Name: Suzuki RM 250
Brand: Suzuki
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Safety Precautions3
Group Index3
How to Use this Manual4
Component Parts and Work to be Done4
Symbol5
General Information/Contents6
Warning/Cautions for Servicing7
Wear a Helmet and Googles/Protective Gear10
Inspect Your Machine before Riding10
Practice on Level Ground10
Precautions10
Serial Number Location11
Location of Parts12
Fuel and Oil Recommendation13
Starting the Engine14
Stopping the Engine15
Transmission15
Break-In (Running-In)15
When Engine Parts Are New/Replaced15
Country and Area Codes16
Periodic Maintenance/Contents17
Periodic Maintenance Chart19
Inspection before Practice/Race21
Spark Plug22
Air Cleaner Element Removal23
Washing23
Installation23
Transmission Oil Level Inspection and Replenishment25
Transmission Oil Change26
Engine Coolant Level Check27
Engine Coolant Density-Freezing Point Curve27
Engine Coolant Replenishment28
Engine Cooling System Inspection28
Clutch Major/Minor Adjustment29
Throttle Cable29
Fuel Hose/Valve30
Cylinder/Cylinder Head31
Piston31
Exhaust Valve31
Exhaust Silencer32
Drive Chain Slack/Adjustment32
20Th Pitch Length33
Drive Chain Lubrication33
Sprocket Inspection33
Drive Chain Guide/Guide Buffer34
Drive Chain Control Roller34
Brake Fluid Level34
Brake Pad35
Front Brake Lever Adjustment35
Brake Pedal Height Adjustment36
Front Fork36
Air Pressure Adjustment36
Steering36
Rear Suspension37
Tire Pressure37
Wheel Rim37
Spoke Nipple37
Rim Lock38
Lubrication39
Engine Dismounting and Mounting/Contents40
Engine Dismounting41
Engine Mounting44
Inspection after Engine Mounting45
Cylinder, Cylinder Head and Piston/Contents46
Constrtuction47
Cylinder/Cylinder Head Removal48
Piston and Piston Ring Removal49
Cylinder/Cylinder Head Inspection50
Piston to Cylinder Clearance50
Conrod51
Piston and Piston Ring Inspection51
Piston and Piston Ring Installation52
Cylinder Installation53
Cylinder Head Installation54
Inspection after Installation54
Clutch/Contents55
Clutch Construction56
Clutch Plate Removal57
Primary Driven Gear Removal58
Clutch Release Camshaft Removal58
Drive/Driven Plate Inspection59
Clutch Spring Inspection59
Clutch Push Rod/Release Camshaft Inspection60
Primary Driven Gear and Clutch Sleeve Hub Inspection60
Bearing and Spacer Inspection60
Oil Seal and Bearing Inspection60
Primary Drive Gear Installation61
Clutch Plate/Cover62
Magneto Cover Installation63
Kick Starter/Contents64
Kick Starter Construction65
Kick Starter Removal/Inspection66
Kick Starter Reassembly67
Magneto Rotor and Stator/Contents69
Magneto Rotor and Stator Construction70
Magneto Rotor and Stator Removal71
Magneto Rotor and Stator Installation72
Transmission and Crankshaft/Contents74
Crankshaft and Crankcase Construction75
Transmission Construction76
Gearshift Linkage Removal77
Primary Drive Gear Removal77
Crankcase and Transmission Removal78
Crankshaft Removal79
Gearshift Shaft Inspection79
Gearshift Cam Driven Gear Inspection79
Transmission Inspection79
Crankshaft Inspection81
Conrod Inspection81
Oil Seal Inspection and Removal82
Oil Seal Installation82
Bearing Inspection, Removal and Installation83
Crankshaft Installation84
Transmission Installation84
Crankcase Installation85
Gearshift Linkage Installation86
Fuel System/Contents88
Fuel System Construction89
Carburetor Tuning90
Carburetor Specifications90
Carburetor Components and Fnctions90
Slow/Power Jet91
Air Screw91
Needle Clip Position92
Jet Needle92
Needle Number92
Main Jet92
Throttle Stop Screw93
Variation in Air (Oxygen) Concentration and Carburetor Conditions94
Judging Air/Fuel Mixture95
Tuning Procedure95
Included Parts and Optional Parts95
Carburetor Removal and Disassembly97
Carburetor Inspection99
Carburetor Reassembly and Remounting99
Carburetor Solenoid Removal and Inspection100
Carburetor Reassembly100
Throttle Position Sensor Inspection101
Throttle Position Sensor Removal and Remounting102
Reed Valve Removal/Inspection/Reassembly102
Cooling System/Contents103
Cooling System Construction104
Cooling Circuit Inspection105
Radiator Cap Inspection105
Rediator Removal105
Water Pump Removal106
Radiator Inspection106
Impeller and Gear Shaft Inspection107
Water Pump Bearing Inspection107
Oil Seal Inspection107
Bearing Replacement107
Water Pump Reassembly108
Exhaust Valve/Contents110
Exhaust Valve Construction111
Exhaust Side Valve (RH) Disassembly112
Exhaust Side (Lh)/Main Valve Disassembly113
Exhaust Valve Inspection/Reassembly114
Exhaust Valve Governer and Actuator Disassembly117
Exhaust Valve Governer and Actuator Inspection/Reassembly118
Constructions/Contents120
Exterior Parts121
Handlebar Controls122
Removal122
Remounting123
Seat Rail, Drive Chain Control Roller125
Front and Rear Wheels/Contents126
Front and Rear Wheels Construction127
Front Wheel Removal and Reassembly128
Rear Wheel Removal128
Rear Wheel Reassembly129
Spacer and Dust Seal Inspection129
Axle Shaft Inspection129
Wheel Rim Inspection129
Wheel Bearing Inspection130
Front/Rear Wheel Bearing Removal130
Front/Rear Wheel Bearing Reassembly131
Disc Plate Replacement131
Rear Sprocket Replacement132
Front and Rear Brakes/Contents133
Front and Rear Brakes Construction134
Bruid Fluid Air Bleeding135
Brake Fluid Replacement136
Front/Rear Brake Pads Replacement137
Brake Disc Inspection138
Caliper138
Front Caliper Removal and Disassembly139
Rear Caliper Removal and Disassembly140
Caliper Inspection140
Caliper Cleaning141
Front Caliper Reassembly141
Rear Caliper Reassembly142
Front Master Cylinder Removal and Disassembly143
Rear Master Cylinder Removal and Disassembly144
Master Cylinder Inspection144
Master Cylinder Cleaning145
Front Master Cylinder Reassembly145
Rear Master Cylinder Reassembly146
Brake Pedal Removal/Reassembly146
Front Fork and Steering/Contents147
Front Fork and Steering Construction148
Front Fork Tuning149
Compression Damping Force Adjustment149
Rebound Damping Force Adjustment149
Oil Quantity Minor Adjustment150
Adding/Reducing the Fork Oil150
Oil Change (Only for Outer Tube Oil Chamber)151
Spring Change153
Front Fork Tuning Procedure155
Suspension Balance156
Balance Test/Tips156
Front Fork Removal157
Front Fork Disassembly158
Inner Tube Removal161
Center Bolt Inspection162
Compression Damper Unit Inspection162
Inner/Outer Tube Inspection163
Damper Rod Inspection163
Spring Coller Inspection163
Fork Spring Inspection163
Slide Bushing and Guide Bushing Inspection164
Inner Tube Reassembly164
Compression Damper Unit165
Steering Removal171
Steering Inspection172
Steering Installation173
Rear Suspension/Contents174
Rear Suspension Construction175
Rear Suspension Tuning176
Low/High Speed Compression Damping Force Adjustment176
Spring Pre-Load Adjustment177
Rear Suspension Tuning Procedure178
Rear Shock Absorber Removal180
Spring Removal181
Rear Shock Absorber Inspection181
Spring Installation183
Rear Shock Absorber Installation183
Oil Replacement Procedure184
Tools and Equipment184
Rear Shock Absorber Disassembly and Inspection187
Rear Shock Absorber Reassembly/Disposal189
Swingarm Disassembly190
Swingarm Inspection191
Bearing Replacement/Reassembly192
Rear Suspension Linkage Disassembly/Inspection193
Bearing Removal/Installation/Reassembly194
Electrical System/Contents197
Electrical Circuit198
Ignition System Peak Voltage Inspection198
Ignition Coil Inspection200
CDI Unit Inspection200
Stator Coil Inspection201
Troubleshooting/Contents202
Troubleshooting Engine203
Troubleshooting Chassis206
Service Data/Contents207
Tightening Torque Engine/Chassis213
Special Tools215
Wiring Diagram217
Wire Harnes Routing218
Cable Routing219
Carburetor/Water Hose Routing220
Front Brake Hose Routing222
Rear Brake Hose Routing223
Handlebar Set-Up224
Muffler Set-Up225
Specifications226
Spare/Optional Parts228
Rear Sproket228

Brand	Suzuki
Model	RM 250
Category	Motorcycle
Language	English

Suzuki RM 250 User Manual

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Suzuki RM 250 Specifications

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