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RGV250L 1990
Suzuki RGV250L 1990 User Manual
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8·9
SERVICING
INFORMATION
CA
BLE
ROUTING
Throttle
cable
in
front
of
brake
hose
pass.
To
right
carburetor
Throttle
cable
left
Oil
pump
cable
Clutch
cable
guide
Choke
cable
guide
Startor
cable
below
";=::,~.",,,
wiring
harness.
::':
(.~)
:---:\'
1HIt----\lI\\-~l-----Throttle
cable
No.
5
Oil
pump
cable
Choke
cable
Throttle
cable
No.
4
Throttle
cable
No.
1
/
To
head
lamp
,.-r---Clutch
cable
185
187
Table of Contents
Group Index
3
General Information
5
Serial Number Location
6
Fuel
6
Engine Oil
6
Transmission Oil
7
Front Fork Oil
7
Brake Fluid
7
Coolant
7
Breaking-In
8
Cylinder Identification
8
Special Materials
9
Precaution and General Lubrication
12
Replacement Parts
12
Asbestor Information
13
Specifications
14
Dimensions and Dry Mass
14
Periodic Maintenance and Tune-Up Procedures
15
Periodic Maintenance Schedule
16
Periodic Maintenance Chart
16
Lubrication Points
17
Maintenance and Tune-Up Procedures
18
Battery
18
Engine Bolts and Nuts
18
Cylinder Head Nuts
18
Cylinder Head, Cylinder and Muffler
19
Air Cleaner
19
Spark Plugs
20
Carburetors
20
Recommended Spark Plug
20
Idle RPM Adjustment
20
Throttle Cable
21
Throttle Cable Play
21
Choke Cable
21
Fuel Lines
22
Oil Pump
22
Clutch
23
Cable Play
23
Drive Chain
25
Cleaning and Lubricating
26
Brakes
26
Brake Fluid Level
26
Brake Pads
27
Brake Pedal Height
27
Brake Light Switches
27
Bleeding Air from the Brake Fluid Circuit
28
Tires
29
Tire Tread Condition
29
Tire Pressure
29
Steering
30
Front Fork
30
Rear Suspension
30
Chassis Bolts and Nuts
31
Engine
33
Engine Removal and Reinstallation
35
Engine Reinstallation
40
Right Exhaust Valve Cable Adjustment
48
Left Exhaust Valve Cable Adjustment
49
Actuator and Exhaust Valve Function Check
49
Actuator Cable Adjustment
50
Engine Disassembly
53
Engine Components Inspection and Servicing
63
Cylinder Head
63
Cylinder and Exhaust Valve
63
Cylinder Bore
64
Piston
64
Decarbon
64
Piston Diameter
64
Piston-Cylinder Clearance
65
Piston Pin Bore
65
Piston Pin O.D.
65
Piston Rings
65
Piston Ring Free End Gap
66
Piston Ring to Groove Clearance
66
Bearings
66
Oil Seals
66
Crankshaft
67
Condition of Big End Bearing
67
Conrod Small End Bore I.D
67
Clutch Plates
67
Clutch String Free Length
68
Clutch Bearings
68
Gearshift for Clearance
68
Shift Fork Groove Width
69
Shift Fork Thickness
69
Engine Reassembly
70
Transmission Gears and Related Parts
72
Countershaft
73
Drive Shaft
73
Kick
76
Fuel and Lubrication System
87
Fuel Tank and Fuel Cock
88
Carburetor Construction
89
I.D. No. Location
90
Needle Valve Inspection
93
Float Height Adjustment
93
Carburetor Idle Angle Adjustment
94
Fuel Level Inspection
94
Bleeding Air
96
Checking Oil Pump
96
Cooling System
99
Cooling System Description
100
Cooling Solution
101
Coolant Density-Boiling Point Curve
101
Coolant Density-Freezing Poitn Curve
101
Water Temperature and Temperature Gauge
104
Temperature Gauge Specification
104
Electrical System
105
Charging System
106
Function of Regulator
106
Charging Output Check
108
AC Generator No-Load Performance
108
AC Generator Continuity Check
109
Regulator/Rectifier
109
Ignition System
110
Ignition Coil
111
Checking with Electro Tester
111
Checking with Pocket Tester
111
Pick-Up Coil
112
CDI Unit
112
Automatic Exhaust Valve Control Unit and Actuator
115
Exhaust Valve Operation
116
Actuator Pulley
116
Actuator Control Unit
116
Water Temperature Meter
118
Water Temperature Meter Inspection
118
Oil Level Gauge
119
Lamps
120
Headlight
120
Tail/Brake Light
120
Turn Signal Light
121
Speedometer
121
Speedometer Wiring Inspection
122
Switches
123
Ignition Switch
123
Lighting Switch
123
Rear Brake Switch
123
Battery Specifications
124
Initial Charging
124
Filling Electrolyte
124
Servicing
125
Recharging Operation
125
Chassis
127
Fairing Construction
128
Front Wheel Construction
130
Wheel Bearings
132
Axle Shaft
132
Wheel
132
Wheel Bearing
132
Speedometer Gearbox
133
Front Brake Construction
134
Brake Caliper
134
Brake Pad Replacement
135
Caliper Removal and Disassembly
135
Caliper and Disc Inspection
136
Cylinder and Piston
136
Rubber Part
136
Disc
136
Caliper Reassembly and Remounting
137
Master Cylinder Removal and Disassembly
137
Master Cylinder Inspection
138
Master Cylinder Reassembly and Remounting
139
Oil Lock Piece, Piston Ring
142
Inner and Outer Tubes
142
Fork Spring
142
Inner Tube Metal
143
Oil Lock Piece
143
Cylinder Lock Bolt
143
Outer Tube Metal, Washer and Oil Seal
143
Front Fork Setting
144
Inner Tube
144
Front Fork Spring
144
Steering Stem
145
Outer Races
148
Stem Nut
148
Rear Brake
150
Rear Wheel
155
Tire and Wheel
160
Tire Removal
160
Valve Installation
163
Tire Mounting
163
Swingarm
165
Rear Shock Absorber and Rear Cuhshion Lever Set
166
Cushion Lever
169
Shock Absorber
170
Swingarm Pivot Shaft
170
Reassembly Information
173
Reassembly Onto Frame
174
Final Inspection and Adjustment
175
Servicing Information
177
Wire Harness
185
Cable Touring
186
Fuel and Breather Hose Routing
189
Oil Hose Routing
190
Fuel Tank Hose Routing
191
Front and Rear Hose Routing
192
Special Tools
193
Tightening Torque
196
Tightening Torque Chart
198
Service Data
199
Rgv250L
205
Throttle Sensor
214
Carburetor
215
Ignition
216
Exhaust
216
Ignition System and Exhaust Valve Operation Check
218
Wiring Procedure
218
Check Procedure
218
Air Solenoid Valve Operation
219
Pocket Tester
220
Air Control Unit
221
Air Solenoid Valve
221
Rgv250M
237
Rgv250N
289
Actuator
297
Operation of Oil Pump
297
4
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Suzuki RGV250L 1990 Specifications
General
Brand
Suzuki
Model
RGV250L 1990
Category
Motorcycle
Language
English
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