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RM-Z250
Suzuki RM-Z250 Service Manual
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20-16 SERVICING INFORMATION
09925-18011
Bearing installer
09930-10121
Spark plug wrench
set
09930-11950
T
orx wrench (T25H)
09930-30104
Rotor remover slide
shaft
09930-35020
Rotor remover
09930-44560
Rotor holder
09940-14911
Steering stem nut
socket wrenc
h
09940-14960
Steering stem nut
socket wrenc
h
09940-34581
Front f
ork assem-
bling attachment (F)
09940-40211
Fuel pressure gauge
adapter
09940-52861
Front f
ork oil seal
installer set
09941-34513
Bearing installer
09941-53630
Front f
ork cap
socket wrenc
h
(50 mm)
09941-53660
RCU socket wrenc
h
(24 mm)
09941-54911
Bearing outer race
remover
09941-74911
Steering race
installer
09943-02810
Rear cushion guard
ring
99565-01010-021
CD-ROM V
er
.21
387
389
Table of Contents
Foreword Group Index
2
Table of Contents
2
General Information
8
General Precautions
9
Warning/Caution/Note
9
Serial Number Location
11
Suzuki Rm-Z250L0 ('10-Model)
11
Fuel, Oil and Engine Coolant Recommendation
12
Fuel (for Usa and Canada)
12
Fuel (for Other Countries)
12
Engine Oil (for Usa)
12
Engine Oil (for Other Countries)
12
Brake Fluid
12
Front Fork Oil
12
Rear Suspension Oil
12
Engine Coolant
13
Break-In (Running-In)
13
When the Motorcycle Is New
13
When Engine Parts Are Replaced
13
Information Labels
14
Specifications
15
Dimensions and Curb Mass
15
Engine
15
Transmission
15
Chassis
16
Electrical
16
Capacities
16
Periodic Maintenance
17
Default Chapter
18
Contents
18
Periodic Maintenance
19
Inspection before Practice
19
Inspection before Race
20
(All Items of Inspection before Practice on Previous
20
Periodic Maintenance Chart
21
Spark Plug
23
Air Cleaner
25
Air Cleaner Element Removal
25
Washing
25
Installation
26
Engine Oil and Oil Filter
27
Inspection before Engine Oil Level Check
27
Engine Oil Level Inspection
28
Engine Oil Change
29
Engine Oil Filter Change
30
Oil Strainers
31
OIL STRAINER (No.1) REMOVAL
31
OIL STRAINER (No.2) REMOVAL
31
Inspection
32
OIL STRAINER (No.2) INSTALLATION
33
OIL STRAINER (No.1) INSTALLATION
33
Engine Coolant
34
Engine Coolant Level Check
34
Engine Coolant Replenishment
35
Cooling System Inspection
35
Clutch Cable
36
Major Adjustment
36
Minor Adjustment
36
Throttle Cable
37
Throttle Cable Adjustment
37
Throttle Cable Oil Supply
38
Hot Starter
39
Throttle Body
39
Fuel Hose
40
Engine Idle Speed
40
Crankcase Breather Hose
40
Valve Clearance
41
Valve Clearance Adjustment
42
Periodic Maintenance
42
Cylinder Head, Cylinder and Piston
45
Cylinder Head Inspection
45
Cylinder Inspection
45
Piston Inspection
45
Drive Chain and Sprockets
46
Drive Chain Slack
46
Crankcase Driveshaft Oil Seal
46
Drive Chain Adjustment
47
20Th Pitch Length
47
Drive Chain Lubrication
48
Sprocket Inspection
48
Drive Chain Guide, Buffer and Tensioner Roller
49
Drive Chain Guide Inspection
49
Drive Chain Buffer and Roller Inspection
49
Brakes
50
Brake Fluid Level
50
Brake Pad
51
Front Brake Lever Adjustment
51
Brake Pedal Height Adjustment
51
Front Fork
52
Rear Suspension
52
Wheels and Tires
52
Wheel Rim and Tires Inspection
52
Spoke Nipple and Rim Lock Inspection
53
Tire Pressure
53
Steering
53
Lubrication
54
Chassis Bolts and Nuts
55
Compression Pressure Check
57
Compression Test Procedure
57
Oil Pressure Check
58
Oil Pressure Test Procedure
58
Troubleshooting
59
Engine
60
Radiator (Cooling System)
66
Chassis
67
Brakes
68
Electrical
69
Machine Tuning
70
Selection of Ecm Tuning Map
71
Short Wire Connecting Procedure
72
Front Fork Tuning
73
Compression Damping Force Adjustment
73
Rebound Damping Force Adjustment
73
Oil Quantity Minor Adjustment
74
OIL CHANGE (Only for Outer Tube Oil Chamber)
75
Spring Change
77
Front Fork Tuning Procedure
79
Rear Suspension Tuning
80
Compression Damping Force Adjustment
80
Rebound Damping Force Adjustment
81
Spring Pre-Load Adjustment
81
Rear Suspension Tuning Procedure
82
Suspension Balance
84
Balance Test
84
Balancing Tips
84
Engine Removal and Installation
85
Cylinder Head, Cylinder and Piston
95
Construction
96
Cylinder Head and Cylinder
96
Camshaft, Cam Chain and Piston
97
Engine Top Side Disassembly
98
Cylinder Head Cover Removal
98
Camshafts (Automatic Decomp.) and Cam Chain Tension Adjuster Removal
98
Cylinder Head Removal
100
Cylinder Removal
101
Piston and Piston Ring Removal
102
CAM CHAIN, CAM CHAIN TENSIONER and CAM CHAIN No.1 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
105
Cylinder Head and Valve Inspection
106
Intake Pipe Removal
114
Intake Pipe Installation
114
Cylinder Inspection
115
Ect Sensor Removal
115
Ect Sensor Inspection
115
Ect Sensor Installation
115
Piston and Piston Ring Inspection
116
Crankshaft and Conrod Inspection
118
Engine Top Side Assembly
119
CAM CHAIN, CAM CHAIN TENSIONER and CAM CHAIN No.1 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
129
Construction
130
Clutch
130
Clutch Plate
131
Removal
131
Inspection
133
Installation
134
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
141
Construction
142
Kick Starter
142
Removal
143
Inspection
144
Installation
145
Kick Starter
143
Gearshifting
149
Construction
150
Gearshift Linkage
150
Removal
151
Inspection
153
Installation
153
Gearshift Linkage
151
Gear Position (Gp) Switch
156
Removal
156
Inspection
156
Installation
156
Transmission and Crankshaft
158
Construction
159
Transmission
159
Crankshaft
160
Engine Bottom Side
161
Primary Drive Gear Removal
161
Crankcase Separation
162
Transmission Removal
162
Crankshaft Removal
163
Crankcase Reed Valve Removal
163
Transmission Inspection
164
Conrod Inspection
165
Crankshaft Inspcection
165
Oil Reed Valve Inspection
165
Crankcase Reed Valve Inspection
166
Oil Seal Inspection
166
Oil Seal Removal and Installation
166
Bearing Inspection
167
Bearing Removal and Installation
168
Crankcase Reed Valve Installation
170
Crankshaft Installation
170
Transmission Installation
172
Crankcase Installation
174
Primary Drive Gear Installation
175
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 Reed Valve Inspection
178
Oil Reed Valve Installation
178
Oil Reed Valve Removal
178
Oil Strainer Installation
178
Oil Strainer Removal
178
Oil Strainers Inspection
178
OIL PUMP No.1 and No.2 REMOVAL
179
Oil Seal Inspection
179
Oil Seal Installation
179
OIL PUMP No.1 and No.2 INSPECTION
181
OIL PUMP No.1 and No.2 INSTALLATION
181
Fi System Diagnosis
184
Precautions in Servicing
186
Connector/Coupler
186
Ecm/Various Sensors
187
Electrical Circuit Inspection Procedure
189
Using the Multi Circuit Tester
192
Fi System Technical Features
193
Injection Time (Injection Volume)
193
Compensation of Injection Time (Volume)
194
Injection Stop Control
194
Fi System Parts Location
195
Fi System Wiring Diagram
197
Ecm Terminal
198
Self-Diagnosis Function
199
Dealer Mode
199
Diagnostic Trouble Code Table
200
Tp Sensor Adjustment
201
Fail-Safe Function
201
Fi System Troubleshooting
202
Visual Inspection
202
Self-Diagnostic Procedures
202
Self-Diagnosis Reset Procedure
203
Use of Sds Diagnostic Procedures
203
Use of Sds Diagnosis Reset Procedure
204
Show Data When Trouble (Displaing Data at the Time of Dtc)
205
Sds Check
206
Dtc and Defective Condition
210
12" (P0335) Ckp Sensor Circuit Malfunction
212
14" (P0120-H/L) Tp Sensor Circuit Malfunction
214
15" (P0115-H/L) Ect Sensor Circuit Malfunction
218
17" (P0105-H/L) Iap Sensor Circuit Malfunction
222
21" (P0110-H/L) Iat Sensor Circuit Malfunction
227
23" (P1651-H/L) to Sensor Circuit Malfunction
231
31" (P0705) Gp Switch Circuit Malfunction
235
32" (P0201) Fuel Injector Circuit Malfunction
237
41" (P0230) Fp Relay Circuit Malfunction
239
63" (P01771) Crankshaft Rotation Signal Circuit Malfunction
241
ECM (FI Control Unit)
243
Removal
243
Installation
243
Sensors
244
Ckp Sensor/Crankshaft Rotation Signal Sensor Inspection
244
Ckp Sensor/Crankshaft Rotation Signal Sensor Removal and Installation
244
Iap Sensor Inspection
244
Iap Sensor Removal and Installation
244
Tp Sensor Inspection
244
Tp Sensor Removal and Installation
244
Ect Sensor Inspection
245
Ect Sensor Removal and Installation
245
Iat Sensor Inspection
246
Iat Sensor Removal and Installation
246
To Sensor Inspection
246
To Sensor Removal and Installation
246
Fuel System and Throttle Body
247
Fuel System
248
Construction
248
Fuel Tank and Fuel Pump Removal
248
Fuel Tank and Fuel Pump Installation
249
Fuel Pressure Inspection
250
Fuel Pump Inspection
251
Fuel Discharge Amount Inspection
252
Throttle Body
253
Construction
253
Removal
254
Disassembly
255
Cleaning
258
Inspection
258
Reassembly
258
Installation
261
Fuel Injector Removal
262
Fuel Injector Inspection
262
Fuel Injector Installation
262
Cooling System
263
Construction
264
Engine Coolant
265
Replacement
265
Cooling Circuit
266
Inspection
266
Radiator
267
Inspection
267
Removal
268
Installation
268
Water Pump
269
Removal
269
Inspection
270
Installation
271
Electrical System
273
Cautions in Servicing
274
Connector
274
Coupler
274
Clamp
274
Switch
274
Semi-Conductor Equipped Part
275
Connecting the Battery
275
Wiring Procedure
275
Using the Multi Circuit Tester
276
Location of Electrical Components
277
Construction
279
Magneto
279
Generating System
280
Inspection
280
Ignition System
283
Troubleshooting
283
Inspection
285
Magneto Rotor
289
Removal
289
Installation
290
Stator
291
Removal
291
Installation
291
Front and Rear Wheels
292
Construction
293
Front Wheel
294
Removal
294
Inspection
294
Dust Seal and Bearing Replacement
295
Disc Plate Replacement
296
Installation
297
Rear Wheel
298
Removal
298
Inspection
299
Dust Seal and Bearing Replacement
299
Disc Plate Replacement
301
Rear Sprocket Replacement
301
Installation
302
Rear Wheel Spokes Replacement
302
Front and Rear Brakes
303
Construction
304
Front Brake
304
Rear Brake
305
Brake Fluid Air Bleeding
306
Brake Fluid Replacement
307
Brake Pads Replacement
308
Front Brake Pads
308
Rear Brake Pads
308
Brake Disc Inspection
309
Caliper
309
Front Caliper Removal and Disassembly
310
Caliper Inspection
311
Caliper Cleaning
311
Front Caliper Reassembly and Installation
311
Rear Caliper Removal and Disassembly
313
Rear Caliper Reassembly and Installation
315
Master Cylinder
316
Front Master Cylinder Removal and Disassembly
316
Master Cylinder Inspection
317
Master Cylinder Cleaning
317
Front Master Cylinder Reassembly and Installation
318
Rear Master Cylinder Removal and Disassembly
319
Master Cylinder Inspection
320
Rear Master Cylinder Reassembly and Installation
320
Brake Lever
321
Removal
321
Installation
321
Brake Pedal
322
Removal
322
Installation
322
Front Fork and Steering
323
Construction
324
Front Fork
324
Steering
325
Handlebar Controls
326
Removal
327
Disassembly
328
Inspection
332
Reassembly
334
Installation
340
Steering
341
Removal
341
Inspection
343
Bearing Replacement
344
Installation
345
Rear Suspension
350
Construction
351
Rear Suspension
351
Rear Shock Absorber
352
Removal
352
Spring Replacement
353
Inspection
354
Bearing Replacement
355
Oil Replacement
356
Disassembly and Inspection
359
Reassembly
360
Installation
361
Disposal
361
Swingarm
362
Removal
362
Inspection
364
Bearing Replacement
365
Installation
366
Rear Suspension Linkage
367
Removal
367
Inspection
368
Bearing Replacement
369
Installation
370
Servicing Information
373
Service Data
374
Tightening Torque
382
Engine
382
Fi System and Intake Air System
383
Cooling System
383
Chassis
384
Special Tools
386
Wiring Diagram
389
Wiring Harness Routing
390
Cable Routing
393
Fuel Hose Routing
395
Radiator Hose Routing
396
Crankcase and Cover Installation
397
Exhaust Pipe and Muffler Installation
398
Clutch Cable Adjuster
399
Hot Starter Lever Installation
400
Brake Pedal Set-Up
401
Front Brake Hose Routing
402
Rear Brake Hose Routing
403
Handlebar Set-Up
404
Chain Roller Installation
405
Rear Wheel Spokes Installation
405
Fuel Tank Cushion Installation
406
Spacer
406
Exterior Parts
407
Front Fender Installation
408
Rear Fender Installation
408
Frame Cover Cushion Installation
409
Frame Cover Installation
409
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Suzuki RM-Z250 Specifications
General
Brand
Suzuki
Model
RM-Z250
Category
Motorcycle
Language
English
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