2003 – 2019 Suzuki VanVan RV125 RV200 Online Service Manual

Do you need to work on a Suzuki VanVan RV125 or RV200 motorcycle? The Cyclepedia Press LLC 2003 – 2019 Suzuki VanVan RV125 RV200 dual-sport online version of our motorcycle manual is one of the best service manuals you can get for your Suzuki VanVan motorcycle. Unlike clunky PDFs this manual is easy to navigate so you can quickly find the information you need. This manual contains color photographs and wiring diagrams, complete specifications with step-by-step procedures performed and written by a veteran dealer trained technician.

This Suzuki VanVan RV125 RV200 motorcycle repair manual provides service and repair information for the following Suzuki dual sport motorcycles:

Models Covered:

Table of Contents

Quick Reference
Specifications
Torque Specifications
VIN and Engine Number

Periodic Maintenance
Periodic Maintenance Chart
Air Filter Servicing
Brake Fluid
Front Brake Inspection
Rear Brake Inspection
Clutch Cable Adjustment
Drive Chain Adjustment
Compression Test
Engine Idle Speed
Engine Oil
Fuel Line(s)
Lubrication
Spark Arrestor Servicing
Spark Plug
Steering Inspection
Suspension Inspection
Throttle Free Play
Tires
Valve Adjustment

External Components
Seat
Side Covers
Airbox
Exhaust System
Chain Guards
Footpegs
Fuel Tank
Front Fender
Rear Fender
Handlebar
Mirrors
Side Stand

Carbureted Fuel System
Carburetor Removal
Carburetor Disassembly
Carburetor Assembly
Carburetor Installation
Fuel Strainer
PAIR Emission System

EFI Fuel System
ECM
Fuel Filter
Fuel Fitting & Level Switch
Fuel Injector
Throttle Body
General FI Troubleshooting
FI System Self-Diagnostics
Service Codes (DTCs)
DTC Troubleshooting – 125cc
DTC Troubleshooting – 200cc
Evaporative Emissions

Engine
Cylinder Head Cover
Camshaft
Cylinder Head
Valves
Valve Lapping
Valve Guide Replacement
Piston and Cylinder
Left Side Engine Components
Right Crankcase (Clutch) Cover
Clutch
Gearshift
Oil Pump
Primary Drive Gear
Oil Cooler (200cc)
Engine Removal
Engine Installation
Crankcase Splitting
Crankcase Bearings
Crankcase Assembly
Crankshaft
Transmission
Transmission Shafts

Final Drive
Drive Chain
Engine Sprocket
Rear Sprocket

Brakes
Front Caliper
Front Disc
Front Master Cylinder
Rear Drum Brake
Rear Brake Rod and Pedal

Wheels
Front Wheel
Rear Wheel
Wheel Inspection
Wheel Bearing Replacement

Steering
Steering Removal
Steering Bearing Service
Steering Installation

Front Suspension
Fork Removal and Installation
Front Fork Disassembly
Front Fork Assembly

Rear Suspension
Shock Absorber
Swing Arm
Swing Arm Overhaul

Electrical Systems
Battery
Charging System
Ignition System
Starter Motor
Starter System
Headlight
Fuse
Horn
Lights
Meter
Relays
Switches
Sensors
Wiring Diagrams