Suzuki RGV250 1989 User manual

SUZUKI

RGV250

MANUFACTURE'S EXEMPTION

SUZUKI RG V250 HOP-UP KIT is a special-purpose designed for exclusive use in competition only on racing

course as distinguished from public road and highways. RGV250 HOP-UP KIT is not equipped for con-

formity with traffic law and regulations, and is not accorded with the benefit of product which SUZUKI

standardly grants on motorcycle of its manufacture.

NOTE:

* The motorcycle on which the HOP-UP KIT is installed,

is

not covered by the SUZUKI WARRANTY.

* This HOP-UP KIT manual describes only service specifications and servicing procedures which

differ from those of the RG V250 service manual,

* Specification will be changed without pre-notice.

*

Please

refer to the RG V250 service manual for details.

S&Z&m MOTOR C0.

f

LTD.

Sales Department E (for

overseas)

Spare Parts & Accessories Division

©COPYRIGHT SUZUKI MOTOR CO., LTD. 1989

CONTENTS

SPECIFICATIONS 1

GENERAL INFORMATION 2

KIT PARTS INSTALLATION PROCEDURES 4

1.

CYLINDER HEAD, CYLINDER, HEAD GASKET 4

2.

PISTON AND PISTON RING 5

3. CLOSE RATIO TRANSMISSION 6

4. CLUTCH (FOR WET TYPE) 8

5. CLUTCH (FOR DRY TYPE) 9

6. OIL CATCH TANK 11

7. WATER CATCH TANK 13

8. CARBURETOR SETTING PARTS 14

9.

MUFFLER REPLACEMENT 22

10.

OIL PUMP REMOVAL AND BLINDING 23

11.

SPROCKET REPLACEMENT 25

12.

REAR SUSPENSION HEIGHT ADJUSTER BRACKET INSTALLATION 26

13.

FRONT FORK 27

14.

REAR SHOCK ABSORBER SPRING REPLACEMENT 34

15.

FRONT BRAKE CALIPER PAD MODIFICATION 36

16.

STEERING DAMPER INSTALLATION 37

17.

SUSPENSION SETTING 40

18.

SUSPENSION SETTING GUIDE 41

19.

STAGE I KIT PARTS ELECTRICAL 42

20.

STAGE II KIT PARTS ELECTRICAL 44

21.

OTHER RECONSTRUCTION 47

SPECIFICATIONS

ENGINE

Type ....... Two-stroke, liquid-cooled

Number of cylinders 2

Bore . . . . 56.0 mm

Stroke . . . . 50.6 mm

Piston displacement 249 cm

3

Compression ratio 8.8 : 1

Carburetor MiKUNI TM34SS, Two

Spark plug . .

N.G.K.:

R5184-9.5, 10, 10.5

TRANSMISSION

Clutch Dry multi-plate type or

Wet multi-plate type

Transmission 6-speed constant mesh

Gearshift pattern 1-down, 5-up

Primary reduction 2.565 (59/23) [DRY CLUTCH 2.560 (64/25)]

Final reduction 46/13 (3.538)

46/15 (3.067 STD)

37/16(2.313)

STANDARD OPTION

Gear ratios, Low 2.454 (27/11) 1.875 (30/16)

2nd 1.625 (26/16) 1.471 (25/17)

3rd 1.235 (21/17) 1.222 (22/18)

4th 1.045 (23/22) 1.040 (26/25)

5th 0.916 (22/24) 0.926 (25/27)

Top 0.840 (21/25) 0.840 (21/25)

Drive chain TAKASAGO: RK520 TR-Z

D.I.D.: 520ERS

-1 -

GENERAL INFORMATION

DFUEL

The engine is of two-stroke type, designed to run on oil~premixed fuel (when the oil pump is removed).

Fuel specification: Racing gasoline or aviation gasoline mixed with oil in the ratio of 30 : 1.

Oil specification : Motul 700E, Shell Sports SX (synthetic).

2) COOLANT

Coolant specification: Soft drinkable water

When filling the cooling system with water, follow the procedures below.

(1)

Remove the radiator cap and pour water through the filler neck.

(2) Bleed air from the water pump.

(3) Holding the handlebars, lean the motorcycle two or three times to expel air trapped in the system.

(4) Squeeze each radiator hose to drive air away.

(5) Loosen the air bleed bolt on the side of radiator to remove air.

(6) Repeat the procedures (1) through (5) above until the water lever becomes constant.

(7) Fit the radiator cap securely.

After the above procedures are completed, start and warm up the engine, then check that there is no

water is no water leakage. Stop the engine, allow to cool and check the water level again.

• During the race interval, drain the system completely to avoid corrosion or other harmful problems in

the radiator and engine water jacket.

• The water temperature for best engine operation is 55

—

65°C.

When more than 70°C, considerable power loss will result.

3) WARMING UP

Always warm up the engine before running in the following manner:

(1)

For

1 —

2 minutes, rev the engine up and down within the range of 5,000

—

6,000 rpm.

(2) For another 1

—

2 minutes, rev the engine up and down limiting the highest revolution to 8,000 rpm.

(3) When the water temperature reaches approximately 65°C, test drive for approximately 50 m and

check the operation of gearshifting, clutch, brake etc if an appropriate warming up site is available.

(If the water temperature rises to more than 90°C, check the system immediately because there may

be problems like leakage, insufficient water etc.)

4) BREAK IN

(1) New machine

Keep the engine speed as constant as possible during running. To shift up or down, keep to the following

rpm limits. Use as high gear as is practically possible.

a. First, run 2

—

3 times in the track limiting the engine speed below 8,000 rpm.

b. Stop and check for parts looseness, leakage etc.

c. Run approximately 30 km limiting the engine speed below 8,000 rpm.

d.

Run approximately 20 km limiting the engine speed below 9,000 rpm.

e. Run approximately 20 km limiting the engine speed below 10,000 rpm.

The total of running distance is approximately 75 km.

CAUTION:

During breaking in period, run the engine on slightly rich carburetion.

(2) When parts replaced

• If the cylinder or crankshaft is replaced, the same break in as new machine is required (approximately

75 km).

_2-

• If the parts such as piston, piston

ring,

transmission gear are replaced, break in as follows:

For 20 km below 8,000 rpm

For 10 km below 9,000 rpm

For 10 km below 10,000 rpm

Total distance

—

40 km

5) REPLACEMENT

(1) Scheduled replacement

PARTS OR ITEM

Piston

Piston ring

Piston pin

Piston pin circlip

Piston pin bearing

Piston pin bearing washer

Crankshaft

Transmission oil

Drive chain

Fork oil

Brake oil

RECOMMENDED CHECK

Every 500 km

Every 1,000 km

Every 300 km

(Each time removed)

Every 500 km

Every 1,000 km

Every 2,000 km

Initial 100 km and every 1,000 km

Every 500 km

Initial 100 km and every 3 races

Every 3 months or after rain

REPLACE IN FOUND

Wear, pitting

Wear, sticking

Seizure, stepped wear

Whenever disassembled

Seizure, wear |

Wear, scratches

Runout, seal damage, bearing wear

Contamination, emulsification

Stretch,

kink

(2) Other wear items to be replaced

ITEM

Spark plug

Reed valve

Clutch spring

Drive sprocket

I Driven sprocket

Expansion chamber spring

Exhaust silencer

REPLACE IF FOUND

Electrode wear, insulator damage

Damaged or deformed reed (Affects low rpm performance)

Fatigue

Wear, crack, break

Fatigue, other damage

Noise level over permitted limit

6) TRANSMISSION OIL

Transmission oil capacity: 700 cc when refilling

800 cc when overhauled

Standard oil specification: 10W-4Q Motor

7) SPARK PLUG

Specification: NGK R5184 # 10 (STD); # 9=5 (Opt); # 10.5 (Opt)

Spark gap : 0,5

—

0,6 mm

8) SPARK PLUG CAP

From '89 model, the ignition system is digitally controlled. The digital control system is susceptible to

radio interference. Therefore, make sure to use the spark plug cap of standard specification.

KIT PARTS INSTALLATION PROCEDURES

This manual explains the installation, handling, setting and other important procedures for each component

of the kit parts. For more fundamental works not contained in this manual, refer to RGV250 Service

Manual.

1 . CYLINDER HEAD, CYLINDER, HEAD GASKET

0 The combustion chamber of kit cylinder head is

finished with a special plating so-called a BN

plating to prevent pitting in case of abnormal

detonation.

(D A thin cylinder head gasket (thickness = 0.7 mm)

is used for this kit to contribute to compression

increase. Also, the dimension of gasket bore is

made as close as possible to that of cylinder for

the purpose of decresing the quenching area,

thereby surpressing abnormal detonation to a

minimum.

(D The kit cylinder is different from the normal

one in its port timing, port shape and height of

cylinder.

® The dowel pins are used because of closer tole-

rance of cylinder head gasket bore off-center.

The dowel holes are provided on the cylinder,

cylinder head and gasket.

(5) To have the compression adjusted, a thinner

cylinder base gasket is used (thickness = 0.6 mm).

^tp

NOTE:

Exhaust timing of the kit cylinder is faster than is standard one. Therefore, if the standard exhaust

valve is installed without modification, the valve will protrude inside the exhaust port resulting in

decreased power.

Therefore, grind off the exhaust valve end so as to be flash with the exhaust port with the valve fully

opened.

Cylinder exhaust

port upper edge

Grind off

REF.

NO.

1.

2.

3.

4.

5.

PART NUMBER

11111-12C60

11141-12C50

11200-12C60

04211-11129

11241-12C50

DESCRIPTION

HEAD,

CYLINDER

GASKET, CYLINDER HEAD

CYLINDER ASSY

PIN,

CYLINDER HEAD

KNOCK

GASKET, CYLINDER

QTY/UNIT

2

4

2

REMARKS

t = 0.7

t = 0.6

2.

PISTON AND PISTON RING

® A forged, light weight piston is used in this kit.

As with cylinder head combustion chamber, the

piston crown is finished with BN plating to pre-

vent pitting in case of abnormal detonation.

©A

thin,

0.8 mm piston ring is used to decrease

weight and friction loss.

@The kit piston pin is light in weight yet highly

rigid due to its double tapered shape bore.

®&®With the change of piston pin, the circlip

and thrust washer are also modified.

NOTE:

When

installing the piston,

position

1,7 mm holes facing exhaust side.

its

two

[REF.

NO.

1.

2.

3.

4.

5.

PART NUMBER

12110-12C53

12140-12C51

12151-12C50

12153-12C50

12152-12C51

DESCRIPTION

PISTON COMP

RING SET, PISTON

PIN,

PISTON

CIRCLIP, PISTON PIN

WASHER, PISTON PIN

BEARING

Q'TY/UNIT

2

4

REMARKS

«5_

3, CLOSE RATIO TRANSMISSION

Modify the gear ratios for better suitability for competition using the parts listed below. Refer to RGV250

Service Manual (99950-12070-01E) for details of replacement procedure.

_6-

|REF.

NO.

1-1

1-2

* 2

* 3

* 4

5

6

7

* 8

* 9

*10

*11

12

*13

14

*15

PART NUMBER

24121-12C50

24121-12C60

24221-12C60

24231-12C60

24251-12C60

24261-12C50

24130-12C51

24311-12C52

24321-12C60

24331-12C60

24341-12C60

24351-12C60

24361-12C50

08211-25321

16320-12C50

24322-12C60

DESCRIPTION

COUNTERSHAFT

GEAR, 2ND DRIVE

GEAR,3RD/4TH DRIVE

GEAR,5TH DRIVE

GEAR,6TH DRIVE

SHAFT, DRIVE

GEAR, 1ST DRIVEN

GEAR, 2ND DRIVEN

GEAR, 3RD DRIVEN

GEAR,4TH DRIVEN

GEAR,5TH DRIVEN

GEAR,6TH DRIVEN

SHIM,

2ND DRIVEN GEAR

GEAR, OIL PUMP DRIVE

BUSH,

2ND DRIVEN GEAR

Q'TY/UNIT

REMARKS

FOR WET CLUTCH

FOR DRY CLUTCH

NT:

17

NT:

18/25

NT:

27

NT:

25

NT:

30

NT:

25

NT:

22

NT:

26

NT:

25

NT:

21

NT:

28

NOTE MARK *: NEWLY DEVELOPED.

4. CLUTCH (FOR WET TYPE)

To reinforce the clutch for competition capability, replace the parts with those listed below. Refer to

RGV250 Service Manual (99950-12070-01E) for details of replacement procedure.

|^REF. NO.

1

2

3

4

5

PART NUMBER

21441-40A01

21451-40A00

21471-12C50

09164-00006

09440-19013

DESCRIPTION

PLATE,

CLUTCH DRIVE

PLATE,

CLUTCH DRIVEN

SEAT, WAVE WASHER

WAVE WASHER

SPRING

QTY/UNIT

8

7

1

6

REMARKS

T: 3 mm

T: 1.6 mm

™g_

5. CLUTCH (FOR DRY TYPE)

IREF. NO.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

PART NUMBER

21000-12850

09282-58001

21211-12C50

21251-12C50

21252-12C50

09263-25033

09280-20001

21220-12C50

09283-35023

21411-12C50

09160-20051

21441-12C50

21451-20A01

21471-12C60

21472-12C50

21462-12C51

21463-15400

09440-18017

22522-12C50

01107-06405

21481-17C50

23165-12C50

23261-20A00

08322-21068

23271-14101

09135-06009

21111-12C50

DESCRIPTION

CLUTCH SET (DRY)

OILSEAL, INNER COVER

GEAR ASSY. PRIMARY

DRIVEN

SPACER, DRIVEN GEAR

BEARING

O-RING

HOUSING, CLUTCH

OILSEAL

HUB,

CLUTCH SLEEVE

THRUST WASHER,

SLEEVE HUB

PLATE,

CLUTCH DRIVE

PLATE,

CLUTCH DRIVEN

SEAT, WAVE WASHER

WAVE WASHER,CLUTCH

SLEEVE HUB

DISC,

CLUTCH PRESSURE

BEARING, PRESSURE DISC

SPRING,

CLUTCH

SPACER, CLUTCH SPRING

BOLT

WASHER

PACK,CLUTCH RELEASE

PINION,

CLUTCH RELEASE

WASHER, CLUTCH

RELEASE PINION

ARM,CLUTCH RELEASE

BOLT, PINION

GEAR, PRIMARY DRIVE

QTY/UNIT

5

6

1

5

REMARKS

INC..REF.N0.1'

58 x 78 x 7

NT: 64/20

25x30x 19.8

35 x 45 x 6

20 x 50 x 2

T: 3 mm

T: 1.6 mm

6.5 x 13x25.6

6x40

6.2 x 18.8 x 1.6

-33

-10-

REF.

NO.

27.

28.

29.

30.

31.

32.

33.

34.

PART NUMBER

11341-12C50

11370-12C50

11482-12C00

11342-12C50

11971-12C50

07120-06252

11972-12C50

24121-12C60

DISCRIPTION

COVER,CLUTCH INNER

COVER, CLUTCH OUTER

GASKET, CLUTCH COVER

PLUG,

KICK SHAFT

PLUG,

OILFILLER

BOLT

PLUG,

OIL DRAIN

COUNTER SHAFT FOR

DRY TYPE

Q'TY/UNIT

1

4

1

REMARKS

6x25

NT:

16 (Not shown)

6. OIL CATCH TANK

1.

Remove the under cowl.

2.

Remove the front seat.

3. Remove the fuel tank.

4.

Remove the air cleaner.

5. Install the oil catch tank on the chassis as shown in Fig. 2.

• Remove the front bolt securing the carburetor idle adjuster screw bracket. Refit this bolt to secure

the rear side of oil catch tank bracket together with the idle adjuster screw bracket.

• Pass the clamp (selt-locking tie strap) through the front bracket of oil catch tank and fasten the

clamp on the frame down tube. Use care at this time not to pinch the wiring harness between the

bracket and frame.

6. Remove the crankcase breather hose from the guide which is fastened together with the 1st muffler

mounting on the lower part of chassis right side. Route this breather hose to the oil catch tank as

shown in Fig. 1.

7. Insert one end of the outlet pipe (overall length 2 m) into the oil catch tank and route the pipe to the

rear of the machine. If the pipe is found too

long,

cut it to the proper length. When clamping the pipe

on the frame together with the wiring harness, use care not to pinch it.

8. Install the air cleaner.

9. Install the fuel tank.

10.

Attach the self-adhesive clamp on the frame (tank rail) as shown in Fig. 1 and Fig. 2.

11.

Replace the fuel tank breather hose with a longer one (length 790 mm).

• Insert one end of the fuel tank breather hose into the oil catch tank and secure the pipe on the

frame by using the clamp previously installed. If the pipe is found too

long,

cut it to the proper

length.

12.

Install the seat and under cowl.

13.

Finally, check that the steering does not interfere with the fuel tank breather hose when fully turned

right and left.

-11 -

Length of hose

inserted

To fuel tank breather

/

(Fig.

1)

To engine crankcase

VIEWC

09352-50823-00B

HOSE,

OIL CATCH TANK

OUTLET

Engine breather hose

09408-00074

CLAMP, FUEL TANK

BREATHER HOSE

To fuel tank breather

Oil catch tank bracket to be

tightened together with

carburetor idle adjuster screw

bracket using front side of bolt.

To crankcase

Secure front bracket on frame down tube by a clamp.

(At this time, do not pinch the side stand switch wiring

between the bracket and frame.)

-12-

7. WATER CATCH TANK

^

Install the tank

with bands.

Water catch tank

To radiator conduction

Make a hole to catch water hose.

Air bleeding hole (3 mm dia.)

Water catch tank

-13-

8. CARBURETOR SETTING PARTS

Set the carburetor in accodance with the conditions of the race course temperature, altitude (atmospheric

pressure), etc. Various types of setting are possible by various combinations of parts.

CARBURETOR TYPE

MIKUNI TM34SS, TWO

BORE SIZE, 34 mm

SETTING PARTS

M.J.

Lea

#310 \

#320

#330

#340

#350

#360

#370

#380

#390

ner

#400

Richer

HJ.

Leaner

05

06

07

08

09

P-0

P-1

P-2

i

1

Richer

J.N.

Leaner

CLIP POSITION

1"t f

1

ri

5th —'

1

i

'

J Richer

P.W.J.

#50

#60

(IS)-

P.J.

#35

#37.5

#40

M.A.J.

#0.5

(#1.0) STD

A.S.

TURNING IN

I

TURNING BAG

Leaner

i

T I

Richer

Leaner

4

Rich

i

ler

Richer

4

\

r

Leaner

Ric

i

her

K

V

Leaner

14-

CARBURETION WITH DIFFERENT CLIMATIC CONDITIONS

Condition

Cold

Hot

Dry

Wet hot

High altitude

Result

Lean

Rich

Lean

Rich

Required adjustment

To make richer

To make leaner

To make richer

To make leaner

Parts to use

MJ or NJ

it

a

ii

a

CARBURETOR TUNING BY BIFFEREWT FAILURE SYMPTOM

SYMPTOM

With full throttle;

• Rev peak too low

• Doesn't rev up quickly

• Poor power output (Rich)

With full throttle;

1 • Hesitates

• Pings or knocks

• Revs up out power not

sufficient.

Performs dull or inter-

j mittent in range 1/4

—

3/4

throttle opening.

Hesitates in range 1/4

—

3/4

throttle opening and torque

is poor.

Responds to gradual but not

to quick throttle opening.

Responce too sharp to

control

AJUSTMENT

• Decrease MJ size.

• Decrease gradually by 1 —

2 sizes while observing

piston crown color.

® Increase MJ size.

« increase gradually by 1 —

2 sizes while observing

piston crown color.

• Increase PWJ size.

Decrease NJ size to make

mixture leaner.

Increase NJ size to make

mixture richer.

Decrease MJ size because of

too rich main system.

Increase PJ size or lower JN

position*

REMARKS

• Check if choke is on.

• Check if not overflowing.

• Check if air not leaking in.

• Check if ignition timing not too

fast.

(Rich at a partial opening)

-15-

DESCRIPTION OF '89 RGV250 CARBURETOR TUNING

Throttle opening

0 15 25 35 50 75 100%

PJ

<

^

y

>

NJ

\

<

>

MJ

PWJ

This diagram indicates where each jet affects the carburetion throughout the throttle opening range.

• PJ (Pilot Jet): With 15% of throttle opening, carburetion is affected in entire revolution range and with

25%

of throttle opening, in the range over 9,000 rpm.

• NJ (Needle Jet): With 15 — 25% of throttle opening, carburetion is affected in entire revolution range;

with 35 - 50% of opening, over 9,000 rpm; and with 75% of opening, over 11,000 rpm.

• MJ (Main Jet): With 75% of throttle opening, carburetion is affected in the revolution range over 9,000

rpm,

and with 100% of throttle opening, in the range over 9,000 rpm,

• PWJ (Power Jet): With 75% of throttle opening, carburetion is affected in the revolution range over

10,000 rpm, and with 100% of throttle opening, in the range over 8,000 rpm.

-16-

CARBURETOR JETTING EXAMPLE (# 1 indicates the left cylinder and # 2 the right.)

FOR STAGE I

MJ

NJ

JN

PJ

MAJ

PWJ

AS

#1

#320

0-9

6FL-76-52-3

35

0.5

60

1%

Turns back

#2

#320

0-9

6FL-76-52-3

35

0.5

60

1%

Turns back

FOR STAGE H

MJ

NJ

JN

PJ

MAJ

PWJ

| AS

#1

#340

P-1

6FL-76-52-3

35

0.5

60

1%

Turns back

#2

#350

P-1

6FL-76-52-3

35

0.5

60

1%

Turns back

Atmospheric temperature: 10°C;

Barometric pressure

For high speed circuit

: 760mmHg.

: Change with larger

MJ 2 - 3 sizes.

Change with larger

NJ by 1 -2 sizes.

Atmospheric temperature: 10°C;

Barometric pressure : 755 mmHg

For high speed circuit

Change with larger

MJ 2 - 3 sizes.

Change with larger

NJ by 1 size.

If aviation gasoline is mixed, the jetting may

be altered from the above charts as indicated

below:

With 50% of mixture If with MJ, smaller by 1 size

100%

avgas If with MJ, smaller by 2 sizes

-17™

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Suzuki RGV250 1989 User manual

Suzuki RGV250 1989 User manual

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