Suzuki RG250 Manuals

Manuals and User Guides for Suzuki RG250. We have 1 Suzuki RG250 manual available for free PDF download: Service Manual

Suzuki RG250 Service Manual (210 pages)

Brand: Suzuki | Category: Motorcycle | Size: 27.9 MB

View of Suzuki RG250 (Full Cowling)
3
Group Index
4
View of Suzuki RG250 (Half Cowling)
5
General Information
6
Table of Contents
6
Serial Number Location
7
Fuel, Oil and Coolant Recommendation
7
Engine Oil/Transmission Oil
7
Brake Fluid
7
Coolant
8
Braking-In Procedure
8
Cylinder Identification
8
Special Materials
9
Precaution and General Instruction
11
Replacement Parts
11
Specifications
12
Periodic Maintenance and Tune-Up Procedures
14
Periodic Maintenance Schedule
15
Lubrication Points
16
Battery Maintenance
17
Periodic Maintenance and Tune-Up Procedures
17
Engine Bolts and Nuts
18
Cylinder Head Nuts and Cylinder Nuts
18
Exhaust Pipe Nuts
18
Cylinder Head, Cylinder and Muffler Maintenance
19
Spark Plug Maintenance
19
Air Cleaner Maintenance
20
Carburetor Maintenance
21
Throttle Cable Adjustment
21
Idle R/Min Adjustment
22
Carburetor Overhaul and Cleaning
22
Radiator Hose Maintenance
23
Coolant Maintenance
23
Fuel Line Maintenance
24
Clutch Maintenance
24
Oil Pump
24
Transmission Oil
25
Drive Chain Maintenance
26
Drive Chain Wear Checking
26
Drive Chain Sag Adjusting
26
Cleaning and Lubrication
27
Brakes Maintenance
28
Brake Fluid Level Maintenance
28
Brake Light Switches Maintenance
28
Brake Pads Maintenance
29
Air Bleeding the Brake Fluid Circuit
29
Brake Pedal Height
31
Steering Maintenance
31
Front Fork Maintenance
31
Rear Suspension Maintenance
32
Air Pressure (Rear Suspension)
32
Tires Maintenance
33
Chassis Bolts and Nuts
33
Tire Thread Condition
33
Tire Pressure
33
Chassis Bolts and Nuts - Illustration
35
Engine
36
Engine Removal
37
Engine Reinstallation
43
Exhaust Valve Control Cable Adjustment
46
Engine Disassembly
47
Engine Components Inspection and Servicing
54
Cylinder Head Decarbon
54
Cylinder Head Distortion
54
Cylinder Inspection
55
Reed Valve Inspection
56
Exhaust Valve Inspection
56
Cylinder Distortion
56
Cylinder Decarboning
56
Bore Check
57
Cylinder Reassembly
57
Piston Decarbon
58
Piston Pin Bore
59
Piston Pin OD
59
Piston Diameter
59
Piston-Cylinder Clearance
59
Piston Rings
60
End Gap, Free End Gap
60
Piston Ring to Groove Clearance
60
Oversize Piston Ring
60
Bearings
61
Oil Seals
61
Con-Rod
61
Small End Bore/Condition of Big Bearing
61
Crankshaft Runout
62
Clutch Release Disassembly
62
Clutch Release Assembly
63
Clutch Plates
64
Clutch Springs
65
Gears and Shift Forks
65
Engine Reassembly
66
Gearshift Cam
67
Oil Seal
69
Transmission Reassembly
69
Countershaft
70
Crankshaft
71
Crankcase
72
Stator and Pick-Up Coil
74
Generator Rotor
74
Primary Drive Gear
75
Countershaft Bearing Retainer
75
Kick Starter
76
Gearshift Shaft
77
Clutch
77
Piston Rings, Piston
79
Cylinder Installation
80
Cylinder Head
80
Cooling System
81
Radiator and Water Hoses
83
Radiator Removal
84
Radiator Installation
85
Thermostat Removal
85
Thermostat Inspection
85
Water Pump
87
Water Pump Inspection
89
Water Pump Reassembly
89
Water Pipe Idle Gear
90
Water Pipe Driven Gear
91
Water Temperature Gauge
91
Temperature Gauge Removal
91
Temperature Gauge Inspection
92
Temperature Gauge Reassembly
92
Fuel and Lubrication System
93
Fuel Tank and Fuel Cock Cleaning
94
Fuel Tank and Fuel Cock Inspection
94
Carburetor Construction
95
Carburetor Removal
96
Carburetor Disassembly
96
Carburetor Inspection
97
Needlve Valve Inspection
97
Float Height Adjustment
98
Diagnosis of Carburetor
98
Mixture Adjustment
98
Carburetion
99
Fuel-Air Mixture Ratio Changing
99
Oil Pump Check
100
Air Bleeding
100
Carburetor Reassembly
100
Carburetor Remounting
100
Electrical System
101
Charging System
102
Function of Regulator
102
Charging Output Check
104
AC Generator No-Load Performance
104
AC Generator Stator Coil
105
Regulator/Rectifier
105
Ignition System
106
Stator Coil
106
Ignition Coil
107
Automatic Exhaust Control Unit and Actuator Diagram
108
Exhaust Valve Operation Check
108
Actuator
109
Actuator Pulley
110
Exhaust Valve Control Unit
110
Combination Meter Inspection
112
Water Temperature Meter Inspection
114
Lamps
115
Head Light Diagram
115
Turn Signal Light Diagram
115
Tail/Brake Light Diagram
116
Switches
116
Ignition Switch
116
Left Handle Switch/Dimmer Switch
117
Turn Signal Switch/Horn Switch
117
Right Handle Switch/Lighting Switch
117
Engine Stop Switch
117
Front Brake Switch
118
Neutral Switch
118
Rear Brake Switch
118
Oil Level Switch
118
Battery Specifications
119
Battery Initial Charging
119
Filling Electrolyte
119
Battery Servicing
119
Based on SG Reading Recharging Operation
120
Battery Service Life
121
Chassis
122
Cowling Construction
123
Cowling Removal
124
Front Brake Pad Replacement
125
Caliper Construction
125
Caliper Removal
126
Caliper and Disc Inspection
128
Caliper Reassembly
129
Master Cylinder Construction
130
Master Cylinder Removal
130
Master Cylinder Disassembly
131
Master Cylinder Inspection
132
Master Cylinder Reassembly
132
Front Wheel Construction
133
Front Wheel Removal
133
Front Wheel Disassembly
134
Wheel Bearings Inspection
135
Axle Chaft Check
135
Front Wheel Inspection
135
Front Wheel Reassembly
136
Wheel Bearing
136
Tire and Wheel Removal
138
Tire and Wheel Inspection
140
Valve Inspection
141
Valve Installation
141
Tire Mounting
142
Front Fork Construction
144
Front Fork Removal
144
Front Fork Disassembly
145
Front Fork Inspection
147
Front Fork Reassembly and Remounting
148
Innter Tube, Outer Tube
148
Posi-Damp Unit
148
Front Fork Cap
148
Damper Rod Bolt
149
Outer Tube Metal, Washer and Oil Seal
149
Posi Damp Unit
149
Fork Oil
149
Fork Spring
150
Steering Contruction
151
Steering Removal
152
Steering Inspection
154
Steering Reassembly
154
Outer Races
154
Steering Bearing
155
Stem Nut
155
Rear Brake Pad Replacement
156
Rear Brake Caliper Construction
157
Rear Brake Caliper Removal
157
Rear Brake Caiper Disassembly
157
Cylinder Wall and Piston Inspection
159
Dust Boot and Piston Seal Inspection
159
Disc Inspection
159
Master Cylinder Construction (Rear)
160
Rear Brake Caliper Reassembly
160
Master Cylinder Removal (Rear)
161
Rear Master Cylinder Disassembly
161
Rear Master Cylinder Inspection
162
Rear Master Cylinder Reassembly
163
Rear Brake Pedal
163
Rear Wheel and Rear Sprocket Construction
164
Rear Wheel and Rear Sprocket Removal
165
Rear Wheel and Rear Sprocket Disassembly
165
Rear Wheel and Rear Sprocket Inspection
166
Mounting Brake Bearings Check
166
Axle Shaft Check
166
Rear Wheel and Rear Sprocket Reassembly and Remounting
167
Cushion Check
167
Sprocket Check
167
Mounting Drum Bearing
168
Rear Sprocket
168
Rear Suspension
169
Swingarm Diagram
169
Rear Shock Absorber Diagram
169
Cushion Lever Diagram
170
Cushion Lever Removal
170
Cushion Lever Disassembly
172
Swingarm
172
Shock Absorber Removal
175
Swing Arm Pivot Shaft Inspection
175
Needle Roller Bearing and Spherical Ball Bearings Inspection
175
Rear Suspension Reassembly and Remount
176
Swingarm Installation
177
Cushion Lever
177
Service Information - Diagram
178
Service Information
179
Engine Troubleshooting
180
Carburetor Troubleshooting
182
Radiator Troubleshooting
182
Electrical Components Troubleshooting
183
Battery Troubleshooting
184
Brakes Troubleshooting
185
Wiring Diagram
186
Cable, Wire and Hose Routing Diagram
187
Handle and Kick Lever Installation
190
Special Tools List
191
Special Tools View
193
Tightening Torque - Engine
195
Tightening Torque - Chassis
196
Tightening Torque Chart
197
Service Data - Cylinder + Piston + Piston Ring
198
Service Data - Conrod + Crankshaft
198
Service Data - Oil Pump/Clutch
198
Service Data - Theremostat + Radiator
198
Service Data - Transmission
199
Service Data - Drive Chain
199
Service Data - Carburetor
199
Service Data - Electrical
200
Wattage
200
Service Data - Brake + Wheel
201
Service Data - Suspension
201
Service Data - Tire Pressure
201
Service Data - Fuel + Oil + Coolant
202
RG250H ('87-Model) Service Data
203

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Suzuki RG250 Service Manual (210 pages)

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