1989-1996 Suzuki RGV250 K/L/M/N/P/R/S/T Motorcycle Service Manual

Inside the 1989–1996 Suzuki RGV250 Service Manual

• Covers 1989–1996 Suzuki RGV250K through RGV250T two-stroke V-twin performance motorcycles.
• Official OEM publication P/N 99500-12077-01E, 1990 Suzuki Motor Corporation copyright.
• Includes 27-item torque specification table for chassis and engine fasteners.
• Contains specific diagnostic data for the Suzuki Intake Pulse Control (S.I.P.C.) and Automatic Exhaust Timing Control (A.E.T.C.) systems.
• Stored against your account so you can retrieve it after a hard-drive loss.
• Indexed PDF search covers every chapter and appendix.
• This 1990 first edition remains the authoritative technical reference for the 1989–1996 Suzuki RGV250 series including A.E.T.C. valve setup and Mikuni VM32SS carburetor tuning.

RGV250 Series Technical Overview

The 1989–1996 Suzuki RGV250 service manual details critical maintenance and engine reconstruction for the two-stroke V-twin platform. Chapters span general information, periodic maintenance schedules, engine disassembly, fuel system architecture, and cooling circuit diagnostics. Primary sections document the Suzuki A.E.T.C. exhaust timing system, oil pump calibration, and transmission gear assemblies. Specialized mechanical references include crankshaft runout limits, clutch plate thickness tolerances, and piston-to-cylinder clearance thresholds for high-revving performance.

Engine and Chassis Specifications

Engine maintenance data includes multi-stage cylinder head torque values of 23–27 Nm and detailed piston ring end-gap specifications. Carburetor technical data documents the Mikuni VM32SS baseline settings including 1300 ± 150 r/min idle and 7.1 mm fuel level. Chassis maintenance documents steering stem torque at 60–100 Nm and front fork oil pressure intervals. Piston-cylinder clearance is listed at 0.120 mm in the engine inspection table. Coolant system capacity for the 1989–1996 Suzuki RGV250 is documented at 1.6 liters. Crankshaft runout service limit is specified at 0.05 mm in the crankshaft inspection table. Learn more about what an OEM service publication covers for these performance cycles.

An official 216-page Suzuki OEM workshop manual covering the 1989–1996 Suzuki RGV250, documenting engine, chassis, electrical, and fuel-system specifications for the K, L, M, N, P, R, S, and T-series builds.