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2-4 PERIODIC MAINTENANCE

INSPECTION BEFORE RACE

(All items of inspection before practice on previous page plus)

WHAT TO CHECK CHECK FOR

Clutch Clutch disc plates wear and distortion

Brake pads Wear

Sprockets Wear

Fuel tank Leakage

Fuel hose • Damage

• Hoses are connected

Exhaust pipe and muffler Damage

Cylinder head Combustion chamber carbon deposit

Piston and Cylinder • Combustion chamber carbon deposit

• Piston head carbon deposit

• Piston and cylinder wear

Air cleaner • Damage

• Loose outlet tube

Foreword Group Index2
- Table of Contents2
General Information8
- General Precautions9
- Warning/Caution/Note9
- Serial Number Location11
- Suzuki Rm-Z250L0 ('10-Model)11
- Fuel, Oil and Engine Coolant Recommendation12
- Break-In (Running-In)13
  - When the Motorcycle Is New13
  - When Engine Parts Are Replaced13
- Information Labels14
- Specifications15
Periodic Maintenance17
- Default Chapter18
  - Contents18
- Periodic Maintenance19
- Spark Plug23
- Air Cleaner25
- Engine Oil and Oil Filter27
- Oil Strainers31
- Engine Coolant34
- Clutch Cable36
  - Major Adjustment36
  - Minor Adjustment36
- Throttle Cable37
  - Throttle Cable Adjustment37
  - Throttle Cable Oil Supply38
- Hot Starter39
  - Throttle Body39
- Fuel Hose40
- Engine Idle Speed40
- Crankcase Breather Hose40
- Valve Clearance41
  - Valve Clearance Adjustment42
- Periodic Maintenance42
Troubleshooting59
- Engine60
- Radiator (Cooling System)66
- Chassis67
- Brakes68
- Electrical69
Machine Tuning70
- Selection of Ecm Tuning Map71
  - Short Wire Connecting Procedure72
- Front Fork Tuning73
- Rear Suspension Tuning80
- Suspension Balance84
  - Balance Test84
  - Balancing Tips84
- Engine Removal and Installation85
Cylinder Head, Cylinder and Piston95
- Construction96
  - Cylinder Head and Cylinder96
  - Camshaft, Cam Chain and Piston97
- Engine Top Side Disassembly98
- Engine Top Components Inspection and Service103
- Engine Top Side Assembly119
Clutch129
- Construction130
  - Clutch130
- Clutch Plate131
- Primary Driven Gear and Clutch Sleeve Hub136
- Clutch Release Camshaft139
Kick Starter141
- Construction142
- Kick Starter143
Gearshifting149
- Construction150
- Gearshift Linkage151
- Gear Position (Gp) Switch156
Transmission and Crankshaft158
- Construction159
  - Transmission159
  - Crankshaft160
- Engine Bottom Side161
Lubrication System176
- Engine Lubrication System177
- Engine Lubrication System Chart177
- Engine Oil Change178
- Engine Oil Filter Change178
- Engine Oil Level Inspection178
- Oil Pressure Check178
- Oil Reed Valve Inspection178
- Oil Reed Valve Installation178
- Oil Reed Valve Removal178
- Oil Strainer Installation178
- Oil Strainer Removal178
- Oil Strainers Inspection178
- OIL PUMP No.1 and No.2 REMOVAL179
- Oil Seal Inspection179
- Oil Seal Installation179
- OIL PUMP No.1 and No.2 INSPECTION181
- OIL PUMP No.1 and No.2 INSTALLATION181
Fi System Diagnosis184
- Precautions in Servicing186
- Fi System Technical Features193
- Ecm Terminal198
- Self-Diagnosis Function199
- Fi System Troubleshooting202
- Sds Check206
- ECM (FI Control Unit)243
  - Removal243
  - Installation243
- Sensors244
Fuel System and Throttle Body247
- Fuel System248
- Throttle Body253
Cooling System263
- Construction264
- Engine Coolant265
  - Replacement265
- Cooling Circuit266
  - Inspection266
- Radiator267
- Water Pump269
Electrical System273
- Cautions in Servicing274
- Location of Electrical Components277
- Construction279
  - Magneto279
- Generating System280
  - Inspection280
- Ignition System283
  - Troubleshooting283
  - Inspection285
- Magneto Rotor289
  - Removal289
  - Installation290
- Stator291
  - Removal291
  - Installation291
Front and Rear Wheels292
- Construction293
- Front Wheel294
- Rear Wheel298
Front and Rear Brakes303
- Construction304
  - Front Brake304
  - Rear Brake305
- Brake Fluid Air Bleeding306
- Brake Fluid Replacement307
- Brake Pads Replacement308
  - Front Brake Pads308
  - Rear Brake Pads308
- Brake Disc Inspection309
- Caliper309
- Master Cylinder316
- Brake Lever321
  - Removal321
  - Installation321
- Brake Pedal322
  - Removal322
  - Installation322
Front Fork and Steering323
- Construction324
- Steering341
Rear Suspension350
- Construction351
  - Rear Suspension351
- Rear Shock Absorber352
- Swingarm362
- Rear Suspension Linkage367
Servicing Information373
- Service Data374
- Tightening Torque382
  - Engine382
  - Fi System and Intake Air System383
  - Cooling System383
  - Chassis384
- Special Tools386
- Wiring Diagram389
- Wiring Harness Routing390
- Cable Routing393
- Fuel Hose Routing395
- Radiator Hose Routing396
- Crankcase and Cover Installation397
- Exhaust Pipe and Muffler Installation398
- Clutch Cable Adjuster399
- Hot Starter Lever Installation400
- Brake Pedal Set-Up401
- Front Brake Hose Routing402
- Rear Brake Hose Routing403
- Handlebar Set-Up404
- Chain Roller Installation405
- Rear Wheel Spokes Installation405
- Fuel Tank Cushion Installation406
  - Spacer406
- Exterior Parts407
- Front Fender Installation408
- Rear Fender Installation408
- Frame Cover Cushion Installation409
- Frame Cover Installation409

Brand	Suzuki
Model	RM-Z250
Category	Motorcycle
Language	English

Suzuki RM-Z250 Service Manual

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