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TROUBLESHOOTING

TROUBLESHOOTING 3-1

CONTENTS

ENGINE ........................................................................................................ 3- 2

RADIATOR (COOLING SYSTEM) .............................................................. 3- 8

CHASSIS ..................................................................................................... 3- 9

BRAKES ...................................................................................................... 3-10

ELECTRICAL ............................................................................................... 3-11

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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