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RM-Z250
Suzuki RM-Z250 Owner's Manual
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4-50 DISASSEMBLY AND ASSEMBLY
•
Tighten the air bleeder bolt
3
to the specified torque.
Radiator air bleeder bolt: 6 N·m (0.6 kgf-m, 4.5 lbf-ft)
•
Add engine coolant up to the radiator inlet.
•
Tighten the radiator cap securely.
•
After warming up and cooling down the engine, add the spec-
ified engine coolant.
129
131
Table of Contents
General Information
13
Serial Number Location
4
Replacement Parts
7
Abbreviations Used in this Manual
9
Table of Contents
13
General Information
13
Location of Parts
14
Accessory
15
Side Stand
15
Fuel and Oil Recommendation
15
Operating Instructions
16
Starting the Engine
16
Stopping the Engine
18
Transmission
18
Break-In (Running-In)
19
When the Motorcycle Is New
19
When Engine Parts Are Replaced
19
Periodic Maintenance
21
Inspection before Practice
23
(All Items of Inspection before Practice on Previous
24
Inspection before Race
24
Periodic Maintenance Chart
25
Spark Plug
27
Air Cleaner
29
Air Cleaner Element Removal
29
Washing
29
Installation
30
Engine Oil and Oil Filter
31
Inspection before Engine Oil Level Check
32
Engine Oil Level Inspection
33
Engine Oil Change
34
Engine Oil Filter Change
35
Oil Strainers
36
OIL STRAINER (No.1) REMOVAL
36
OIL STRAINER (No.2) REMOVAL
36
Inspection
37
OIL STRAINER (No.2) INSTALLATION
37
OIL STRAINER (No.1) INSTALLATION
38
Engine Coolant
39
Engine Coolant Level Check
39
Engine Coolant Replenishment
40
Cooling System Inspection
40
Clutch Cable
41
Major Adjustment
41
Minor Adjustment
41
Throttle Cable
42
Throttle Cable Adjustment
42
Throttle Cable Oil Supply
43
Hot Starter
44
Throttle Body
44
Engine Idle Speed
45
Crankcase Breather Hose
46
Fuel Hose
46
Valve Clearance
47
Valve Clearance Adjustment
48
Cylinder Head, Cylinder and Piston
51
Cylinder Head Inspection
51
Cylinder Inspection
51
Piston and Piston Ring Replacement
51
Drive Chain and Sprockets
52
Drive Chain Slack
52
Crankcase Driveshaft Oil Seal
52
Drive Chain Adjustment
53
20Th Pitch Length
53
Drive Chain Lubrication
54
Sprocket Inspection
54
Drive Chain Guide, Buffer and Tensioner Roller
55
Drive Chain Guide Inspection
55
Drive Chain Buffer and Roller Inspection
55
Brakes
56
Brake Fluid Level
56
Brake Pad
57
Front Brake Lever Adjustment
58
Brake Pedal Height Adjustment
58
Front Fork
59
Front Fork Oil Replacement
59
Rear Suspension
59
Wheels and Tires
60
Wheel Rim and Tires Inspection
60
Spoke Nipple and Rim Lock Inspection
60
Tire Pressure
60
Frame
61
Steering
61
Swingarm
61
Lubrication
62
Machine Tuning
65
Selection of Ecm Tuning Map
66
Short Wire Connecting Procedure
67
Front Fork Tuning
68
Compression Damping Force Adjustment
68
Rebound Damping Force Adjustment
68
Oil Quantity Minor Adjustment
69
OIL CHANGE (Only for Outer Tube Oil Chamber)
70
Spring Change
72
Front Fork Tuning Procedure
75
Rear Suspension Tuning
76
Compression Damping Force Adjustment
76
Rebound Damping Force Adjustment
77
Spring Pre-Load Adjustment
77
Rear Suspension Tuning Procedure
78
Suspension Balance
80
Disassembly and Assembly
81
Engine Removal and Installation
82
Removal
82
Installation
87
Cylinder Head, Cylinder and Piston
92
Engine Top Side Disassembly
92
Engine Top Side Assembly
99
CAM CHAIN, CAM CHAIN TENSIONER and CAM CHAIN No.1 GUIDE
101
Clutch
112
Clutch Plate
112
Primary Driven Gear and Clutch Sleeve Hub
118
Clutch Release Camshaft
122
Kick Starter
124
Throttle Body
125
Removal
125
Installation
127
Tp Sensor Adjustment
128
Engine Coolant
129
Replacement
129
Electrical System
131
Magneto Rotor
131
Front and Rear Wheels
134
Front Wheel
134
Rear Wheel
137
Front and Rear Brakes
141
Brake Fluid Air Bleeding
141
Brake Fluid Replacement
143
Brake Pads Replacement
144
Caliper
145
Brake Pedal
151
Front Fork and Steering
152
Front Fork
152
Steering
169
Rear Suspension
178
Rear Shock Absorber
178
Swingarm
182
Removal
182
Installation
184
Rear Suspension Linkage
185
Removal
185
Installation
186
Servicing Information
189
Tightening Torque
190
Engine
190
Fi System and Intake Air System
191
Cooling System
191
Chassis
192
Special Tools
195
Wiring Diagram
197
Cable Routing
198
Fuel Hose Routing
200
Radiator Hose Routing
201
Crankcase and Cover Installation
202
Exhaust Pipe and Muffler Installation
204
Clutch Cable Adjuster
205
Hot Starter Lever Installation
206
Rear Brake Pedal Set-Up
207
Front Brake Hose Routing
208
Rear Brake Hose Routing
209
Handlebar Set-Up
210
Rear Wheel Spokes Installation
211
Specifications
212
Drive Train
212
Dimensions and Curb Mass
212
Engine
212
Transmission
212
Chassis
213
Electrical
213
Capacities
213
Spare Parts List
214
Optional Parts
215
Setting Data
216
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Suzuki RM-Z250 Specifications
General
Brand
Suzuki
Model
RM-Z250
Category
Motorcycle
Language
English
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