 6 000 r min Up to 1600 km Below 8 000 r min...

Page 9: ...HREAD LOCK SUPER 1322 99000 32110 SUZUKI BOND No 1215 99000 31110 THREAD LOCK SUPER 1333B 99000 32020 PART PAGE Side stand pivot 2 2 Brake pedal pivot and brake rod link Gearshift lever mounting boss...

Page 10: ...starter shaft stopper 3 43 Cylinder lock bolt 7 13 Magneto rotor nut Disc plate bolt 3 50 7 3 7 28 Counter bearing shaft retainer 3 41 Shifting cam shaft 3 41 Cam stopper arm support bolt 3 41 Cam sto...

Page 11: ...SUZUKI BRAKE FLUID 99000 23110 0 5L RUNt FORK OIL 1I SUZUKI FORK OIL 10 99000 99044 10G SUZUKI GOLDEN CRUISER 1200 NA Non Amine type 2 0L 99000 99032 1 OX GENERAL INFORMATION 1 6 PART PAGE PART PAGE...

Page 12: ...rts and recommended oils o When 2 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 extre...

Page 13: ...ls are used they should always be so equipped If possible dampen before cutting or drilling Dampen dust and place it in a properly closed receptacle and dispose of it safely Any domestic asbestos prod...

Page 14: ...5 21 17 4th 1 045 23 22 5th 0 916 22 24 Top 0 840 21 25 Drive chain DAIDO DID 520V 2 TAKASAGO RK520M06 114 links CHASSIS Front suspension Telescopic coil spring oil damped spring 5 way adjustable Rear...

Page 15: ...E AND TUNE UP PROCEDURES 2 3 BATTERY 2 3 ENGINE BOL TS AND NUTS 2 3 CYLINDER HEAD CYLINDER AND MUFFLER 2 4 AIR CLEANER 2 4 SPARK PLUGS 2 5 CARBURETORS 2 5 FUEL LINES 2 7 OIL PUMp 2 7 CLUTCH 2 8 TRANSM...

Page 16: ...2 12 24 36 48 comes first Battery I I I I Engine bolts and nuts T T T T T Cylinder head cylinder and muffler C C C C Air cleaner Clean every 3 000 km Spark plugs I R R R R Carburetors I I I I I I I I...

Page 17: ...the motorcycle Major lubrication points are indicated below NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subj...

Page 18: ...2 0V Remove the battery e and E8 lead wires and remove the battery from the frame CAUTION Read the ELECTRICAL SECTION for servicing the battery_ ENGINE BOLTS AND NUTS Tighten at Initially 1 000 km 2 m...

Page 19: ...in the cleaning solvent and wash it clean Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands do not twist or wring the element or it will develop tea...

Page 20: ...insulators Proper heat range would be indicated if both insulators were light brown in color If they are blacken ed by carbon they should be replaced by a hot type B R8ES if baked white by NGK BR10ES...

Page 21: ...en the lock nut CID and turn the adjuster in or out to obtain the correct play CD 0 5 1 0 mm 0 02 0 04 in After adjusting the play tighten the lock nut CID WARNING After the adjustment is completed ch...

Page 22: ...llowing manner to confirm correct operation for all throttle valve opening positions Remove the magneto cover Remove the oil pump inspection cap Remove the air cleaner cap Turn the throttle grip gradu...

Page 23: ...km 2 months and Every 6 000 km 12 months After a long period of use the transmission oil will deteriorate and quicken the wear of sliding and interlocking surfaces Re place the transmission oil perio...

Page 24: ...ed induce vomiting and call physician im mediately Flush the radiator with fresh water Tighten the radiator hose clamp CID securely Pour the specified coolant up to the radiator inlet hole Loosen the...

Page 25: ...en axle nut CD Tense the drive chain fully by tightening the chain adjuster lock nuts CID Count out 21 pins 20 pitch on the chain and measure the distance between the two If the distance exceeds follo...

Page 26: ...ly as drive chain oil Such oil too can spoil the 0 rings or seals CAUTION The standard drive chain is DAIDO 0 1 0 520V 2 or TAKA SAGO RK520M06 SUZUKI recommends that the above mentioned standard drive...

Page 27: ...acks and hose joints for leakage before riding BRAKE PADS Wearing condition of brake pads can be checked by observing the limit line CD marked on the pad When the wear exceeds the limit line replace t...

Page 28: ...bleeding the air always start with the inboard valve and then the outboard valve Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it...

Page 29: ...ONT 1 6 mm O 063 in REAR 2 0 mm O 079 in TIRE PRESSURE If the tire pressure is too high or too low steering will be ad versely affected and tire wear increased Therefore maintain the correct tire pres...

Page 30: ...ly by grasping the lower fork tubes near the axle and pulling forward when the machine is supported with the front wheel off the ground and positioned straight ahead If play is found perform steering...

Page 31: ...s mounting bolt 15 25 1 5 2 5 Front brake master cylinder mounting bolt 5 8 0 5 0 8 Front caliper mounting bolt 25 40 2 5 4 0 C j Front caliper housing bolt 18 23 1 8 2 3 Brake hose union bolt 15 20 1...

Page 32: ...2 17 PERIODIC MAINTENANCE AND TUNE UP PROCEDURES...

Page 33: ...ER HEAD 3 30 CYLINDER AND EXHAUST VALVE 3 30 PISTON 3 31 PISTON PIN O D 3 32 PISTON RINGS 3 32 BEARINGS 3 33 OIL SEALS 3 33 CRANKSHAFT 3 34 CLUTCH PLATES 3 34 GEARSHIFT FORK CLEARANCE 3 35 ENGINE REAS...

Page 34: ...Carburetors 3 3 Clutch cover 3 22 Magneto cover 3 5 Radiator 3 4 Water pump 3 22 Oil pump 3 16 Muffler 3 6 Clutch 3 23 Gearshift lever 3 17 Actuator 3 8 Gearshift shaft 3 24 Magneto stator 3 20 Cylin...

Page 35: ...hing bolt and remove the seat Loosen the left frame cover attaching screws to detach the left frame cover NOTE To prevent damage to the frame cover the seat must be remov ed before frame cover is deta...

Page 36: ...he carburetor clamp screws Move the air cleaner case rearward and remove the carbure tors Remove the gearshift lever Loosen the clamps and disconnect the following lead wires Neutral indicator switch...

Page 37: ...sis CAUTION When loosening the radiator mounting nuts hold the damper with open end wrench Radiator mounting nut tightening torque 7 9 N m 0 7 0 9 kg m Disconnect the clutch cable CD Loosen the box br...

Page 38: ...l and disengage the drive chain from the rear sprocket Disengage the drive chain from the engine sprocket and remove the engine sprocket Remove the oil pump inspection cap Slightly pry the tab on the...

Page 39: ...unting nuts Remove the engine mounting brackets Remove the engine mounting bolt CD and engine mounting bolt CAUTION Care should be taken not to drop the engine accidentally when the engine mounting bo...

Page 40: ...removal When remounting the engine engage the drive chain to the engine sprocket and mount the engine sprocket to the drive shaft Tightening torque N m kg m Transmission 20 25 2 0 2 5 oil drain plug...

Page 41: ...r Remove the exhaust valve cable bracket J Remove the exhaust valve cables from the pulley Remove the thermostat case Remove the electric parts holder from the frame Remove the actuator assembly Remov...

Page 42: ...ere are two lines and on the bracket Line full close position Line full open position CD Throttle cable adjuster carburetor side Oil pump cable adjuster Actuator cable adjuster Throttle cable adjuster...

Page 43: ...tor pulley cable Throttle cable Right carburetor Left carburetor Junction box Actuator 12C 3 Left valve pulley Full open mark Actuator cable Exhaust valve cable r __ _ ENGINE 3 10 Full close reference...

Page 44: ...m 0 4 0 6 kg m Install the actuator assembly to the electric parts holder With the actuator mounted install the electric part holder j on the frame I nstall the thermostat case Assemble the throttle...

Page 45: ...g bolt CD then the under mounting bolt CID Attach the frame down tube on the frame and insert the engine front mounting bolt Tighten the frame down tube attaching bolts and nuts J and temporarily When...

Page 46: ...stall the water hoses and Secure the water hoses with clamp properly Install the radiator assembly I nstall the water hoses and Secure the water hoses with clamp properly Connect the transmission oil...

Page 47: ...ignition switch Check that the index line CD on the actuator pulley is point ing to the line CID on the bracket Connect the exhaust valve control cables to the pulleys Hitch the spring end to the pull...

Page 48: ...on the left exhaust valve RIGHT EXHAUST VALVE CABLE ADJUSTMENT Turn the lock nut to move the exhaust valve cable adjuster CD until the pulley alignment slot comes in alignment with the alignment hole...

Page 49: ...ck nuts ACTUATOR AND EXHAUST VALVE FUNCTION CHECK NOTE The ignitor checker can be used for this check When the ignition switch is turned on the actuator slowly turns until it reaches the full close po...

Page 50: ...ent inspection procedure ACTUATOR CABLE ADJUSTMENT Verify that the actuator pulley adjustment is properly made Verify that the oil pump cable is properly adjusted relative to the throttle cable adjust...

Page 51: ...our 700 ml 23 7 24 6 US Imp oz when overhauling engine of transmission oil SAE 10W 40 MOTOR OIL into the engine Check the oil level by removing the transmission oil level screw CD Install the gear shi...

Page 52: ...routing and cable routing and adjust the following items to the specification Page Rear brake pedal 2 12 Brake light switch 2 12 Clutch cable 2 8 Throttle cables 2 6 Choke cables 2 6 Idling adjustment...

Page 53: ...arter lever Tightening torque 18 28 N m 1 8 2 8 kg m Remove the cylinder head Remove the cylinder Remove the exhaust valve pulley Remove the exhaust valve pulley lever CD Remove the exhaust valve leve...

Page 54: ...shaft arm Slide out the exhaust valve assembly CID Disassemble the spacer pin valve and guide Remove the oil seal retainer Remove the oil seal 09921 20200 Bearing remover NOTE Disassemble the Right c...

Page 55: ...E Scribe the cylinder No on the piston crown Remove the magneto rotor nut while holding the rotor with the special tool 09930 40113 Rotor holder Remove the rotor with the special tool 09930 30190 Atta...

Page 56: ...shaft with a snap ring pliers 09900 06107 Snap ring pliers Remove the oil pump Remove the neutral switch body a ring switch contact and spring Remove the intake pipes CD and CID Remove the reed valve...

Page 57: ...ove the water pump driven gear circlip CD Remove the wave washer CID Remove the water pump driven gear Remove the pin and washer Remove the water pump shaft Remove the water pump shaft oil seal Remove...

Page 58: ...h a chisel Hold the clutch sleeve hub securely with a clutch sleeve hub holder and loosen the hub nut with a socket wrench 09920 53710 Clutch sleeve hub holder Remove the clutch sleeve hub thrust wash...

Page 59: ...ove the circlip with the special tool and detach the flat washer or wave washer whichever is fitted Then draw out the kick starter idle gear and washer 09900 06107 Snap ring pliers Remove the pawl lif...

Page 60: ...d Pull out the gearshift cam shaft Remove the countershaft J and drive shaft Disassemble the gears following the instructions below Countershaft gears To disassemble the 2nd drive gear the ring should...

Page 61: ...8211 Bearing installer Remove the countershaft bearing in the same manner as drive shaft bearing 09913 80112 Bearing installer Flatten the lock washer and remove the primary drive gear nut with the sp...

Page 62: ...Separate the crankcase halves evenly at front and at rear 09912 34510 Cylinder disassembling tool Remove the crankshaft from the crankcase Remove the countershaft bearing retainer CD Remove the oil s...

Page 63: ...dge exceeds the limit rework the surface by rubbing it against emery paper of about 400 laid flat on the surface plate in a lapping manner The gasketed surface must be smooth and perfectly flat in ord...

Page 64: ...roove and this condition will lead to reduced engine power output A piston whose sliding surface is badly grooved or scuffed due to overheating must be replaced Shallow grooves or minor scuff can be r...

Page 65: ...ng a micrometer measure the piston pin outside diameter at three positions 09900 20205 Micrometer 0 25 mm Service Limit 15 980 mm 0 6291 in PISTON RINGS PISTON RING END GAP Check each ring for end gap...

Page 66: ...e of piston and ring Standard clearance 1st 0 02 0 06 mm 0 0008 0 0024 in 2nd 0 02 0 06 mm 0 0008 0 0024 in NOTE 1st ring and 2nd ring differ in the shape Be sure to bring the T marked side to top whe...

Page 67: ...ng of the conrod can be estimated by check ing the movement of the small end of the rod This method can also check the extent of wear on the parts of the con rod s big end If wear exceeds the limit co...

Page 68: ...pect clutch bearing for any abnormality particu larly cracks upon removal from the clutch to decide whether it can be re used or should be replaced Smooth engagement and disengagement of the clutch de...

Page 69: ...oth 09900 20803 Thickness gauge Shift fork groove clearance Service Limit 0 5 mm 0 0196 in Shift fork groove width No 1 No 2 Standard No 3 Shift fork thickness No 1 No 2 Standard No 3 4 0 4 1 mm 0 157...

Page 70: ...UPER GREASE A Install the drive shaft bearing retainer together with the gasket When tightening the screws applySUZUKI BOND No 1215 to threads of them 99000 31110 SUZUKI BOND No 1215 Position the cran...

Page 71: ...the upper crankcase half properly and tighten the bolts When tightening proceed with larger diameter bolts then smaller bolts With the same diameter bolts in one group tighten them evenly in a diagona...

Page 72: ...to prevent the nut from loosening NOTE Check that the crankshaft rotates smoothly by hand Assemble the following oil pump parts Trochoid oil pump outer rotor G Trochoid oil pump inner rotor Pump shaf...

Page 73: ...m a shaft A used circlip should be discarded and a new circlip must be installed When installing a new circlip care must be taken not to expand the end gap larger than required to slip the circlip ove...

Page 74: ...all the gearshift pawllifter Install the gearshift cam stopper j and spring Tightening torque 15 23 N m 1 5 2 3 kg m With the spring hook hitched on the shifting cam guide install the guide by first t...

Page 75: ...being inserted I nsert the oil pump spacer Apply oil to the spacer Tighten all the nuts through except for which is tightened after the kick starter shaft is installed Tightening torque 8 12 N m O 8...

Page 76: ...lip CID as shown Install the kick starter shaft stopper Thread lock should be applied to the screw threads 99000 32030 THREAD LOCK SUPER 303 Fit the return spring on the gearshift shaft CID Insert the...

Page 77: ...a h ft IC i j Kick starter s a uid j and Spacer the spacer i j Spring Spnng g gear spring hook h tko Er to the spacer k starter g 00 QI Fit the klc k starter gear sprm Also fit the klc t per nu 1 9 k...

Page 78: ...ch sleeve hub subassembly using lock washer and nut When tightening the nut I lock the sleeve hub rotation with special tool Tightening torque 40 60 N m 4 0 6 0 kg m 09920 53710 Clutch sleeve hub hold...

Page 79: ...to specification Tightening torque 8 12 N m 0 8 1 2 kg m Apply SUZUKI BOND No 1215 to the water pump mechanical seal housing CD and press in the clutch cover with the special tool 99000 31110 SUZUKI...

Page 80: ...me use care not to bend the oil seal lip 09925 98220 Bearing installer Assemble the following parts on the pump shaft Washer Pin Water pump gear Spring washer and Circlip Insert the clutch release pin...

Page 81: ...properly with the respective gears on crankcase side Tightening torque 6 10 N m 0 6 1 0 kg m Position the impeller on the shaft When installing the seal make sure that the painted mark faces inside A...

Page 82: ...0 ring j and Switch body After the switch body is tightened route the lead wire through the clearance Secure the lead wire with the clamp located on the intake pipe Install the oil pump on the engine...

Page 83: ...e oily matter to make these surfaces completely dry Apply TH READ LOCK SUPER 1324 to the nut and tighten it to the specified torque with the special too 99000 32120 THREAD LOCK SUPER 1324 09930 40113...

Page 84: ...e exhaust port side The circlip should be mounted in such a position that the mating ends of the circlip do not coincide with the groove portion of the piston Before inserting the piston in the cylind...

Page 85: ...hamfer side facing top I nstall the valve pin with the flange side facing the markings 19 and 20 Insert the exhaust valve assembly into the cylinder Assemble the valve shaft shaft arm j and spacer on...

Page 86: ...ton slowly and carefully so as not to damage the piston ring Position the cylinder head gasket Tightening torque 23 27 N m 2 3 2 7 kg m Install the cylinder head On the two stud bolts out of total fiv...

Page 87: ...4 2 I D NO LOCATION 4 3 REMOVAL AND DiSASSEMBLy 4 3 NEEDLE VALVE INSPECT N 4 ES FLOAT HEIGHT ADJUSTMENT 4 ES CARBURETOR IDLE ANGLE ADJUSTMENT 4 7 FUEL LEVEL INSPECTION 4 7 REASSEMBLY AND REM UNTING 4...

Page 88: ...RES position an auxiliary passage opens for supplying reserve fuel With the lever in OFF position both of the passages are closed Fuel tank cap water drain hose Left carburetor MAINTENANCE Fuel tank...

Page 89: ...t jet Float Power jet Air jet Filter ITEM Carburetor type I D Number Idle r min Fuel level Float height Main jet Jet Needle Needle jet Pilot jet Air screw A S Starter jet FUEL AND LUBRICATION SYSTEM 4...

Page 90: ...mber CD stamped on the carbure tor body according to its specifications REMOVAL AND DISASSEMBLY Remove the lower fairings Refer to page 7 1 Remove the fuel tank Remove the air cleaner Remove the screw...

Page 91: ...le Remove the idle adjustment bracket bolts Remove the hose Remove the E ring from the throttle stop screw knob NOTE When disconnecting the throttle cables and choke cable it is necessary to remove th...

Page 92: ...throttle valve CD and return spring Remove the throttle cable CD Throttle valve Jet needle E ring Ring Spring CID O ring j Top cap Remove the float chamber screws Remove the float pin and float CAUTIO...

Page 93: ...sible limits similar trouble will occur Conversely if the needle sticks gasoline will not flow into the float chamber Clean the float chamber and float parts with gasoline If the needle is worn as sho...

Page 94: ...to the specification Use a piece of 0 7 mm wire or a drill bit for checking the clearance Clearance 0 7 mm FUEL LEVEL INSPECTION Remove carburetor drain plug and install the fuel level gauge 09913 10...

Page 95: ...he throttle stop screw knob bracket on the frame The rear bolt should be tightened together with the fairing stay THROTTLE CABLE ADJUSTMENT Refer to page 2 6 Adjust the cable slack of right and left c...

Page 96: ...y out an air bleeding operation with the oil pump in place before returning the machine to the user To bleed the air hold the machine in standstill condition Loosen the screw CD to let out the air and...

Page 97: ...for 2 minutes For this operation the reading taken on the device should be 4 1 5 3 ml 09900 21602 CCI oil gauge Oil discharge amount 4 1 5 3 ml at 2 000 r min for 2 minutes NOTE Adjust both throttle...

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Page 99: ...COOLING SYSTEM CONTENTS COOLING SySTEM S 1 COOLING SOLUTION S 2 flEMO L INSJ ECTION S THERMOST T S 4 W TEfl TEMJ Efl TURE ND TEMJ Efl TURE G UGE S S...

Page 100: ...ependent con trol over the flow of water through the radiator The valve is actuated by the temperature sensitive wax contained in the pellet Referring to the following illustration the thermostat is i...

Page 101: ...o 55 or 60 according to the Fig 2 NOTE The characteristics of different anti freezes vary Read the label to know the protection you will have CAUTION Do not put in more than 60 anti freeze or less tha...

Page 102: ...by using the radiator tester in the following manner Fit the cap to the tester as shown and build up pressure slowly by operating the tester Make sure that the pressure build up stops at 110 10 kPa 1...

Page 103: ...on the thermometer Read the thermometer just when the thermostat drops to the bottom of the jar This reading which is the temperature level at which the thermostat valve begins to open should be anyw...

Page 104: ...n a stove heat the water to raise its temperature slow Iy reading the thermometer placed in the jar and also the ohmmeter A temperature gauge whose ohmic value does not change in the proportion indica...

Page 105: ...STEM CONTENTS CHARGING SySTEM 6 1 IGNITION SySTEM 6 5 AUTOMATIC EXHAUST VALVE CONTROL UNIT AND ACTUATOR 6 8 ATER TEMI ERATURE METER 6 1 OIL LEVEL GAUGE 6 14 LAMI E 6 15 SI EEDOMETER 6 16 S TCHES 6 18...

Page 106: ...ctifier and is converted into DC current then it charges the battery r r L ___________________ L ___________ _ Function of Regulator I I I I I I I While the engine r min is low and the generated volta...

Page 107: ...rection from point to point With the SCR conductive the current generated from the AC generator is short circuited through SCR without charging the battery and returns to AC generator again At the end...

Page 108: ...rmance and regulator rectifier NOTE When making this test be sure that the battery is in fully charged condition STD charging output 13 0 15 0V DC at 5 000 r min 09900 25002 Pocket tester AC GENERATOR...

Page 109: ...and windshield Using the pocket tester x 1 kn range measu re the resistance between the lead wires in the following table If the resistance checked is incorrect replace the regulator rectifier 09900...

Page 110: ...SCR connected to the capacitor becomes conductive turns on when a forward voltage signal is sent to its gate allowing the electric energy stored in the capacitor C to discharge instantly to the ignit...

Page 111: ...must be replaced 09900 28107 Electro tester STD Spark performance 8 mm 0 3 in IGNITION COl L Checking with Pocket Tester A SUZUKI pocket tester or an ohmmeter may be used instead of the electro teste...

Page 112: ...0 n COl UNIT Checking with Pocket Tester Using the SUZUKI pocket tester bring the EB probe and the e probe into contact with each lead wire of the COl unit check for continuity and measure the resista...

Page 113: ...10 CD 00 00 00 O B 2 20 2 20 2 20 3 30 2 20 00 5 30 00 2 20 00 B W 0 0 1 10 1 10 1 10 00 2 20 00 00 00 B Y 1 10 1 10 2 20 2 20 2 20 00 3 30 00 00 1 10 COl UNIT Checking with Ignitor Checker This sect...

Page 114: ...With all the lead wires properly connected check the CD I unit as follow Depress MODE 4 button then POWER button This time POWER lamp should come on If not battery is under charged NOTE In this check...

Page 115: ...e revolution detecting circuit counts the ignition primary pulse signal sent from the COl unit and outputs a current signal to the drive operating circuit when the engine speed has reached a predeterm...

Page 116: ...y at the this time The pulley should move within the angle range indicated by the arrow CAUTION Do not force the pulley in an attempt to move it beyond the angle range indicated by the arrow ACTUATOR...

Page 117: ...10 100 When the continuity and the resistance values are as shown in the above table the control unit is judged to be normal 09900 25002 SUZUKI Pocket tester Measure the resistance between the leads...

Page 118: ...gnition switch r I NI N2 LI N3 N4 I 0 I 11 12 I R I 1 1 I Ir I f L _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Battery I WATER TEMPERATURE METER INSPECTION As the coil spring is installed on the needle shaft of the...

Page 119: ...f its pointer indicates the H position when the resistor is changed to 19 2 ohms If either one or both indications are abnormal replace the water temperature meter with a new one WATER TEMPERATURE MET...

Page 120: ...6 15 ELECTRICAL SYSTEM LAMPS HEADLIGHT TAIL BRAKE LIGHT...

Page 121: ...ELECTRICAL SYSTEM 6 16 TURNS IGNAL LIGHT SPEEDOM E T E R...

Page 122: ...If the continuity measured is incorrect replace the respective parts 09900 25002 Pocket tester NOTE When making this test it is not necessary to remove the com bination meter B Turn L EB I U Lg Turn R...

Page 123: ...0 L 0 FRONT BRAKE SWITCH ON I OFF ELECTRICAL SYSTEM 6 18 REAR BRAKE SWITCH I B B ON 0 0 OFF NEUTRAL SWITCH BI BI Neutral position PASSING SWITCH I ONO Sh I OIR Y 0 0 HORN BUTTON I ONO Sh I G B W 0 0...

Page 124: ...fall Take precaution not to allow any of the fluid to spill Use wire cutters to cut the protruding part on the bottom of each container and leave in this position for about 10 minutes After confirmin...

Page 125: ...y charger CAUTION When recharging the battery remove the battery from the motorcycle NOTE Do not remove the stoppers on the battery top while recharg ing Recharging time 3A for half hour or O 3A for 5...

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Page 127: ...CHASSIS CONTENTS FA RING 7 1 FRONT WHEEL 7 3 FRONT BRAKE 7 7 FRONT FORK 7 13 STEERING STEM 7 18 REAR BRAKE 7 23 REAR WHEEL 7 28 T RE AND WHEEL 7 33 REAR SUSPENSION 7 38...

Page 128: ...7 1 CHASSIS FAIRING CONSTRUCTION CD Screen CV Upper fairing Fairing brace Lower fairing Center lower fairing...

Page 129: ...e hexagon wrench set Remove the speedometer cable For the left side lower fairing pull out the speedometer cable from the cable guides Remove the right and left rear view mirrors by loosening respecti...

Page 130: ...wrench set REMOUNTING Remount the fairing in the reverse order of removal FRONT WHEEL CONSTRUCTION Tightening torque Item N m kg m 50 80 5 0 8 0 15 25 1 5 2 5 CID CD Spacer Disc plate Bearing Spacer...

Page 131: ...calipers by loosening caliper mounting bolts Loosen the axle clamp bolts Loosen the axle shaft Draw out the axle shaft and take off the front wheel Remove the securing bolts and separate both the dis...

Page 132: ...dial gauge check the axle shaft for runout and replace it if the runout exceeds the limit 09900 20606 Dial gauge 1 100 09900 20701 Magnetic stand Service Limit 0 25 mm 0 0098 in WHEEL Make sure that...

Page 133: ...ith L on the left side SPEEDOMETER GEARBOX Before installing the speedometer gearbox grease it When installing the speedometer gearbox to the wheel hub be sure to align the four cutaway portions CD on...

Page 134: ...ke caliper mounting bolts FRONT BRAKE CONSTRUCTION MASTER CYLINDER AND CALlPER 0 ___ CD CD Reservoircap Diaphragm rr Reservoir tank Master cylinder Master cylinder holder Cupset 0 1Y 1 Piston 3 Piston...

Page 135: ...or long periods WARNING Brake fluid if it leaks will interfere with safe running and dis color painted surfaces Check the brake hose for cracks and hose joint for leakage before riding Remove the two...

Page 136: ...each rubber part for damage and wear DISC Using 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 is shown...

Page 137: ...reassembling the caliper Refer to page 2 13 MASTER CYLINDER REMOVAL AND DISASSEMBLY Place a rag underneath the union bolt on the master cylinder to catch the spilled drops of brake fluid Unscrew the...

Page 138: ...e piston primary cup and return spring CD Return spring CID Primary cup Piston Circlip Dust boot MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage Inspect t...

Page 139: ...line to wash them Apply brake fluid to the cylinder bore and all the internal parts to be inserted into the bore 99000 23110 SUZUKI BRAKE FLUID DOT3 4 When mounting the master cylinder on the handleba...

Page 140: ...t Spacer Pin l Spring seat Cap O ring Adjust bolt Inner tube cap Bolt Bolt Bolt f Apply TH READ REMOVAL AND DISASSEMBLY Remove the fairing Refer to page 7 1 Remove the front wheel Refer to page 7 3 Re...

Page 141: ...olt I spacer I spring seat I and spring I nvert the fork and stroke it several times to remove the oil Hold the fork inverted for a few minutes to drain the oil Remove the damper rod securing bolt wit...

Page 142: ...ny time the fork is disassembl ed Remove the oil lock piece CD INSPECTION OIL LOCK PIECE PISTON RING Inspect the oil lock piece piston ring for wear on damage INNER AND OUTER TUBES I nspect the inner...

Page 143: ...oil lock piece CD as shown in the photograph CYLINDER LOCK BOLT Refer to page 7 13 Tighten the cylinder lock bolts OUTER TUBE METAL WASHER AND OIL SEAL Install the outer tube metal washer and oil sea...

Page 144: ...cap upper surface located higher than the upper bracket by 10 mm 0 393 in and then tighten the clamp bolt FRONT FORK SETTI NG Turn the spring adjuster CD for desired stiffness NOTE The reference lines...

Page 145: ...J Right handlebar Right handlebar holder Left handlebar holder Right handlebar Balancer Spacer Balancer Handlebar cap Screw Steering stem head nut Front fork upper clamp bolt Handlebars set bolt Hand...

Page 146: ...assembly by loosening three bolts 09900 00401 L type hexagon wrench set Disconnect the lead wires of the meter assembly and the headlight assembly Remove the headlight assembly Using a center punch a...

Page 147: ...raw out the steering stem 09940 14911 Steering stem nut wrench NOTE Hold the steering stem lower bracket by hand to prevent it from falling Remove the lower race Push out the steering stem bearing rac...

Page 148: ...teering stem nut wrench Turn the steering stem bracket about five or six times all the way to the left and right so that the bearings will be seated properly Turn back the stem nut by 1 4 1 2 turn NOT...

Page 149: ...also individually available as spare parts Using the special bolts attach the ignition switch on the steering stem upper bracket in place and run in the bolts with the special tool 09930 11910 T orx...

Page 150: ...out the shims and pads CAUTION Do not operate the brake pedal while dismounting the pads Replace the brake pad as a set otherwise braking perform ance will be adversely affected CD Reservoir tank CID...

Page 151: ...ly Remove the pads Refer to page 7 23 Remove the caliper housing bolts and separate the caliper halves CD Caliper ID Pad Shim Clip Spring Pin Remove the O ring NOTE Once the caliper halves have been s...

Page 152: ...ch rubber part for damage and wear DISC Using 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 is shown be...

Page 153: ...Pull out the cotter pin CD and take off the pin CID Remove the two master cylinder mounting bolts Place a cloth underneath the union bolt on the master cylin der to catch spilled drops of brake fluid...

Page 154: ...ip with the special tool 09900 06105 Snap ring pliers Draw out the push rod cup piston set INSPECTION CYLINDER Inspect the cylinder bore wall for any scratches or other dam age PISTON CUP SET AND RUBB...

Page 155: ...he internals to be inserted into the bore CAUTION Bleed the air after reassembling master cylinder Refer to page 2 13 Adjust the rear brake light switch and brake pedal height after installation Refer...

Page 156: ...t Disengage the drive chain from the rear sprocket and remove the rear wheel Separate the rear sprocket mounting drum from the wheel Separate the rear sprocket from the sprocket mounting drum by loose...

Page 157: ...ight and left Refer to page 7 5 CAUTION The removed bearing should be replaced with a new one Remove the six cushions INSPECTION WHEEL AND SPROCKET MOUNTING DRUM BEARINGS Refer to page 7 5 AXLE SHAFT...

Page 158: ...o carry out the following steps WHEEL AND SPROCKET MOUNTING DRUM BEARINGS Apply grease before installing the bearings 99000 25010 SUZUKI Super grease A WHEEL BEARINGS Install the wheel bearing with th...

Page 159: ...rear wheel BRAKE DISC Make sure that the brake disc is clean and free of any greasy matter Refer to page 7 28 REAR SPROCKET Tighten the rear sprocket bolts to the specified torque Refer to page 7 28...

Page 160: ...For tire removal the following tools are required oo I m J I 8 A CD CD Remove the valve core from the valve stem and deflate the tire completely NOTE Mark the tire with chalk to note the position CD o...

Page 161: ...arm and dis mount the bead from the rim Turn the wheel over and dis mount the other bead from the rim Install the rim guide roller CID I nstall the rim protector and raise the tire bead with the tire...

Page 162: ...in A scratch or split at the side wall Tread depth less than 1 6 mm 0 06 in in the front tire and less than 2 0 mm 0 08 in in the rear tire Ply separation Tread separation Tread wear is extraordinari...

Page 163: ...ten the lock nut ID Do not overtighten the nut CD as this may distort the rubber packing and cause an air leak TIRE MOUNTING Apply a special tire lubricant or neutral soapy liquid to the tire bead CAU...

Page 164: ...ire could burst with sufficient force to cause severe injury Never stand directly over the tire while inflating it NOTE Check the rim line cast on the tire side walls It must be equidistant from the w...

Page 165: ...g torque Item N m kg m 22 34 2 2 3 4 85 110 8 5 11 0 CD Torque link Spacer Dust seal Bearing Washer Dust seal j Washer Spacer Bearing Spacer j Pivot shaft Bearing Plug Chain buffer Torque link nut CHA...

Page 166: ...0 70 100 7 0 10 0 70 100 7 0 10 0 CD Shock absorber upper mounting bolt CID Shock absorber lower mounting bolt Bolt Rear cushion rod CID Bolt Bolt ill Bearing Spacer Bearing Spacer Bearing Spacer Spa...

Page 167: ...he lower fender Remove the torque link Remove the rear brake caliper hose union bolt CAUTION Completely wipe off any brake fluid adhering to any part of motorcycle The fluid reacts chemically with pai...

Page 168: ...sion assembly Remove the shock absorber cushion lever and cushion rod from swingarm SWINGARM Remove the dust seals washers and spacers from swingarm Draw out the swingarm bearings with a swingarm bear...

Page 169: ...earing installer CAUTION The bearings removed should be replaced with new ones INSPECTION SWINGARM Insert the spacer into bearing and check the play by moving the spacer up and down If excessive play...

Page 170: ...disassemble the rear shock absorber unit It is unserviceable SWINGARM PIVOT SHAFT Check the pivot shaft runout with a dial gauge If it exceeds the limit replace with a new one 09900 20606 Dial gauge 1...

Page 171: ...installer 09941 34513 Steering outer race installer NOTE When installing the bearings punch marked side of bearing comes outside Apply grease to the spacers and dust seals when installing them 99000 2...

Page 172: ...CHASSIS CUSHION LEVER Force fit the bearings into the cushion lever with a bearing installer 09924 84510 Bearing installer Apply grease to the spacers when installing them 99000 25010 SUZUKI Super Gre...

Page 173: ...Left side Right side Shock absorber Swing arm Cushion lever rod Apply SUZUKI Super grease A Cushion lever Apply SUZUKI Super grease A T4 Apply SUZUKI Super grease A tt i5 Ts Apply SUZUKI Super grease...

Page 174: ...hion lever and cushion rods on the swingarm I nstall the upper part of rear shock absorber onto frame NOTE Install the shock absorber with the damping force adjuster located on the left Install the fr...

Page 175: ...talling the rear suspension and wheel the following adjustments are required before driving Drive chain Refer to page 2 10 Rear brake Refer to page 2 11 Tire pressure Refer to page 2 14 Chassis bolts...

Page 176: ......

Page 177: ...SERVICING INFORMATION CONTENTS TROUBLESHOOTING 8 1 WIRING DIAGRAM 8 7 CABLE HARNESS AND HOSE ROUTING 8 8 SPECIAL TOOLS 8 16 TIGHTENING TORQUE 8 19 SERVICE DATA 8 22...

Page 178: ...ston or cylinder worn down 2 Combustion chamber fouled with carbon 3 Piston pin or piston pin bore worn 4 Piston ring groove worn 5 Piston pin bearing worn Noise seems to come from clutch 1 Worn splin...

Page 179: ...fective ignition coil Replace 4 Defective pick up coil or CDI unit Replace 5 Float chamber fuel level too low Adjust 6 Clogged air cleaner element Clean 7 Clogged fuel pipe resulting in inadequate fue...

Page 180: ...ottle valve is not operating properly Check throttle valve for operation 4 Filter is clogged Check and clean Overflow and fuel 1 Needle valve is worn or damaged Replace level fluctuations 2 Float is n...

Page 181: ...carburetors Generator does 1 Open or short in lead wires or loose lead connections Repair or replace or not charge retighten 2 Shorted grounded or open generator coils Replace 3 Shorted or punctured...

Page 182: ...es Clean too rapidly 2 Battery is too old Replace BRAKES Complaint Symptom and possible causes Remedy Insufficient brake 1 Leakage of brake fluid from hydraulic system Repair or replace power 2 Worn p...

Page 183: ...k oil too viscous Replace too stiff 2 Too much fork oil Drain excess oil Noisy front 1 Not enough fork oil Refill suspension 2 Loosen nuts on suspension Retighten Wobbly rear wheel 1 Distorted wheel r...

Page 184: ...11Ulj I TIff I I I I I I I UI COOLANT TEMPERATURE GAUGE g 4 1 o o NEUTRAL SIDE STAND HORN INDICATOR SWITCH LIGHT SWITCH D D IGNITION COIL NO 1 iD IGNITION COIL NO 2 m REAR BRAKE LIGHT SWITCH REAR TURN...

Page 185: ...SERVICING INFORMATION 8 8 WIRE HARNESS Clamp Magneto Side stand switch Earth terminal of water temp with thermostat clamp A...

Page 186: ...brake hose pass To right carburetor Throttle cable left Oil pump cable Clutch cable guide Choke cable guide Startor cable below wiring harness 1HIt lI l Throttle cable No 5 Oil pump cable Choke cable...

Page 187: ...Thread Lock 1342 Pulser coil No 1 Speedometer cable Front fork SERVICING INFORMATION 8 10 To magneto cover side G _ Clamp 1 _ Lead wire Pulser coil No 2 Neutral indicator light switch Speedometer Rad...

Page 188: ...n hose frt Clamp wi ing h rness and oil 1 r hose and 011 dram hose J I Y _ _ i J f v I r I i jj drain hose J I tt j I I v yt _ J e J ijj _ LJ U Clamp e I m 0 J 0 I m 0 0 C j Z G Bleeding hole upper si...

Page 189: ...ck Tighten wiring harness and oil hose and oil drain together Front Clamp Engine brather hose To hose guide SERVICING INFORMATION 8 12 Fuel tank water drain hose Fuel hose Tighten wiring harness and d...

Page 190: ...8 13 SERVICING INFORMATION OIL HOSE ROUTING Oil check valve Oil hose clamp Oil hose cover No 2 l U pper Oil check valve crankcase Drive shaft retainer Oil hose No 1 Oil hose No 2 Oil hose No 2...

Page 191: ...SERVICING INFORMATION 8 14 FUEL TANK HOSE ROUTING Fuel tank breather hose Fuel tank Fuel cock ON position Left carb Right carb RES position...

Page 192: ...o not twist the hose when installed Turn the hose fitting all the way until it stops with the stopper to locate it in the correct angle while tightening NOTE Do not twist the hose when installed Turn...

Page 193: ...n rod stopper 09900 06105 Snap ring pliers Micrometer 1 100 mm 25 50 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20805 Tire depth gauge 09900 26006 Engine tachometer 09910 34510 Piston pin pu...

Page 194: ...seal Clutch sleeve hub 09921 20200 Bearing puller 09924 84510 installer holder Bearing remover 17 20 mm Bearing installer set 09925 98220 09930 11910 09930 14530 09930 30102 09930 30190 Bearing insta...

Page 195: ...ring remover 09943 88211 Bearing installer 09941 54911 Bearing outer race remover 09941 74910 Steering bearing installer SERVICING INFORMATION 8 18 09941 84510 Bearing remover 09943 74111 Front fork o...

Page 196: ...ission cover nut Clutch sleeve hub nut Clutch spring bolt Clutch cover bolt Magneto rotor nut Water pump impeller bolt Water temp gauge Radiator mounting nut Carburetor mounting bolt N m kg m 14mm 20...

Page 197: ...ke hose union bolt 15 20 1 5 2 0 Air bleeder valve Front and rear 6 9 0 6 0 9 Front and rear disc bolt 15 25 1 5 2 5 Swingarm pivot nut 85 110 8 5 11 0 Rear brake rod lock nut 15 25 1 5 2 5 Rear shock...

Page 198: ...rked bolt 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...

Page 199: ...to groove clearnce 1st 2nd 0 02 0 06 0 0008 0 0024 Piston pin bore 16 002 16 010 16 036 0 6300 0 6303 0 6313 Pistion pin 0 0 15 995 16 000 15 980 0 6297 0 6299 0 6291 CON ROD CRANKSHAFT Unit mm in IT...

Page 200: ...ratio 3 066 46 15 Gear ratios Low 2 454 27111 2nd 1 625 26 16 3rd 1 235 21117 4th 1 045 23 22 5th 0 916 22 24 Top 0 840 21 25 Shift fork to groove clearance 0 1 0 3 0 5 0 004 0 011 0 0196 Shift fork...

Page 201: ...ITEM SPECIFICATION NOTE Ignition timing 14 B T D C at 1 300 r min Spark plug Type NGK BR9ES Gap 0 7 0 S Spark performance Over S 0 3 at 1 atm Ignition coil resistance Primary B y W L 0 17 0 230 Secon...

Page 202: ...8 0 16 Rear 4 8 5 1 4 5 0 19 0 20 0 18 Brake disc runout 0 3 0 01 Master cylinder bore Front 15 870 15 913 0 6248 0 6264 Rear 12 700 12 743 0 4999 0 5016 Master cylinder piston Front 15 827 15 854 0 6...

Page 203: ...gal Engine oil type SUZUKI CCI or CCI SUPER OIL Engine oil tank capacity 1 1 L 1 2 1 0 US Imp qt Transmission oil type SAE 10W 40 Transmission oil capacity Change 700 ml 23 6 24 6 US Imp oz Overhaul 8...

Page 204: ......

Page 205: ...learly indicated with the asterisk marks Please refer to the section 1 though 8 for details which are not given in this section r CONTENTS SPECIFICATION 9 1 SERVICE DATA 9 2 TIGHTENING TORQUE 9 7 THRO...

Page 206: ...114 links These specifications are subject to change without notice Asterisk mark indicates the new L model specifications CHASSIS Front suspension Telescopic coil spring oil damped spring 5 way adjus...

Page 207: ...0 06 0 0008 0 0024 Piston pin bore 16 002 16 010 16 036 0 6300 0 6303 0 6313 Piston pin 0 0 15 995 16 000 15 980 0 6297 0 6299 0 6291 CONROD CRANKSHAFT Unit mm in ITEM STANDARD LIMIT Conrod small end...

Page 208: ...ow 2 454 27 11 2nd 1 625 26 16 3rd 1 235 21 17 4th 1 045 23 22 5th 0 916 22 24 Top 0 840 21 25 Shift fork to groove clearance 0 1 0 3 0 5 0 004 0 011 0 0196 Shift fork groove width No 1 4 0 4 1 No 2 0...

Page 209: ...OTE Ignition timing 14 B T D C at 1 300 r min Spark plug Type NGK BR9ES Gap 0 7 0 8 Spark performance Over 8 0 3 at 1 atm Ignition coil resistance Primary B Y W L 0 17 0 23 n Secondary Plug cap Termin...

Page 210: ...kness Front 4 3 4 7 4 0 0 17 0 18 0 16 Rear 4 8 5 1 4 5 0 19 0 20 0 18 Brake disc runout 0 3 0 01 Master cylinder bore Front 15 870 15 913 0 6248 0 6264 Rear 12 700 12 743 0 4999 0 5016 Master cylinde...

Page 211: ...ere they are available Fuel tank including reserve 17 L 4 5 3 7 US Imp gal reserve 5 5 L 1 5 1 2 US I mp gal Engine oil type SUZUKI CCI or CCI SUPER 01 L Engine oil tank capacity 1 1 L 1 2 1 0 US I mp...

Page 212: ...ver bolt Transmission cover nut Clutch sleeve hub nut Clutch spring bolt Clutch cover bolt Magneto rotor nut Water pump impeller bolt Water temp gauge Radiator mounting nut Carburetor mounting bolt kg...

Page 213: ...Front and rear 6 9 0 6 0 9 Front and rear disc bolt 15 25 1 5 2 5 Swingarm pivot nut 85 110 8 5 11 0 Rear brake rod lock nut 15 25 1 5 2 5 Rear shock absorber mounting nut 40 60 4 0 6 0 Upper and lowe...

Page 214: ...shaft arm with the boss provided on the side of the throttle pulley Attach two throttle sensor fitting screws and bring them to finger tight Turn the sensor body all the way in the direction indicated...

Page 215: ...V250L 90 MODEL 9 10 CD Top cap CID Spring Jet needle Throttle valve Ring Needle jet f Air screw stop adjuster Throttle valve Needle valve O ring Main jet Pilot jet Float Power jet Airjet Filter Hose H...

Page 216: ...CR s gate The moment the capacitor discharges the elec tricalenergy to the primary windings a very high voltage is induced within the secondary windings and a hot spark jumps across the air gap betwee...

Page 217: ...ODEL 9 12 Ignition switch Solenoid valve I The air valve control unit receives the ignition coil primary pulse signal which is then processed for deter mining the current engine revolution speed When...

Page 218: ...lead is connected to the battery 8 ter minal and Red lead to the ffi terminal Before connecting the power source leads make sure both POWER button and START switch are in off posi tion POWER button no...

Page 219: ...ely in any throttle position EXHAUST VALVE OPERATION Throttle position Revolution dial Exhaust valve CLOSED 0 8 CLOSED POSITION CLOSED 4 OPEN at 8 CLOSE 4 HALF OPEN ANY POSITION 9 11 1 0 OPEN POSITION...

Page 220: ...ween the leads Tester range x kn W BI B W O B B w mB W R W Br W Unit Approx kn E8 Probe of tester to Br W R W B W O B Br W 0 1 5 0 1 5 00 0 R W 0 1 5 0 1 5 00 Q BIW 0 1 5 0 1 5 00 Cl Q O B 1 10 1 10 0...

Page 221: ...asure the resistance between the leads Tester range x kn Unit Approx kn Probe of tester to BIY BIW OIB Y G BIY 00 00 00 0 0 Cl BIW 100 00 00 1 5 0 0 0 OIB c e 00 5 20 10 50 Q Y G 00 00 00 AIR SOLENOID...

Page 222: ...he EB probe and the e probe into contact with each lead wire of the COl or Neutral Circuit check for continuity and measure the resistance value 09900 25002 Pocket tester When the continuity and the r...

Page 223: ...following table MAGNETO Circuit is judged to be normal Unit Approx kn EB Probe of tester to Br R W B Br 1 10 1 10 1 10 o R 1 10 1 10 1 10 Q 0 0 0 c W 1 10 1 10 0 CD B 1 10 1 10 0 ACTUATOR CIRCUIT Che...

Page 224: ...g the SUZUKI pocket tester bring the EB probe and the 8 probe into contact with each lead wire of the Throt tle Sensor Circuit check for continuity and measure the resistance value 09900 25002 Pocket...

Page 225: ...tainer I nsert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any of the fluid...

Page 226: ...aps Using SUZUKI pocket tester measure the battery voltage The tester should indicate more than 12 SV DC as shown in the Fig If the battery voltage is lower than the specifica tion charge the battery...

Page 227: ...5A at any time After recharging wait for more than 30 minutes and check the battery voltage with a pocket tester If the battery voltage is less than the 12 5V recharge the battery again I f battery vo...

Page 228: ...179 mm 7 05 in 2 9 2 Dual riding 3 179 mm 7 05 in 2 9 2 Adjust range 5 5 mm 8 20 in 4 20 NOTE REAR SUSPENSION DAMPING ADJUSTMENT Fully turn the damping force adjuster clockwise it is at 0 position an...

Page 229: ...o tIll 1 ii go H rU PA L P U S H i 0 HORN DIMMER SWITCH TURN SIGNAL HORN SWITCH r L _____ HTSWI _____ j TEMP GAUGE NEUTRAL SIDE STANDI IGNITION SOLENOID VALEVE INDICATOR SWITCH COIL 1 E WIRE COlOR B B...

Page 230: ...temp with thermostat Electric parts holder I Clamp earth terminal with ignition coil Control unit coupler White Control unit coupler 8 Spare face bag set rightward Control unit coupler White WI lp i W...

Page 231: ...lamp upward Pass lead wire of rear brake Clamp Wiring harness battery minus lead wire oil level switch lead wire Base for positioning Clamp switch between brake hose and frame A Clamp wiring harness H...

Page 232: ...thread lock 1342 Clamp To magneto side Clamp I f r Lead wire Pulser coil No 2 Neutral indicator light switch Pulser coil No 1 Clamp Clamp side stand switch lead wire with neutral lead wire Notice not...

Page 233: ...Clamp oil hose Oil check valve I _ 20o Oil hose clamp Right cylinder Upper crankcase o r J o en m lJ o c I Z Cl a CO N U I o r c d o 3 Cl Cl m r C Q N co...

Page 234: ...9 29 RGV250L 90 MODEL REAR SHOCK ABSORBER RESERVOIR TANK ROUTING Rear shock absorber...

Page 235: ...FUEL AND AIR HOSE ROUTING To Fuel tank Hoses Throttle stop J A t screws To Fuel cock RGV250L 90 MODEL 9 30 nction box Air solenoid valve Fuel tank water drain hose Fuel hose Air hose...

Page 236: ......

Page 237: ...TIONS 10 1 SERVICE DA TA 10 2 TIGHTENING TORQUE 10 7 CHANGES 10 9 MAGNETO ROTOR 10 9 STATOR 10 9 CARBURETOR AIR CONTROL SySTEM 10 10 CONTROL UNIT INSPECTION 10 12 THROTTLE SENSOR 10 14 EXHAUST VAL VE...

Page 238: ...cifications are subject to change without notice Asterisk mark indicates the New M model specifications CHASSIS Front suspension Inverted telescopic coil spring oil damped inner rod type spring 5 way...

Page 239: ...arance 1st 2nd 0 02 0 06 0 0008 0 0024 Piston pin bore 16 002 16 010 16 036 0 6300 0 6303 0 6313 Piston pin 0 0 15 995 16 000 15 980 0 6297 0 6299 0 6291 CONROD CRANKSHAFT Unit mm in ITEM STANDARD LIM...

Page 240: ...2nd 1 625 26 16 3rd 1 235 21 17 4th 1 045 23 22 5th 0 916 22 24 Top 0 840 21 25 Shift fork to groove clearance 0 1 0 3 0 5 0 004 0 011 0 0196 Shift fork groove width No 1 4 0 4 1 No 2 0 157 0 161 No...

Page 241: ...AL Unit mm in ITEM SPECIFICATION NOTE Ignition timing 10 B T D C at 1 300 r min Spark plug Type NGK BR9ECM ND W27EMR C Gap 0 7 0 8 Spark performance Over 8 0 3 at 1 atm Ignition coil resistance Primar...

Page 242: ...17 0 18 0 16 Rear 4 8 5 1 4 5 0 19 0 20 0 18 Brake disc runout 0 3 0 01 Master cylinder bore Front 15 870 15 913 0 6248 0 6264 Rear 12 700 12 743 0 4999 0 5016 Master cylinder piston Front 15 827 15 8...

Page 243: ...where they are available Fuel tank including reserve 16 L 4 2 3 5 US Imp gal reserve 3 5 L 0 9 0 S US Imp gal Engine oil type SUZUKI CCI or CCI SUPER OIL Engine oil tank capacity 1 1 L 1 2 1 0 US Imp...

Page 244: ...28 1 8 2 8 13 0 20 0 Down tube 22 28 2 2 2 8 16 0 20 0 Kick starter lever bolt 18 28 1 8 2 8 13 0 20 0 Cylinder head nut 26 27 2 6 2 7 19 0 19 5 Cylinder nut 26 27 2 6 2 7 19 0 19 5 Crankcase bolt 6m...

Page 245: ...bolt 18 28 1 8 2 8 13 0 20 0 Swingarm pivot nut 85 115 8 5 11 5 61 5 83 0 Rear brake rod lock nut 15 25 1 5 2 5 11 0 18 0 Rear shock absorber mounting nut 48 72 4 8 7 2 35 0 52 0 Upper and lower Rear...

Page 246: ...LY Wipe off the oily matter from the tapered portion of the rotor and also the crankshaft Apply THREAD LOCK SUPER 1324 to the nut and tighten it to the specified torque 99000 32120 THREAD LOCK SUPER 1...

Page 247: ...ry air to the pilot air and main air passages This control is performed by the control unit which receives the throttle sensor and engine revolution input signals And after processing these signals th...

Page 248: ...10 11 RGV250M 91 MODEL PILOT AIR PASSAGE MAIN AIR PASSAGE A i r _ Fuel Air Mixture Fuel A i r Fuel Air Mixture Fuel...

Page 249: ...ure START switch is in off position before connecting the power source lead NOTE When making this test be sure that the battery is fully charged condition 1 SPARKING CHECK Place the spark plugs on eac...

Page 250: ...odel For E 02 04 21 2 4 For E 1 model At 2 000 rpm OFF I and 34 models At 500 rpm OFF At 4 000 rpm ON OFF At 500 rpm OFF OFF 1 At 1 000 rpm ON OFF At 6 000 rpm OFF 2 4 6 I At 1 000 rpm ON 0 51 2 At 2...

Page 251: ...e the throttle sensor mounting screws This com ponent is PRE SET at the factory by the very specialized equipment EXHAUST VALVE Valve guide OPERATION LOW SPEED RANGE MIDDLE SPEED RANGE RGV250M 91 MOOE...

Page 252: ...EASSEMBLY Apply SUZUKI THREAD LOCK SUPPER 1322 Spring Valve guide No 2 Valve No 1 Valve Apply THREAD LOCK SUPER 1322 to the lock bolt and tighten it 99000 32110 THREAD LOCK SUPER 1322 Tightening torqu...

Page 253: ...TH READ LOCK SUPE R 1 1322 to the exhaust valve lever set screw 99000 32110 THREAD LOCK SUPER 1322 EXHAUST VALVE CABLE LOCATION OF ADJUSTERS Throttle cable adjuster 1 exhaust valve cable adjuster 2 e...

Page 254: ...et to the battery 8 terminal Actuator slightly moves On this condition turn OF F the ignition switch Disconnect the lead wire from the battery e terminal Actuator does not move Check that the index li...

Page 255: ...r cable is lightly pushed sideways by finger For Right cylinder exhaust valve cable Give the cable play when the outer cable is lightly pulled by finger Tighten the lock nuts Cable slack Approx 3 5 mm...

Page 256: ...10 19 RGV250M 91 MODEL ACTUATOR REASSEMBLY o o Align the index lines Tightening torque N m kg m Ib ft 4 6 0 4 0 6 3 0 4 5 Apply SUZUKI THREAD LOCK SUPPER 1322...

Page 257: ...to the full close position Adjust the throttle valve idle position by turning the throttle stop screw so that the minimum clearance between the throttle valve and the bore comes to the specification U...

Page 258: ...10 21 RGV250M 91 MODEL TRANSMISSION DRIVESHAFT COUNTERSHAFT...

Page 259: ...FRONT FORK Outer tube Oil lock piece Inner tube Spring joint Spring Dust seal RGV250M 91 MODEL 10 22 Inner rod...

Page 260: ...ront fork clamp bolts Remove the stopper ring CD and spring adjuster Remove the spring adjuster pin assembly CID Loosen the front fork cap Remove the front fork cap stopper screw Compress the fork spr...

Page 261: ...es Remove the damper rod bolt with the hexagon wrench 09900 00401 ilL type hexagon wrench set Remove the inner rod damper rod cartridge out of the inner tube CAUTION Do not attempt to disassemble the...

Page 262: ...e and outer tube sliding surface for any scuffing Fork spring Measure the fork spring free length If it is shorter than the service limit replace it with a new one Service limit 330 mm 13 0 in REASSEM...

Page 263: ...ps with a vinyl film to prevent oil seal damage Do not use solvents for washing to prevent oil seal damage CD Dust seal CV Oil seal stopper ring Oil seal Oil seal retainer Anti friction metal outer tu...

Page 264: ...inner rod holder NOTE Pour front fork oil up to the top of the outer tube to find bubbles while bleeding air Pour specified front fork oil up to the top level of the outer tube again Fully stroke the...

Page 265: ...10 24 Tighten the front fork cap stopper screw Install the spring adjuster pin assembly CD spring adjuster and stopper ring NOTE When installing the spring adjuster pin assembly CD align the three pi...

Page 266: ...SE Th 1322 Apply THREAD LOCK SUPER 1322 Tightening torque Item N m Kg m 6 9 0 6 0 9 20 31 2 0 3 1 DRIVE CHAIN To cut and rejoin the drive chain use the special tool in the following procedures 09922 2...

Page 267: ...e fits over the chain joint pin properly Tighten the pressure bolt A with the bar Turn in the pressure bolt B with the bar and force out the drive chain joint pin CAUTION Continue turning in the press...

Page 268: ...positioning the joint plate on the tool bring its stamp mark on the joint plate holder side Set the drive chain on the tool as illustrated and turn in the adjuster bolt CID to secure the wedge holder...

Page 269: ...tely 7 8 turn the pressure bolt A with the bar until the pin end diameter becomes the specified dimension Pin end diameter specification DID 5 3 5 6 mm 0 20 0 22 in RK 5 4 5 8 mm 0 21 0 23 in CAUTION...

Page 270: ...RBER AND CUSHION LEVER Tightening torque 48 72 N m 4 8 7 2 kg m 35 0 52 0 Ib ft f 84 120 N m 8 4 12 0 kg m 61 0 87 0 Ib ft CD Shock absorber Cushion lever rod Cushion lever Spacer Spacer Spacer G Appl...

Page 271: ...the rear fenderCD Remove the shock absorber upper mounting bolt Remove the shock absorber lower mounting bolt Remove the shock absorber Cut the drive chain with the special tool Refer to page 30 0992...

Page 272: ...ingarm pivot nut Remove the pivot thrust adjuster lock nutCD 09940 14940 Pivot thrust adjuster lock nut wrench Loosen the pivot thrust adjuster 09940 14950 Pivot thrust adjuster wrench Remove the swin...

Page 273: ...ring with a new one Cushion lever rod Inspect the spacer for any flaws or other damage Insert the spacer into the bearing and check the play by mov ing the spacer up and down If an excessive play is n...

Page 274: ...941 44910 Swingarm bearing remover CAUTION The removed bearings should be replaced with new ones Cushion lever Remove the spacers Remove the bearings by using the special tool 09923 73210 Bearing remo...

Page 275: ...wing points Swingarm Press fit the bearings into the swingarm pivot 09941 34513 Steering outer race installer NOTE When installing the bearings punch marked side of bearing faces outside Apply grease...

Page 276: ...A REASSEMBLY INFORMATION Tightening torque N m kg m 84 120 8 4 12 0 Apply SUZUKI SUPER GREASE A Ib ft LEFT SIDE RIGHT SIDE Apply SUZUKI SUPER GREASE A Apply SUZUKI SUPER GREASE A Tightening torque N m...

Page 277: ...swingarm pivot nut to the specified torque 85 115 N m 8 5 11 5 kg m 61 5 83 0 Ib ft 3 Tighten the lock nut to the specified torque 60 70 N m 6 0 7 0 kg m 43 5 50 5 Ib ft Swingarm pivot shaft Swingarm...

Page 278: ...riding 4 179 mm 7 05 in NOTE REAR SUSPENSION DAMPING ADJUSTMENT Rear Damping force Extension Compression Rebound 1 Standard 1 2 9 2 2 9 2 2 9 2 Fully turn the damping force adjuster clockwise it is a...

Page 279: ...RN A_m A t SOLENOID HANDLE SWITCH L t VALVE 2 1 I ACTUATOR 12V WATER TEMP GAUGE IGNITION COIL 1 1 BATTERY IGNITION COIL 2 SOLENOID VALVE 1 WIRECOLOR B Black R Red Br W Brown with White tracer Br Brown...

Page 280: ...Wiring harness Clamp Clamp Pass the meter and pilot box lead wire under the reservoir tank hose Clamp Ignition switch Wiring harness Clamp Water temperature earth lead wire To handle switch RH Genera...

Page 281: ...oEB o cc CD RGV250M 91 MOOEL 10 44...

Page 282: ...hose 1 1 Fuel cock joint hose Reservoir tank inlet hose Idle adjuster Guide Throttle cable Brake hose Throttle cable No 3 I nterference hose Reservoir tank inlet hose Choke cable Pilot air solenoid va...

Page 283: ...solenoid hose Reservoir tank inlet hose Fuel hose I nterference hose Main air solenoid hose Drain tube IVV Overflow hose Radiator hose Throttle No 1 cable Throttle No 2 cable J o en m 0 o C f 2 C J J...

Page 284: ...c I I I Lt 3 T if Face the air bleeding hole on the hermo u id rr A A j a C N Con s c C 3 c C m C...

Page 285: ...rong connection of hoses otherwise piston seizuring may happen Pilot air hose Adjust the following points after assembling the carburetor Adjustment of engine idle speed Adjustment of throttle cable p...

Page 286: ...hose Brake hose No 1 Keep union in touch with the stopper taking care of union angle Brake disc J 1 Brake hose joint Brake hose No 2 LH Caliper JJ l Q CC 2 a t C to N U I JJ l s cD m J 0 Q Cl m Cl m...

Page 287: ...cylinder Keep union in touch with the stopper taking care of union angle Reservoir tank Brake hose plate Press the clamp after assembling sleeve 10 11 mm 0 m l 0 OJ 0 l m z o rn m 0 o C I 2 G c CO N...

Page 288: ...10 51 RGV250M 91 MODEL RESERVOIR TANK HOSE ROUTING C 0 x l E E 1 0...

Page 289: ...ions and service data are clearly indicated with the asterisk marks Please refer to the sec tions 1 through 10 for details which are not given in this section CONTENTS SPECIFICA TIONS 11 1 SERVICE DAT...

Page 290: ...520SM0l9 114 links These specifications are subject to change without notice Asterisk mark indicates the New N model specifications CHASSIS Front suspension Inverted telescopic coil spring oil damped...

Page 291: ...Piston ring to groove clearance 1st 2nd 0 02 0 06 0 0008 0 0024 Piston pin bore 16 002 16 010 16 036 0 6300 0 6303 0 6313 Piston pin 0 0 15 995 16 000 15 980 ro 6297 0 6299 0 6291 CON ROD CRANKSHAFT...

Page 292: ...27 11 2nd 1 625 26 16 3rd 1 235 21 17 4th 1 045 23 22 5th 0 916 22 24 Top 0 840 21 25 Shift fork to groove clearance 0 1 0 3 0 5 0 004 0 011 0 0196 Shift fork groove width No 1 4 0 4 1 No 2 0 157 0 1...

Page 293: ...Unit mm in ITEM SPECIFICATION NOTE _ Ignition timing 10 B T D C at 1 300 r min Spark plug Type NGK BR9ECM ND W27EMR C Gap 0 7 0 8 Spark performance Over 8 0 3 at 1 atm Ignition coil resistance Primar...

Page 294: ...ckness Front 4 3 4 7 4 0 0 17 0 18 0 16 Rear 4 8 5 1 4 5 0 19 0 20 0 18 Brake disc runout 0 3 0 01 Master cylinder bore Front 15 870 15 913 0 6248 0 6264 Rear 12 700 12 743 0 4999 0 5016 Master cylind...

Page 295: ...and should be unleaded type where they are available Fuel tank including reserve 16 L 4 2 3 5 US Imp gal reserve 3 5 L 0 9 0 8 US Imp gal Engine oil type SUZUKI CCI or CCI SUPER 01 L Engine oil tank c...

Page 296: ...11 7 RGV250N 92 MODEL TIRE PRESSURE NORMAL RIDING COLD INFLATION SOLO RIDING DUAL RIDING TIRE PRESSURE kPa kg cm 2 psi kPa kg cm 2 psi FRONT 200 2 00 29 200 2 00 29 REAR 225 2 25 33 250 2 50 36...

Page 297: ...ush the oil pump pulley groove and thus oil pump is operated by the oil pump pulley when the exhaust valve is over half opening condition DISASSEMBL Y Remove the oil pump pulley by removing the boltCD...

Page 298: ...oil pump pulley to the lug on the actuator pulley THROTTLE SENSOR CAUTION Do not remove the throttle sensor CD from the throttle cable case This component is PRE SET at the factory by the very special...

Page 299: ...SPENSION SETTING SUSPENSION SETTING TABLE GEAR POSITION Low 2nd 3rd and 4th At 2000 rpm OFF At 4 000 rpm liON At 6 000 rpm OFF GEAR POSITION Neutral 5th and Top Any rpm OFF Front Spring preload Spring...

Page 300: ...o Jo Jo I a 8 J a I a I B t B 1 D AlD eo a P Ia II Mla 0 IFo4 H O cc M lS 0 0 JgH O AI AlO a o a o a I I 0 0 If H ill Al6 HIM i Mla MI6 7 Ir D f I e 0 J 8 8 8 18 0 10 MI6 J o Jo m m 0 n i Urn n CDL m...

Page 301: ...us lead wire ahead of the battery box Clamp RGV250N 92 MODEL 11 12 Clamp Generator Neutral switch Clamp Tighten the water temp grolind lead wire with the thermostat box Pass the combination meter and...

Page 302: ...11 13 RGV25DN 92 MODEL CABLE ROUTING Throttle No 4 cable Clamp l J ali Crankcase Pass through the seat lock cable behind the frame Seat lock cable Clamp Frame...

Page 303: ...air solenoid filter Be sure to face the hole on the pilot air solenoid filter to the downward Main air solenoid valve Throttle No 1 cable Throttle No 2 cable Main air solenoid fi Iter Main air soleno...

Page 304: ...11 15 RGV250N 92 MODEL CAUTION Be careful not to make the wrong connection of hoses otherwise piston seizuring may happen Air filter To fuel cock Pilot air solenoid valve...

Page 305: ...RGV250P 93 MODEL CONTENTS SPECIFICA TIONS 12 1 SERVICE DATA 12 2...

Page 306: ...ive chain DID 520V2 or RK520SMOZ9 114 links These specifications are subject to change without notice CHASSIS Front suspension Rear suspension Steering angle Caster Trail Turning radius Front brake Re...

Page 307: ...27 Piston ring to groove clearance 1st 2nd 0 02 0 06 0 0008 0 0024 Piston pin bore 16 002 16 010 16 036 0 6300 0 6303 0 6313 Piston pin 0 0 15 995 16 000 15 980 0 6297 0 6299 0 6291 CONROD CRANKSHAFT...

Page 308: ...3 14 Gear ratios Low 2 454 27 11 2nd 1 625 26 16 3rd 1 235 21 17 4th 1 045 23 22 5th 0 916 22 24 Top 0 840 21 25 Shift fork to groove clearance 0 1 0 3 0 5 0 004 0 011 0 0196 Shift fork groove width N...

Page 309: ...cable play 0 5 1 0 mm 0 02 0 04 in ELECTRICAL Unit mm in ITEM SPECIFICATION NOTE Ignition timing 10 B T D C at 1 300 r min Spark plug Type NGK BR9ECM ND W27EMR C Gap 0 7 0 8 Spark performance Over 8 0...

Page 310: ...Unit mm in ITEM STANDARD LIMIT Rear brake pedal height 60 70 2 36 2 76 Brake disc thickness Front 4 3 4 7 4 0 0 17 0 18 0 16 Rear 4 8 5 1 4 5 0 19 0 20 0 18 Brake disc runout 0 3 0 01 Master cylinder...

Page 311: ...pivot shaft runout 0 3 FUEL OIL COOLANT ITEM SPECIFICATION NOTE Fuel type The gasoline used should be graded 85 to 95 octane in Research Method and should be unleaded type where they are available Fue...

Page 312: ...e with aluminum radiator mixed with distilled water only at the ratio of 50 50 Radiator including reserve 1 900 ml 2 0 1 7 US Imp qt TIRE PRESSURE NORMAL RIDING COLD INFLATION SOLO RIDING DUAL RIDING...

Page 313: ...RGV250R 94 MODEL CONTENTS SPECIFICA TIONS 13 1 SERVICE DATA 13 2 WIRING DIAGRAM 13 8 HOSE ROUTING 13 9...

Page 314: ...DID 520V2 or RK520SMOZ9 114 links These specifications are subject to change without notice CHASSIS Front suspension Inverted telescopic coil spring oil damped inner rod type spring 5 way adjustable...

Page 315: ...27 Piston ring to groove clearance 1st 2nd 0 02 0 06 0 0008 0 0024 Piston pin bore 16 002 16 010 16 036 0 6300 0 6303 0 6313 Piston pin 0 0 15 995 16 000 15 980 0 6297 0 6299 0 6291 CONROD CRANKSHAFT...

Page 316: ...071 43 14 Gear ratios Low 2 454 27 11 2nd 1 625 26116 3rd 1 235 21 17 4th 1 045 23 22 5th 0 916 22 24 Top 0 840 21 25 Shift fork to groove clearance 0 1 0 3 0 5 0 004 0 011 0 0196 Shift fork groove wi...

Page 317: ...LECTRICAL Unit mm in ITEM SPECIFICATION NOTE Ignition timing 10 B T D C at 1 300 r min Spark plug Type NGK BR9ECM ND W27EMR C Gap 0 7 0 8 Spark performance Over 8 0 3 at 1 atm Ignition coil resistance...

Page 318: ...Unit mm in ITEM STANDARD LIMIT Rear brake pedal height 60 70 2 36 2 76 Brake disc thickness Front 4 3 4 7 4 0 0 17 0 18 0 16 Rear 4 8 5 1 4 5 0 19 0 20 0 18 Brake disc runout 0 3 0 01 Master cylinder...

Page 319: ...pivot shaft runout 0 3 FUEL OIL COOLANT ITEM SPECIFICATION NOTE Fuel type The gasoline used should be graded 85 to 95 octane in Research Method and should be unleaded type where they are available Fue...

Page 320: ...le with aluminum radiator mixed with distilled water only at the ratio of 50 50 Radiator including reserve 1 900 ml 2 0 1 7 US Imp qt TIRE PRESSURE NORMAL RIDING COLD INFLATION SOLO RIDING DUAL RIDING...

Page 321: ...1 COIL 2 SOLENDID VALVE 2 OIG OIR OIW OIY RIB RIW WIB WIBI WIR YIG Orange with Green tracer Orange with Red tracer Orange with White tracer Orange with Yellow tracer Red with Black tracer WIRE CalOR...

Page 322: ...el hose Main air solenoid valve Pilot air solenoid hose No 1 Main air solenoid hose No 2 Pilot air solenoid hose No 2 Main air solenoid valve Main air solenoid hose No 3 I o en m J J o C I 2 G w m Cl...

Page 323: ...RGV250T 96 MODELLj CONTENTS SPECIFICATIONS 14 1 SERVICE DATA 14 2 NOTE The specifications and service data are the same as those of the R MODEL III...

Page 324: ...2 or RK520SMOZ9 114 links These specifications are subject to change without notice CHASSIS Front suspension Inverted telescopic coil spring oil damped inner rod type spring 5 way adjustable Rear susp...

Page 325: ...27 Piston ring to groove clearance 1st 2nd 0 02 0 06 0 0008 0 0024 Piston pin bore 16 002 16 010 16 036 0 6300 0 6303 0 6313 Piston pin O D 15 995 16 000 15 980 0 6297 0 6299 0 6291 CONROD CRANKSHAFT...

Page 326: ...ratio 3 071 43 14 Gear ratios Low 2 454 27 11 2nd 1 625 26 16 3rd 1 235 21 17 4th 1 045 23 22 5th 0 916 22 24 Top 0 840 21 25 Shift fork to groove clearance 0 1 0 3 0 5 0 004 0 011 0 0196 Shift fork g...

Page 327: ...Unit mm in ITEM SPECIFICATION NOTE Ignition timing 10 B T D C at 1 300 r min Spark plug Type NGK BR9ECM ND W27EMR C Gap 0 7 0 8 Spark performance Over 8 0 3 at 1 atm Ignition coil resistance Primary...

Page 328: ...ITEM STANDARD LIMIT Rear brake pedal height 60 70 2 36 2 76 Brake disc thickness Front 4 3 4 7 4 0 0 17 0 18 0 16 Rear 4 8 5 1 4 5 0 19 0 20 0 18 Brake disc runout 0 3 0 01 Master cylinder bore Front...

Page 329: ...ingarm pivot shaft runout 0 3 FUEL OIL COOLANT ITEM SPECIFICATION NOTE Fuel type The gasoline used should be graded 85 to 95 octane in Research Method and should be unleaded type where they are availa...

Page 330: ...Coolant type Use an anti freeze Summer coolant com patible with aluminum radiator mixed with distilled water only at the ratio of 50 50 Radiator including reserve 1 900 ml 2 0 1 7 US Imp qt TIRE PRESS...

Page 331: ......

Page 332: ...Prepared by SUZUKI MOTOR CORPORATION Overseas Service Department 7th Ed November 1995 1st Ed November 1988 Part No 99500 12077 01E Printed in Japan 328...

Page 333: ......

Page 334: ...SUZUKI MOTOR CORPORATION...

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