1983-1987 Suzuki RG250 Service Manual (P/N 99500-12061-01E)

• 100-page official Suzuki OEM workshop manual covering the 1983–1987 Suzuki RG250 (both half-cowling and full-cowling variants)
• Official Suzuki Motor Corporation publication P/N 99500-12061-01E, copyright 1990
• Features 12 exploded-view diagrams, 8 torque specification tables, and factory-recommended maintenance schedules
• Documents the RG250H '87 model update alongside earlier 1983-1986 specifications, serving as the definitive reference for the entire production run

Manual Organization

The 1983–1987 Suzuki RG250 service manual provides a detailed breakdown of the machine's maintenance and overhaul requirements. The document divides into nine major groups. It begins with general information, such as frame and engine serial number locations, fuel and oil recommendations, and engine break-in procedures. Later chapters cover periodic maintenance intervals for the air cleaner, carburetor, and cooling system.

Engine repair sections follow the cooling and fuel systems, outlining the exact removal, disassembly, inspection, and reassembly order. The final section specifically addresses the 1987 RG250H model, highlighting unique requirements for that production year. Each technical chapter incorporates clear exploded-view diagrams that identify component sequences. Furthermore, the publication includes detailed torque-specification tables for critical engine and chassis components. When referencing these factory specifications for maintenance, always strictly adhere to standard shop safety protocols and ensure the motorcycle is properly supported before beginning any teardown.

Specification Highlights

Technical data provided includes primary gear ratios (3.000), final reduction (2.785), and specific ratios for low through top gears. Fluid capacities are clearly documented. Transmission oil capacity is 850 ml, while total cooling system capacity is 1500 ml. For internal engine measurements, the manual lists a piston-to-cylinder clearance limit of 0.120 mm and a crankshaft runout service limit of 0.05 mm. The standard spark plug gap is specified at 0.6–0.8 mm for NGK B9ES or BR9ES plugs.