The RG250W, produced for the 1983 and 1984 model years, was a notable entry in the 250cc sportbike category. This liquid-cooled, two-stroke parallel-twin motorcycle was engineered for performance, featuring a 247cc engine that produced approximately 45 horsepower. Its design emphasized sporty handling and offered technical advancements for its era, including front and rear disc brakes and a 6-speed transmission. The RG250W was part of an esteemed series, known for delivering agile performance and appealing to riders seeking a capable and engaging machine. This comprehensive Service Repair Manual provides detailed guidance for the RG250W (1983-1984). It covers all essential aspects of maintenance, repair, and troubleshooting across the vehicle's systems. Sections include in-depth engine overhaul, transmission servicing, chassis and suspension adjustments, brake system maintenance, and electrical system diagnostics. The manual offers step-by-step repair procedures, routine maintenance schedules, and technical specifications, making it an indispensable resource for owners and technicians aiming to keep the RG250W in optimal condition. 🏷️ Basic Information Identification Make: Suzuki Model: RG250W Year: 1983-1984 👋 Introduction Market Position Historical Context: The Suzuki RG250W was a significant motorcycle in the 250cc class, known for its performance and sporty handling, competing with other lightweight two-stroke sportbikes of its era. Competitive Analysis Competitors: Yamaha RZ250, Kawasaki KR250, Honda VT250F. Key Features Performance Focus: Designed for sporty performance and track-day potential within its displacement class. 📋 Manual Details Coverage Areas Manual Type: Service Repair Manual Language: English Format: PDF Download Applicable Models: Suzuki RG250W Applicable Years: 1983, 1984 Page Count Estimated Pages: Approx. 300-400 pages (typical for this era of comprehensive service manuals) 📖 Manual Coverage Systems Covered Engine: Comprehensive engine overhaul, tuning, lubrication system, cooling system, fuel system (carburetors, fuel lines, filters), ignition system (CDI, spark plugs). Transmission: Gearbox assembly, clutch operation, shift mechanism, lubrication, troubleshooting. Chassis: Frame inspection and repair, suspension (front forks, rear shock absorber), steering system, wheel bearings, spokes. Brakes: Front and rear brake systems (disc brakes), hydraulic lines, master cylinders, calipers, brake pad replacement, bleeding procedures. Electrical: Wiring diagrams, lighting system, ignition system components, charging system (stator, regulator/rectifier), battery maintenance, starting system, switches. Bodywork: Fairing removal and installation, seat, fuel tank, fenders, general body panel maintenance. Procedures Included Maintenance: Regular scheduled maintenance, oil changes, filter replacements, spark plug checks, chain lubrication and adjustment, brake adjustments. Repair: Detailed step-by-step instructions for engine rebuilds, carburetor tuning and overhaul, suspension component replacement, brake system repairs, electrical system troubleshooting. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting guides for common mechanical and electrical issues. Technical Depth Diagnostic Capabilities: Advanced diagnostic procedures, component testing, and troubleshooting for complex faults. Rebuild Procedures: Complete engine and transmission disassembly, inspection, reassembly, and tuning instructions for full rebuilds. Repair Manual Scope: Comprehensive workshop manual covering all aspects of repair, maintenance, and troubleshooting. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable PDF for easy navigation and information retrieval. Print Quality: High-resolution scans ensuring clarity of text and diagrams. File Size: Varies based on source scan quality, typically 30-70 MB for a high-quality PDF. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, Parallel-Twin, Liquid-cooled Displacement: 247 cc Bore X Stroke: 54.0 mm x 54.0 mm Compression Ratio: 7.2:1 (typical, may vary slightly by market) Power Output: Approx. 45 hp @ 9,000 rpm (European/Japanese spec, US spec may differ) Torque: Approx. 3.6 kgf-m @ 8,500 rpm Cooling System: Liquid-cooled (water-cooled) Fuel System Carburetors: Mikuni VM26SS x 2 (or similar specification) Fuel Type: Unleaded gasoline (minimum 91 octane recommended), requires 2-stroke oil pre-mix or separate oil injection system. Lubrication Oil System: Suzuki Posi-Force oil injection system or manual pre-mix. 🔧 Transmission Standard Type: 6-speed, constant mesh Gear Ratios: Refer to manual for specific ratios per gear. Features Clutch: Wet, multi-plate 📐 Dimensions Exterior Length: Approx. 2050 mm Width: Approx. 720 mm Height: Approx. 1120 mm Wheelbase: Approx. 1365 mm Weights Dry Weight: Approx. 135 kg Wet Weight: Approx. 149 kg (fully fueled and ready to ride) 🛡️ Safety Features Active Features Braking System: Front: Disc brake, Rear: Disc brake. Passive Features Lighting: Halogen headlamp, taillight, turn signals. 💡 Technology Features Infotainment Dashboard Instruments: Analog speedometer, tachometer, engine temperature gauge, indicator lights (oil, neutral, turn signals, high beam). Driver Assistance ABS: N/A (ABS was not standard or commonly available on motorcycles of this class in this era). Connectivity Bluetooth: N/A 🔧 Maintenance Service Intervals Oil Change: Every 3,000 km or annually. Refer to manual for precise interval based on usage. Spark Plug Check: Every 3,000 km. Replacement interval as specified in manual (e.g., NGK B9ES or equivalent). Air Filter Cleaning: Every 3,000 km. Cleaning or replacement based on condition. Chain Maintenance: Lubrication and adjustment every 500-1,000 km, depending on riding conditions. Fluid Specifications Engine Oil: 2-stroke engine oil, JASO FD or higher specification. Capacity: Approx. 0.6 Liters...