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RM-Z250
Suzuki RM-Z250 Owner's Service Manual
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FU
EL
S
YSTEM
12-
9
•
Rem
ove t
he f
loat p
in

W
.
•
Rem
ove t
he f
loat

X
w
ith th
e floa
t val
ve

Y
.
•
Rem
ove t
he f
ollowi
ng par
ts.

Z
Main jet

[
Main nozzle

\
Bu
ffer pla
te

]
St
arter je
t

^
Slow jet
•
Rem
ove t
he sl
ow ai
r jet

a
.
191
193
Table of Contents
Group Index 1
9
Serial Number Location
5
Replacement Parts
7
Table of Contents
9
Location of Parts
11
Accessory
12
Side Stand
12
Fuel and Oil Recommendation
12
Operating Instructions
13
Starting the Engine
13
Stopping the Engine
14
Transmission
14
Break-In (Running-In)
15
When the Motorcycle Is New
15
When Engine Parts Are Replaced
15
Exterior Parts
16
Periodic Maintenance 2
18
Periodic Maintenance
20
Inspection before Practice
20
Inspection before Race
21
(All Items of Inspection before Practice on Previous
21
Periodic Maintenance Chart
22
Spark Plug
24
Air Cleaner
26
Air Cleaner Element Removal
26
Washing
26
Installation
26
Engine Oil and Oil Filter
27
Inspection before Engine Oil Level Check
28
Engine Oil Level Inspection
28
Engine Oil Change
29
Engine Oil Filter Change
30
Oil Strainers
31
Inspection
31
Engine Coolant
32
Engine Coolant Level Check
32
Engine Coolant Replenishment
33
Cooling System Inspection
33
Clutch Cable
34
Major Adjustment
34
Minor Adjustment
34
Throttle Cable
35
Throttle Cable Adjustment
35
Throttle Cable Lubrication
35
Hot Starter
36
Crankcase Breather Hose
37
Engine Idle Speed
37
Fuel Filter
38
Fuel Hose
38
Valve Clearance
39
Valve Clearance Adjustment
40
Cylinder Head, Cylinder and Piston
43
Cylinder Head Inspection
43
Cylinder Inspection
43
Piston Inspection
43
Exhaust Silencer
44
Silencer Inspection and Replacement
44
Drive Chain and Sprockets
45
Drive Chain Slack
45
Drive Chain Adjustment
45
20Th Pitch Length
45
Drive Chain Lubrication
46
Sprocket Inspection
46
Drive Chain Guide, Buffer and Chain Roller
47
Drive Chain Guide Inspection
47
Drive Chain Buffer and Roller Inspection
47
Brakes
48
Brake Fluid Level
48
Brake Pad
49
Front Brake Lever Adjustment
49
Brake Pedal Height Adjustment
49
Front Fork
50
Rear Suspension
50
Wheels and Tires
50
Wheel Rim and Tires Inspection
50
Spoke Nipple and Rim Lock Inspection
51
Tire Pressure
51
Steering
51
Lubrication
52
Compression Pressure Check
53
Compression Test Procedure
53
Oil Pressure Check
54
Oil Pressure Check Procedure
54
Troubleshooting
56
Engine
57
Carburetor
61
Radiator (Cooling System)
61
Chassis
62
Brakes
63
Electrical
64
Machine Tuning
66
Carburetor Tuning
67
Principles of Carburetor Tuning
67
Slow System
68
Main System
70
Intermediate System
70
Carburetor Tuning in Practice
72
Front Fork Tuning
75
Compression Damping Force Adjustment
75
Rebound Damping Force Adjustment
75
Oil Quantity Minor Adjustment
76
OIL CHANGE (Only for Outer Tube Oil Chamber)
77
Spring Change
79
Front Fork Tuning Procedure
81
Rear Suspension Tuning
82
Compression Damping Force Adjustment
82
Rebound Damping Force Adjustment
83
Spring Pre-Load Adjustment
83
Rear Suspension Tuning Procedure
84
Suspension Balance
86
Balance Test
86
Balancing Tips
86
Engine Removal and Installation
88
Cylinder Head, Cylinder and Piston
96
Construction
97
Cylinder Head, Cylinder and Piston
97
Engine Top Side
98
Cylinder Head Cover Removal
98
Camshafts (Automatic Decomp.) and Cam Chain Tension Adjuster Removal
98
Cylinder Head Removal
99
Cylinder Removal
100
Piston and Piston Ring Removal
101
Cam Chain, Cam Chain Tensioner and Cam Chain Guide Removal
102
Engine Top Components Inspection and Service
103
Automatic Decomp. Inspection
103
Camshaft Inspection
103
Cam Chain Tension Adjuster Inspection
105
Cam Chain Tensioner Inspection
106
Cylinder Head and Valve Inspection
106
Intake Pipe Removal
114
Intake Pipe Installation
114
Cylinder Inspection
115
Piston and Piston Ring Inspection
116
Piston Diameter
116
Piston Ring Groove Width
117
Piston Ring Thickness
117
Piston Ring End Gap
117
Crankshaft and Conrod Inspection
118
Cam Chain, Cam Chain Tensioner and Cam Chain Guide Installation
119
Piston and Piston Ring Installation
120
Cylinder and Cylinder Head Installation
122
Camshaft (Automatic Decomp.) and Cam Chain Tension Adjuster Installation
124
Cylinder Head Cover Installation
128
Clutch
128
Clutch
130
Construction
131
Clutch
131
Clutch Plate
132
Removal
132
Inspection
133
Installation
135
Primary Driven Gear and Clutch Sleeve Hub
136
Removal
136
Inspection
137
Installation
137
Clutch Release Camshaft
139
Removal
139
Inspection
139
Installation
140
Kick Starter
142
Construction
143
Kick Starter
143
Removal
144
Inspection
145
Installation
146
Gearshifting
150
Construction
151
Gearshift Linkage
151
Removal
152
Inspection
154
Installation
154
Transmission and Crankshaft
158
Construction
159
Transmission and Crankshaft
159
Engine Bottom Side
160
Primary Drive Gear Removal
160
Crankcase Separation
161
Transmission Removal
161
Crankshaft Removal
162
Reed Valve Removal
162
Transmission Inspection
163
Conrod Inspection
164
Crankshaft Inspcection
165
Oil Seal Inspection
165
Crankshaft Runout
165
Oil Seal Removal and Installation
166
Bearing Inspection
166
Bearing Removal and Installation
167
Reed Valve Installation
170
Crankshaft Installation
170
Transmission Installation
171
Crankcase Installation
173
Primary Drive Gear Installation
174
Lubrication System
176
Engine Lubrication System
177
Engine Lubrication System Chart
177
Engine Oil Change
178
Engine Oil Filter Change
178
Engine Oil Level Inspection
178
Oil Pressure Check
178
Oil Seal Inspection
178
Oil Seal Removal
178
Oil Strainers Inspection
178
Oil Strainers Installation
178
Oil Strainers Removal
178
Oil Pump Removal
179
Oil Seal Installation
179
Oil Pump Inspection
180
Oil Pump Installation
181
Fuel System
184
Fuel Tank and Fuel Valve
185
Construction
185
Removal
185
Cleaning and Inspection
186
Installation
186
Carburetor
187
Construction
187
Removal
188
Disassembly
189
Cleaning
193
Inspection
193
Reassembly
195
Installation
199
Throttle Position Sensor
200
Inspection
200
Removal
201
Installation
201
Cooling System
202
Construction
203
Engine Coolant
204
Replacement
204
Cooling Circuit
205
Inspection
205
Radiator
206
Removal
206
Inspection
206
Installation
206
Water Pump
207
Removal
207
Inspection
208
Installation
209
Electrical System
212
Cautions in Servicing
213
Connector
213
Coupler
213
Semi-Conductor Equipped Part
213
Using the Multi-Circuit Tester
213
Switch
213
Location of Electrical Components
214
Construction
215
Electrical System
215
Electrical Circuit
215
Troubleshooting
216
Ignition System
218
Ignition System Peak Voltage Inspection
218
Ignition System Coil Inspection
219
Ignition Coil Primary Peak Voltage Inspection
220
Ignition Coil/Plug Cap Inspection
221
Engine Stop Switch Inspection
222
Magneto Rotor
223
Removal
223
Installation
224
Stator
225
Removal
225
Installation
225
Front and Rear Wheels
226
Construction
227
Front Wheel
228
Removal
228
Inspection
228
Dust Seal and Bearing Replacement
229
Disc Plate Replacement
230
Installation
231
Rear Wheel
232
Removal
232
Inspection
233
Dust Seal and Bearing Replacement
233
Disc Plate Replacement
235
Rear Sprocket Replacement
235
Installation
236
Rear Wheel Spokes Replacement
236
Front and Rear Brakes
238
Construction
239
Brake Fluid Air Bleeding
240
Brake Fluid Replacement
241
Brake Pads Replacement
242
Front Brake Pads
242
Rear Brake Pads
242
Brake Disc Inspection
243
Caliper
243
Front Caliper Removal and Disassembly
244
Caliper Inspection
245
Caliper Cleaning
245
Front Caliper Reassembly and Installation
245
Rear Caliper Removal and Disassembly
246
Rear Caliper Reassembly and Installation
247
Master Cylinder
249
Front Master Cylinder Removal and Disassembly
249
Master Cylinder Inspection
250
Master Cylinder Cleaning
250
Front Master Cylinder Reassembly and Installation
251
Rear Master Cylinder Removal and Disassembly
252
Master Cylinder Inspection
253
Rear Master Cylinder Reassembly and Installation
253
Brake Lever
254
Removal
254
Installation
254
Brake Pedal
255
Removal
255
Installation
255
Front Fork and Steering
256
Construction
257
Front Fork, Steering
257
Handlebar Controls
258
Removal
259
Disassembly
260
Inspection
264
Reassembly
266
Installation
272
Steering
273
Removal
273
Inspection
275
Bearing Replacement
276
Installation
277
Rear Suspension
282
Construction
283
Rear Suspension
283
Rear Shock Absorber
284
Removal
284
Spring Replacement
285
Inspection
286
Bearing Replacement
287
Oil Replacement
288
Disassembly and Inspection
291
Reassembly
292
Installation
293
Disposal
293
Swingarm
294
Removal
294
Inspection
296
Bearing Replacement
297
Installation
298
Rear Suspension Linkage
299
Removal
299
Inspection
300
Bearing Replacement
301
Installation
302
Servicing Information
306
Service Data
307
Oil Pump
309
Tightening Torque
315
Special Tools
319
Wiring Diagram
322
Cable Routing
323
Wiring Harness Routing
325
Fuel Hose Routing
326
Fuel Tank Cushion Installation
327
Radiator Hose Routing
328
Water Pump Installation
328
Crankcase and Cover Installation
329
Magneto Installation
330
Front Brake Hose Routing
331
Rear Brake Hose Routing
332
Front Number Plate Installation
333
Rear Brake Pedal Set-Up
333
Handlebar Set-Up
334
Clutch Cable Adjuster
335
Rear Wheel Spokes Installation
335
Exhaust Pipe and Muffler Installation
336
Rim Lock Installation
336
Front Fender Installation
337
Rear Fender Installation
337
Frame Cover Cushion Installation
338
Frame Cover Installation
338
Specifications
339
Dimensions and Dry Mass
339
Optional Parts
341
Spare Parts List
341
Setting Data
342
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Suzuki RM-Z250 Specifications
General
Brand
Suzuki
Model
RM-Z250
Category
Motorcycle
Language
English
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