Suzuki RGV250T 1996

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09941-50110

Bearing remover

09943-88211

Bearing installer

09941-54911

Bearing

outer

race

remover

09941-74910

Steering bearing

installer

SERVICING

INFORMATION

8-18

09941-84510

Bearing remover

09943-74111

Front

fork

oil level

gauge

Main Page

Group Index3
General Information5
Serial Number Location6
Fuel6
Engine Oil6
Transmission Oil7
Front Fork Oil7
Brake Fluid7
Coolant7
Breaking-In8
Cylinder Identification8
Special Materials9
Precaution and General Lubrication12
Replacement Parts12
Asbestor Information13
Specifications14
Dimensions and Dry Mass14
Periodic Maintenance and Tune-Up Procedures15
Periodic Maintenance Schedule16
Periodic Maintenance Chart16
Lubrication Points17
Maintenance and Tune-Up Procedures18
Battery18
Engine Bolts and Nuts18
Cylinder Head Nuts18
Cylinder Head, Cylinder and Muffler19
Air Cleaner19
Spark Plugs20
Carburetors20
Recommended Spark Plug20
Idle RPM Adjustment20
Throttle Cable21
Throttle Cable Play21
Choke Cable21
Fuel Lines22
Oil Pump22
Clutch23
Cable Play23
Drive Chain25
Cleaning and Lubricating26
Brakes26
Brake Fluid Level26
Brake Pads27
Brake Pedal Height27
Brake Light Switches27
Bleeding Air from the Brake Fluid Circuit28
Tires29
Tire Tread Condition29
Tire Pressure29
Steering30
Front Fork30
Rear Suspension30
Chassis Bolts and Nuts31
Engine33
Engine Removal and Reinstallation35
Engine Reinstallation40
Right Exhaust Valve Cable Adjustment48
Left Exhaust Valve Cable Adjustment49
Actuator and Exhaust Valve Function Check49
Actuator Cable Adjustment50
Engine Disassembly53
Engine Components Inspection and Servicing63
Cylinder Head63
Cylinder and Exhaust Valve63
Cylinder Bore64
Piston64
Decarbon64
Piston Diameter64
Piston-Cylinder Clearance65
Piston Pin Bore65
Piston Pin O.D.65
Piston Rings65
Piston Ring Free End Gap66
Piston Ring to Groove Clearance66
Bearings66
Oil Seals66
Crankshaft67
Condition of Big End Bearing67
Conrod Small End Bore I.D67
Clutch Plates67
Clutch String Free Length68
Clutch Bearings68
Gearshift for Clearance68
Shift Fork Groove Width69
Shift Fork Thickness69
Engine Reassembly70
Transmission Gears and Related Parts72
Countershaft73
Drive Shaft73
Kick76
Fuel and Lubrication System87
Fuel Tank and Fuel Cock88
Carburetor Construction89
I.D. No. Location90
Needle Valve Inspection93
Float Height Adjustment93
Carburetor Idle Angle Adjustment94
Fuel Level Inspection94
Bleeding Air96
Checking Oil Pump96
Cooling System99
Cooling System Description100
Cooling Solution101
Coolant Density-Boiling Point Curve101
Coolant Density-Freezing Poitn Curve101
Water Temperature and Temperature Gauge104
Temperature Gauge Specification104
Electrical System105
Charging System106
Function of Regulator106
Charging Output Check108
AC Generator No-Load Performance108
AC Generator Continuity Check109
Regulator/Rectifier109
Ignition System110
Ignition Coil111
Checking with Electro Tester111
Checking with Pocket Tester111
Pick-Up Coil112
CDI Unit112
Automatic Exhaust Valve Control Unit and Actuator115
Exhaust Valve Operation116
Actuator Pulley116
Actuator Control Unit116
Water Temperature Meter118
Water Temperature Meter Inspection118
Oil Level Gauge119
Lamps120
Headlight120
Tail/Brake Light120
Turn Signal Light121
Speedometer121
Speedometer Wiring Inspection122
Switches123
Ignition Switch123
Lighting Switch123
Rear Brake Switch123
Battery Specifications124
Initial Charging124
Filling Electrolyte124
Servicing125
Recharging Operation125
Chassis127
Fairing Construction128
Front Wheel Construction130
Wheel Bearings132
Axle Shaft132
Wheel132
Wheel Bearing132
Speedometer Gearbox133
Front Brake Construction134
Brake Caliper134
Brake Pad Replacement135
Caliper Removal and Disassembly135
Caliper and Disc Inspection136
Cylinder and Piston136
Rubber Part136
Disc136
Caliper Reassembly and Remounting137
Master Cylinder Removal and Disassembly137
Master Cylinder Inspection138
Master Cylinder Reassembly and Remounting139
Oil Lock Piece, Piston Ring142
Inner and Outer Tubes142
Fork Spring142
Inner Tube Metal143
Oil Lock Piece143
Cylinder Lock Bolt143
Outer Tube Metal, Washer and Oil Seal143
Front Fork Setting144
Inner Tube144
Front Fork Spring144
Steering Stem145
Outer Races148
Stem Nut148
Rear Brake150
Rear Wheel155
Tire and Wheel160
Tire Removal160
Valve Installation163
Tire Mounting163
Swingarm165
Rear Shock Absorber and Rear Cuhshion Lever Set166
Cushion Lever169
Shock Absorber170
Swingarm Pivot Shaft170
Reassembly Information173
Reassembly Onto Frame174
Final Inspection and Adjustment175
Servicing Information177
Wire Harness185
Cable Touring186
Fuel and Breather Hose Routing189
Oil Hose Routing190
Fuel Tank Hose Routing191
Front and Rear Hose Routing192
Special Tools193
Tightening Torque196
Tightening Torque Chart198
Service Data199
Rgv250L205
Throttle Sensor214
Carburetor215
Ignition216
Exhaust216
Ignition System and Exhaust Valve Operation Check218
Wiring Procedure218
Check Procedure218
Air Solenoid Valve Operation219
Pocket Tester220
Air Control Unit221
Air Solenoid Valve221
Rgv250M237
Rgv250N289
Actuator297
Operation of Oil Pump297

Suzuki RGV250T 1996 - Page 195

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