Suzuki RG 250 — Example photo: Veej, CC BY-SA 4.0, Wikimedia Commons

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Suzuki · Two-stroke twin, oil injection, chain drive

RG 250

Library entry covers 1984-1988

26 factory 57 guideline

Published source

Suzuki RG250 service manual, periodic maintenance schedule printed p.2-1 (ManualsLib 862155 p.15)

Factory service manual. Covers Suzuki RG250 service manual, edition year not shown on the page read.

83 items for a 1988 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Two-stroke
Engine lubrication: Two-stroke oil injection (Autolube, Injectolube, Pilgrim pump...)
Oil filtration: None (no filter)
Valve gear: None (two-stroke porting)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Two or more carburetors
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Separate gearbox oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1988 Suzuki RG 250

On the road: every 200 km

1 item

Check two-stroke oil tank / carry premix oil

Pre-ride / on the road

Guideline

Running a two-stroke out of oil seizes it. Injection bikes: check the tank. Premix: carry oil and a measure.

On the road: every 500 km

3 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Guideline

Lube warm, ideally at the end of the riding day so it soaks in overnight. Sooner after rain.

On the road: every 800 km

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 1,000 km

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 1,000 km or 2 months

1 item

Spark plug (inspect)

Engine

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I at 1000 km (2 months).

Every 1,000 km

1 item

Drive chain (clean and lubricate)

Final drive

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. Clean and lubricate every 1000 km.

Every 1,600 km or 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Guideline

Wet-cell batteries on old machines need regular topping up, more in hot weather.

Every 1,600 km or 6 months

1 item

Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 3,000 km or 12 months

1 item

Replace spark plugs (two-stroke)

Engine

Guideline

Every 3,000 km

1 item

Air cleaner (clean)

Fuel and air

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. Clean every 3000 km.

Every 5,000 km or 12 months

12 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering head bearing adjustment

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline
Check spoke tension and wheel true

Wheels and tires

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 5,000 km or 2 years

1 item

Decarbonize exhaust ports, pipes and baffles

Engine

Guideline

Two-strokes coke up the exhaust port and muffler baffles; power falls off gradually.

Every 6,000 km or 12 months

14 items

Chassis bolts and nuts (tighten)

Engine

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. T at 1000 km, then every 6000 km (4000 mi) or 12 months.
Cylinder head, cylinder and muffler (clean)

Engine

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. C every 6000 km (4000 mi) or 12 months.
Engine bolts and nuts (tighten)

Engine

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. T at 1000 km, then every 6000 km (4000 mi) or 12 months.
Oil pump (inspect)

Engine

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I at 1000 km, then every 6000 km (4000 mi) or 12 months.
Spark plug (replace)

Engine

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. R every 6000 km (4000 mi) or 12 months.
Carburetor (inspect)

Fuel and air

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I at 1000 km, then every 6000 km (4000 mi) or 12 months.
Fuel line (inspect)

Fuel and air

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I at 1000 km, then every 6000 km (4000 mi) or 12 months.
Battery (inspect)

Ignition and electrics

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I every 6000 km (4000 mi) or 12 months.
Clutch (inspect)

Primary and gearbox

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I at 1000 km, then every 6000 km (4000 mi) or 12 months.
Drive chain (inspect)

Final drive

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I at 1000 km, then every 6000 km (4000 mi) or 12 months.
Steering (inspect)

Front end

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I at 1000 km, then every 6000 km (4000 mi) or 12 months.
Brake (inspect)

Brakes

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I at 1000 km, then every 6000 km (4000 mi) or 12 months.
Brake hose (inspect)

Brakes

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I at 1000 km, then every 6000 km (4000 mi) or 12 months.
Tires (inspect)

Wheels and tires

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I at 1000 km, then every 6000 km (4000 mi) or 12 months.

Every 6,500 km or 12 months

3 items

Check / bleed / adjust oil injection pump cable

Engine

Guideline
Inspect, clean and gap spark plugs

Engine

Guideline
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Guideline

Every 9,500 km or 12 months

8 items

Inspect coolant hoses and clamps

Engine

Guideline
Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Synchronize carburetors

Fuel and air

Guideline
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 9,500 km or 2 years

1 item

Change gearbox oil

Primary and gearbox

Guideline

Every 12,000 km or 2 years

4 items

Radiator hose (inspect)

Engine

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I at 1000 km, then every 12000 km (7500 mi) or 24 months.
Rear suspension (inspect)

Engine

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I every 12000 km (7500 mi) or 24 months.
Transmission oil (replace)

Primary and gearbox

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. R at 1000 km, then every 12000 km (7500 mi) or 24 months.
Front fork (inspect)

Front end

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. I every 12000 km (7500 mi) or 24 months; inspect air pressure every 6 months.

Every 13,000 km or 2 years

1 item

Replace spark plugs

Engine

Guideline

Every 16,000 km or 2 years

2 items

Compression test (or leak-down)

Engine

Guideline
Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 19,500 km or 2 years

3 items

Replace air filter element

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 29,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 32,000 km or 4 years

2 items

Repack / replace steering head bearings

Front end

Guideline

Many old machines use loose balls in cups and cones. Taper roller conversions are common.
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

6 items

Coolant (change)

Engine

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. Change every 2 years.
Replace coolant

Engine

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Brake fluid (replace)

Brakes

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. Replace every 2 years.
Replace brake fluid

Brakes

Guideline

Every 4 years

7 items

Radiator hose (replace)

Engine

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. Replace every 4 years.
Replace oil injection delivery lines

Engine

Guideline
Fuel line (replace)

Fuel and air

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. Replace every 4 years.
Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Brake hose (replace)

Brakes

Factory

Factory: Periodic maintenance schedule (Suzuki RG250 service manual, printed p.2-1). Intervals by km, miles or months: 1000 km/600 mi/2 months; 6000/4000/12; 12000/7500/24; 18000/11000/36; 24000/15000/48. Key: C clean; I inspect; R replace; T tighten. Severe conditions may need more frequent servicing. Replace every 4 years.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.