Suzuki RM-Z250 Owner's Manual

DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY 4-1
4
ENGINE REMOVAL AND INSTALLATION .................................................. 4-2
REMOVAL ............................................................................................... 4-2
INSTALLATION ...................................................................................... 4-7
CYLINDER HEAD, CYLINDER AND PISTON ............................................ 4-12
ENGINE TOP SIDE DISASSEMBLY .................................................... 4-12
ENGINE TOP SIDE ASSEMBLY .......................................................... 4-19
CAM CHAIN, CAM CHAIN TENSIONER AND
CAM CHAIN No.1 GUIDE ..................................................................... 4-21
CLUTCH ...................................................................................................... 4-32
CLUTCH PLATE ................................................................................... 4-32
PRIMARY DRIVEN GEAR AND CLUTCH SLEEVE HUB ................... 4-38
CLUTCH RELEASE CAMSHAFT ......................................................... 4-42
KICK STARTER .................................................................................... 4-44
THROTTLE BODY ...................................................................................... 4-45
REMOVAL ............................................................................................. 4-45
INSTALLATION .................................................................................... 4-47
TP SENSOR ADJUSTMENT ................................................................ 4-48
ENGINE COOLANT .................................................................................... 4-49
REPLACEMENT ................................................................................... 4-49
ELECTRICAL SYSTEM .............................................................................. 4-51
MAGNETO ROTOR .............................................................................. 4-51
FRONT AND REAR WHEELS .................................................................... 4-54
FRONT WHEEL .................................................................................... 4-54
REAR WHEEL ...................................................................................... 4-57
FRONT AND REAR BRAKES .................................................................... 4-61
BRAKE FLUID AIR BLEEDING ........................................................... 4-61
BRAKE FLUID REPLACEMENT .......................................................... 4-63
BRAKE PADS REPLACEMENT .......................................................... 4-64
CALIPER ............................................................................................... 4-65
BRAKE PEDAL ..................................................................................... 4-71
FRONT FORK AND STEERING ................................................................. 4-72
FRONT FORK ....................................................................................... 4-72
STEERING ............................................................................................ 4-89
REAR SUSPENSION .................................................................................. 4-98
REAR SHOCK ABSORBER ................................................................. 4-98
SWINGARM ............................................................................................... 4-102
REMOVAL ........................................................................................... 4-102
INSTALLATION .................................................................................. 4-104
REAR SUSPENSION LINKAGE ............................................................... 4-105
REMOVAL ........................................................................................... 4-105
INSTALLATION .................................................................................. 4-106
CONTENTS

Suzuki RM-Z250 Specifications

General

Brand	Suzuki
Model	RM-Z250
Category	Motorcycle
Language	English