The Suzuki RGV250M, produced in 1991, is a celebrated lightweight sportbike renowned for its potent 247 cc liquid-cooled, 2-stroke, 90-degree V-twin engine. This model, chassis code VJC21A, embodies Suzuki's racing heritage, offering sharp handling, aggressive styling, and impressive performance for its era, often competing with other performance-oriented two-strokes. Key features include its lightweight chassis, dual Mikuni VM28SS carburetors, a 6-speed transmission, and advanced suspension systems designed for spirited riding. This comprehensive service and repair manual provides in-depth guidance for maintaining and repairing the 1991 Suzuki RGV250M. It covers all essential systems, including the engine, transmission, fuel and ignition systems, cooling, electrical components, chassis, suspension, and brakes. The manual details routine maintenance tasks, troubleshooting procedures for common issues, and step-by-step repair instructions for component disassembly and reassembly, making it an invaluable resource for owners and technicians seeking to preserve the performance and longevity of this iconic sportbike. 🏷️ Basic Information Identification Make: Suzuki Model: RGV250M Year: 1991 Codes Chassis Code: VJC21A 👋 Introduction Market Position Segment: Lightweight sportbike, performance two-stroke category. Competitive Analysis Rivals: Yamaha TZR250, Kawasaki KR-1/KR-1S, Honda NSR250R. Key Features Selling Points: Lightweight chassis, potent two-stroke V-twin engine, aggressive styling, advanced RSU (Rain Suction Unit) engine cooling system (on some variants/years), sharp handling. 📋 Manual Details Coverage Areas Systems Covered: Engine, Transmission, Fuel System, Ignition System, Cooling System, Electrical System, Chassis, Suspension, Brakes, Bodywork, Troubleshooting, Maintenance Page Count Estimated Pages: 300+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly and reassembly of the 2-stroke V-twin engine, including cylinder head, pistons, connecting rods, crankshaft, crankcase, and all associated components. Fuel System: Carburetor adjustment and overhaul (Mikuni VM28SS), fuel pump, fuel lines, and fuel tank maintenance. Ignition System: CDI ignition system, spark plugs, ignition coils, and timing adjustments. Cooling System: Liquid cooling system, radiator, water pump, hoses, and thermostat service. Transmission And Drivetrain: Clutch operation and adjustment, gearbox disassembly and reassembly, gear ratios, chain maintenance, and sprocket replacement. Electrical System: Wiring diagrams, lighting, charging system (alternator, rectifier/regulator), starting system (starter motor, battery), indicators, and horn troubleshooting. Chassis And Suspension: Frame inspection, front fork (conventional telescopic, RSU - Rain Suction Unit system) service and adjustment, rear shock absorber service, steering head bearing maintenance. Brakes: Front and rear disc brake systems, brake caliper overhaul, master cylinder service, brake fluid replacement, and bleeding procedures. Bodywork And Trim: Fairing removal and installation, seat, fuel tank, and minor body panel repairs and maintenance. Procedures Included Maintenance Tasks: Regular servicing, oil changes (premix or oil injection system), filter replacements, chain lubrication and adjustment, spark plug replacement, brake pad replacement, and coolant flushes. Troubleshooting: Systematic diagnostic procedures for common and uncommon problems, fault finding charts, and solutions for performance issues, starting problems, and electrical faults. Repair Procedures: Step-by-step instructions for component disassembly, repair, and reassembly for all major systems. Technical Depth Depth: Comprehensive coverage suitable for both home mechanics and professional technicians, from basic maintenance to full engine rebuilds and advanced diagnostics. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution scans with clear diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, 2-stroke, 90-degree V-twin Displacement: 247 cc Bore X Stroke: 54.0 mm x 54.4 mm Compression Ratio: 7.5:1 Power Output: Approx. 60-65 PS (44-48 kW) @ 11,000 rpm (varies by market and specific tuning) Torque: Approx. 37 Nm (27 lb-ft) @ 10,500 rpm Performance Top Speed: Approx. 120-130 mph (193-209 km/h) Fuel System Carburetors: Dual Mikuni VM28SS constant velocity carburetors Fuel Type: Unleaded gasoline (min. 95 octane recommended) Oil Delivery: Oil injection system (Suzuki Posi-Force) or Premix 🔧 Transmission Standard Type: 6-speed constant mesh, claw-shift Gear Ratios: 1st: 2.538 (33/13), 2nd: 1.812 (29/16), 3rd: 1.400 (28/20), 4th: 1.150 (23/20), 5th: 1.000 (22/22), 6th: 0.875 (21/24) Features Clutch: Wet multi-plate Final Drive: O-ring sealed chain, 520 size 📐 Dimensions Exterior Length: Approx. 1990 mm (78.3 in) Width: Approx. 710 mm (28.0 in) Height: Approx. 1125 mm (44.3 in) Wheelbase: Approx. 1375 mm (54.1 in) Weights Dry Weight: Approx. 130 kg (286.6 lbs) Wet Weight: Approx. 144 kg (317.5 lbs) Fuel Capacity: 16 L (4.2 US gal) 🛡️ Safety Features Ratings Classification: Sportbike Active Features Braking System: Dual front hydraulic disc brakes, Single rear hydraulic disc brake. Suspension Features: Anti-dive front suspension (often referred to as SEPF - Suzuki Electronic Performance Suspension or similar marketing terms, actual mechanism is mechanical anti-dive), adjustable rear monoshock. Passive Features Lighting: Halogen headlight, LED taillight. 💡 Technology Features Infotainment Features: Analog instrument cluster with tachometer, speedometer, coolant temperature gauge, and indicator lights. No modern infotainment or electronic rider aids. Driver Assistance Features: None. Connectivity Features: None. 🔧 Maintenance Service Intervals Oil Change: Every 5,000 km (3,000 miles) or annually. Engine oil...