1983-1987 Suzuki RG250 Service Manual

Suzuki RG250 (1983–1987) Technical Service Documentation

• Covers 1983–1987 Suzuki RG250, including both half-cowling and full-cowling variants
• Official Suzuki Motor Corporation publication P/N 99500-12061-01E, copyright 1990
• Includes 12 exploded-view diagrams, 8 torque specification tables, and factory-recommended maintenance schedules
• Downloads to your account within seconds of checkout
• Re-download the file any time, no expiration
• Laid out for standard letter and A4 printing
• Indexed PDF search covers every chapter and appendix
• This specific document documents the RG250H '87 model update alongside the earlier 1983-1986 RG250 specifications, making it the definitive reference for the full production run

Manual Organization and Scope

The 1983–1987 Suzuki RG250 service manual provides a structured walkthrough of the machine's maintenance and overhaul requirements. The document is divided into nine major groups, beginning with general information such as frame and engine serial number locations, fuel and oil recommendations, and the recommended engine break-in procedures. Later chapters detail the periodic maintenance requirements, including air cleaner, carburetor, and cooling system service intervals.

Engine repair sections follow the cooling and fuel systems, detailing removal, disassembly, inspection, and reassembly. The final group specifically addresses the 1987 RG250H model, highlighting unique requirements for that year. Each technical chapter incorporates clear exploded-view diagrams identifying component sequences, and the publication includes detailed torque-specification tables for critical engine and chassis components.

Specification Highlights

Technical specifications provided include primary gear ratios (3.000), final reduction (2.785), and gear-specific ratios for low through top gears. Transmission oil capacity is listed at 850 ml, while total cooling system capacity is documented at 1500 ml. For the engine, piston-to-cylinder clearance limit is 0.120 mm, and crankshaft runout service limit is 0.05 mm. Standard spark plug gap is specified at 0.6–0.8 mm for NGK B9ES or BR9ES plugs.

Understanding how factory workshop documentation is structured assists technicians in navigating the detailed torque and assembly instructions provided. This 100-page official Suzuki OEM workshop manual covers the 1983–1987 Suzuki RG250, documenting engine, chassis, cooling, and electrical specifications for both the half and full cowling variants.