Suzuki RG250 Manuel utilisateur

•

~----------~

99SQ8-'286101E

FOREWORD

The

SUZUKI

RG250

has

been

developed

a new generation motorcycle.

packed

with highly advanced design concepts including automatic exhaust control system, a liquid

cooling system, a

G.D.

ignition system,

positive damping

fork

and

a full-floater

suspen-

sion system. Combined with precise control and easy handling the

RG250

provides excel-

lent

performance and outstanding riding comfort.

This service manual

has

been produced

primarily

for

experienced mechanics whose

job

inspect, adjust, repair and service

SUZUKI

motorcycles. Apprentice mechanics and

do-it-yourselfmechanics,

will

also

find

this manual

extremely useful guide.

Model RG250 manufactured

standard specifications

the main subject

matter

this manual. However, the RG250 machines distributed in

your

country

might

differ

minor

respects from the standard-specification and,

they do,

because

some

minor

modifications (which are

consequence

most

cases

far

servicing

concerned)

had

be made to

comply

with

the

statutory

requirements

your

country_

This manual contains up-to-date

information

the time

its

issue.

Latermade

modifi-

cations

and

changes

will

explained to each

SUZUKI

distributor

in respective markets,

to whom you

are

kindly

requested

make query

about

updated information,

any.

SUZUKI MOTOR CORPORATION

Motorcycle Technical Service Department

YRIGHT SUZUKI MOTOR CORPORATION

1990

VIEW

SUZUKI

RG250

(FULL

COWLING)

RIGHT SIDE

LEFT SIDE

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE AND

TUNE-UP PROCEDURES

"------

IENGINE

LCOOLING

SYSTEM

FUEL

AND

LUBRICATION

SYSTEM

ELECTRICAL

SYSTEM

CHASSIS

SERVICING INFORMATION

RG250H

(,87

-MODEL)

VIEW

OF SUZUKI

RG250

(HALF

COWLING)

RIGHT SIDE

LEFT

SIDE

GENERAL INFORMATION

,---------------

CONTENTS

-------

SERIAL NUMBER LOCATION

··

·....···

···············

····

·····

··

FUEL,

OIL

AND COOLANT

RECOMMENDATION

····················

············

···

········

....

........

..·1- 1

BREAKING-IN

PROCEDURE

·········

··

·························

········

····

CYLINDER IDENTIFICATION·············

·····························

·······

SPECIAL

MATER

IALS

·········································

················

PRECAUTION AND GENERAL INSTRUCTION

········..

············

SPECIFICATIONS···············

··························

·· ·

······

···········

·1- 6

I-I GENERAL

INF

ORMATION

SERIAL

NUMBER

LOCATION

The frame

l number or

V.1.

N. (Vehicle Identi-

fication

Number)

sta

the

steering

head pipe. T

engine serial number @

locat

on the

sid

e of the cran

kcase.

hese

numbers

are

requir

esp

ally f

registering the machi

and orde

spare part

FUEL, OIL

AND

COOLANT

RECOMMENDATION

FUEL

Gasol

ine u

d should

graded 85 -95 octane in

earch

thod and should

unle

ade

d or

low-lead type where they

are

available.

GINE

OIL

Use

UZUK

"CC

I" o

ZUKI

eel Super

oil.

ey are

for

mulated

best engine per·

formance with le

ast

combustion chamber depos

least

preignitio

maximum

spark plug

lif

e a

best lubrication.

they

are

not

available, a good

quality

WO-S

TRO

L (non-

diluent

typ

should be used.

TRANSMISSION

OIL

Use

a good qua

lity

20W/40 malt

grade m

otor

BRAKE

FLUID

Spe

ficat

ion and

class

ficat

ion :

99000-23021

SAE

703.

SUZU

KI Brake fluid

WARNING:

* Since the brake system

this

motorcycle

filled

with

a glycol-based brake

fluid

the manufacturer,

not

use

mix

differ

ent

types

fluid

such

silicone-based

and petroleum-based

fluid

for

refilling the

system, otherwise serious damage

will

result.

* Do

not

use

any brake

fluid

taken

from

old

used

unsealed containers.

* Never re-

use

brake

fluid

left

over

from

the

prevIous servicing and stored

for

a long

period.

FRONT

FORK

OIL

e f

k oil = 10.

COOLANT

Use

anti-freeze & Summer coolant compatible

with

aluminum

radiator, mixed with distilled

water

only. at the ratio

50 : 50.

WATER FOR

MIXING

Use

distilled water

only

_ Water

other

than

distilled

ter

can

corrode

and

dog

the aluminum radiator.

ANT1-FREEZE & SUMMER

COOLANT

The

coolant performs

corrosion and rust inhibi-

tor

as well as anti-freeze. Therefore,

the

coolant

should

used

at all times

even

though the atmos-

pheric temperature in

your

area

does

not

down

freezing point.

SUZUKI recommends the

use

SUZUKI GOLD-

CRUISER 1 200 anti-freeze & summer coolant.

this

not

available,

use

equivalent which

compatible

with

aluminum radiator.

REQUIRED

AMOUNT

OF WATER/

COOLANT

Solution capacity (total): 1 500 ml

Water

30%

1050

Coolant 450 ml

--Water

900ml

40%

Coolant 600

-Water 750

% -Coolant

750ml

CAUTION:

Mixing

anti-freeze & summer coolant

should be limited

Mixing beyond

would reduce its efficiency.

the anti-freeze

& summer coolant mixing ratio

below 30

rust inhibiting performance

greatly reduced.

sure

mix

above 30%

eve

tho

ugh

the

atmospheric temperature does

not

down

freezing point.

Every new

unit

filled

with

anti-leakage

material, Bar

ak.

GENERAL

INFORMATION

-2

BREAKING-IN

PROCEDURE

During manufacture only the best possible materi-

als

are

used

and all machined parts

are

finished

high standard

but

still

necessary

allow

the moving parts

"BR

EAK

-IN" before subject-

ing the engine

maximum

stresses.

The future

performance and reliability

the engine depends

on the

care

and restraint exercised during its early

life. The general rul

are

follows:

•

Keep

these

breaking-in engine

speed

limits:

Initial 800 km Below 6 000

rlmin

1 600 km Below 8 000 rlmin

Over 1 600 km Below

12000

rlmin

• Upon reaching

odometer reading

1600

km you

can

subject the motorcycle

full

throttle

operation.

However, do not exceed

12000

rlmin at any

time.

• Do

not

maintain constant engine

speed

for

extended time period during any portion

the

break-in.

Try

the

throttle

position.

CYLINDER

IDENTIFICATION

The two cylinders

this engine

are

identified

left

and

right cylinder

(as

viewed by the rider on

the seat).

1-3

GENERAL I

NFORMAl

ION

SPE

CIAL

MATERIALS

The materials listed below

are

needed

for

maintenance

work

on the

250, and should

kept on

for

ready

use.

They supplement such standard materials

cleaning fluids, lubricants, emery cloth and the

like. How

use

them and where

use

them

are

described

the

text

this manual.

Mater

l Part P

age

Part P

age

~:=J

• Oil

seals

3·21 • Wheel bearings 7·14

3-33

7·45

•

Throttle

grip 7-46

• Sprocket

mounting

drum

bearing

" • Speedometer cable 7·

• Swing arm bearing and

dust

seal

• Tachometer cable Brake pedal shaft

'Sl-."",

•

• Cushion lever bearing 7·56

SUZUKI • Steering stem bearings and races 7·33

• R

ear

shock bearing 7·

SUPER

GREASE

"AU • Clutch lever

and

release

99000-25010

• Side stand

• Clutch release 3

·2

SUZUKI

MOLY

PASTE

99000

-25140 • Mating surfaces

upper 3·37 • Water temperature

gauge

4·10

and lower crankcase

- ,

.;'

-• Mechanical

seal

4- 8

SUZUKI

BOND

No. 1207B

99000

31140

• Brake

fluid

2-14

SUZUKI

BRAKE

FLUID

99000

·23021 (O.5L) • Oil

seal

outer

surface 3·

"'i

THREAD

OCK

" '

322

99000·

32110

• Gearshift shaft stopper 3·31

•

Kick

starter

gea

r retainer 3·32

bolt

•

'--=:-

THREAD

LOCK

SUPER

"1303"

99000-32030

GENERAL

INFORMATION

1-4

Mat

rial

Part

Page

P.rt

p,,.

• Generator

rotor

nut

3·38

I'".

'-=-

THREAD

LOCK

"1324"

99000·32

• Gearshift cam guide screw 3-32

I'".

• Gearshift pawl lifter screw 3·32

• Countershaft bearing-

3·39

I'\i1l

retainer

'--=-'

THREAD

LOCK SUPER

"13338" 99000-32020

•

prevent

leakage

cooling

solution

from small

hole.

SUZUKI BAR's

LEAK

99000·24240

• Cooling

solution

SUZUK

GOLDEN

CRUI

SER

1200

!2L)

99000·24120

• Disc

bolt

].15

I'".

7·46

}!:,q

i§l§

'-=-

THREAD LOCK

"1360"

99000-32130

•

Stator

securi

screws. 3·38

I'".

•

Front

fork

damper rod

bolt

7-27

I'Th1§

• Reed

valve

3·22

THREAD

LOCK

"1342"

99000-32050

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