Suzuki Service Manual: RGV250, RGV250K, RGV250L, RGV250M, RGV250N, RGV250P, RGV250R, RGV250S, RGV250T Motorcycle, 1989-1996, PDF

Suzuki RGV250 Service Manual: 1989-1996 V-Twin Two-Stroke Sportbike Repair Guide

Master the maintenance and repair of your Suzuki RGV250 with this comprehensive professional-grade service manual. Known as one of the most iconic 250cc two-stroke motorcycles, the RGV250 features advanced racing technology like the 90-degree V-twin engine and the A.E.T.C. (Automatic Exhaust Timing Control) system. This manual provides the technical depth required to keep these high-performance machines running at their peak.

Whether you are performing a routine oil change or a complete engine overhaul, this guide delivers step-by-step instructions specifically for the RGV250 series. It covers the standard models and the specialized year-specific updates that defined the evolution of this legendary "Repli-Racer."

Models Covered in This Manual

This manual includes detailed information for the following model years and technical designations:

• RGV250 (General Service Data)
• RGV250K (1989)
• RGV250L (1990)
• RGV250M (1991)
• RGV250N (1992)
• RGV250P (1993)
• RGV250R (1994)
• RGV250S (1995)
• RGV250T (1996)

Identification and Serial Numbers

For accurate part ordering and technical identification, the manual provides exact locations for:

• Frame Serial Number: Located on the right side of the steering head pipe.
• Engine Serial Number: Located on the upper crankcase.
• Engine Identification: VJ21A (Early models) and subsequent series configurations.

Key Technical Highlights

• V-Twin Engine Performance: Complete teardown and reassembly guides for the 249cc 90-degree V-twin, including S.B.C. (Suzuki Boron Composite) cylinder coating data.
• Advanced Cooling: Service procedures for the Radial Flow Radiator and high-capacity centrifugal water pump.
• Carburetion: Detailed tuning for the Slingshot carburetors and the air induction system.
• Chassis and Suspension: Service specs for the DC-ALBOX type frame rails, high-rigidity front forks, and the full-floating rear suspension system.
• Electrical Systems: Full wiring diagrams, ignition timing specs, and troubleshooting for the A.E.T.C. actuator and control unit.

Comprehensive Table of Contents

1. General Information: Specifications, break-in procedures, and cylinder identification.
2. Periodic Maintenance: Scheduled intervals for spark plugs, transmission oil, and drive chain adjustment.
3. Engine: Removal, installation, and detailed servicing of the crankshaft, pistons, and clutch.
4. Fuel and Lubrication: Carburetor disassembly, float height adjustment, and oil pump bleeding.
5. Cooling System: Thermostat testing and radiator maintenance.
6. Electrical System: Charging system, CDI unit, and oil level gauge inspection.
7. Chassis: Front and rear brake overhaul, tire specifications, and steering stem adjustment.
8. Servicing Information: Troubleshooting guides, torque settings, and special tool lists.
9. Model-Specific Supplements: Dedicated sections for the evolution from the K-model through to the T-model, ensuring you have the correct data for your specific year.

This manual is the ultimate resource for RGV250 owners and mechanics looking to maintain the precision engineering of Suzuki’s two-stroke masterpiece.