Suzuki RM-Z250 User manual

GROUP INDEX

GENERAL INFORMATION

1

PERIODIC MAINTENANCE

2

TROUBLESHOOTING

3

MACHINE TUNING

4

ENGINE REMOVAL AND INSTALLATION

5

CYLINDER HEAD, CYLINDER AND PISTON

6

CLUTCH

7

KICK STARTER

8

GEARSHIFTING

9

TRANSMISSION AND CRANKSHAFT

10

LUBRICATION SYSTEM

11

FI SYSTEM DIAGNOSIS

12

FUEL SYSTEM AND THROTTLE BODY

13

COOLING SYSTEM

14

ELECTRICAL SYSTEM

15

FRONT AND REAR WHEELS

16

FRONT AND REAR BRAKES

17

FRONT FORK AND STEERING

18

REAR SUSPENSION

19

SERVICING INFORMATION

20

FOREWORD

This manual contains an introductory description on

the SUZUKI RM-Z250 and procedures for its

inspection, service and overhaul of its main compo-

nents.

Other information considered as generally known is

not included.

Read the GENERAL INFORMATION section to

familiarize yourself with the motorcycle and its

maintenance. Use this section as well as other sec-

tions as a guide for proper inspection and service.

This manual will help you know the motorcycle bet-

ter so that you can assure your customers of fast

and reliable service.



* This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modifications have been made since

then, differences may exist between the con-

tent of this manual and the actual motorcycle.

* Illustrations in this manual are used to show

the basic principles of operation and work

procedures. They may not represent the

actual motorcycle exactly in detail.

* This manual is written for persons who have

enough knowledge, skills and tools, including

special tools, for servicing SUZUKI motorcy-

cles. If you do not have the proper knowledge

and tools, ask your authorized SUZUKI

motorcycle dealer to help you.

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the

services described in this manual.

Improper repair may result in injury to the

mechanic and may render the motorcycle

unsafe for the rider.

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX.

3. Holding the manual as shown at the right will allow you to find

the first page of the section easily.

4. The contents are listed on the first page of each section to

help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service information

such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front and rear wheels

1 Rear disc plate

2

Rear wheel (1.85

× 19)

3 Spacer

4 Disc cover

5 Bead stopper

6 Rear sprocket

7 Rear axle shaft

8 Front axle shaft

9

Front wheel (1.60

× 21)

0 Front disc plate

A Rear axle nut

B Disc plate bolt (Rear)

C Rear sprocket nut

D Disc plate bolt (Front)

E Front axle nut



ITEM N·m

kgf-m

lbf-ft

A 90 9.0 65.0

B 26 2.6 19.0

C 30 3.0 21.5

D 11 1.1 8.0

E 35 3.5 25.5

FWD

SYMBOL MARKS AND MATERIALS

Listed in the table below are the symbols indicating instructions and other information. The meaning of each

symbol is also included in the table.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Data beside it indicates specified

torque.

Apply THREAD LOCK SUPER “1360”

or equivalent.

99000-32130

Apply oil. Use engine oil or transmission

oil unless otherwise specified.

Use SUZUKI FORK OIL SS-05

or equivalent.

99000-99001-SS5

Apply molybdenum oil solution.

(Mixture of engine oil and SUZUKI

MOLY PASTE in a ratio of 1:1)

Use REAR SUSPENSION OIL SS-25 or

equivalent.

Apply SUZUKI SUPER GREASE “A”

or equivalent.

99000-25010

Use engine coolant or equivalent.

Apply SUZUKI SILICONE GREASE

or equivalent.

99000-25100

Apply or use brake fluid. (DOT 4)

Apply SUZUKI MOLY PASTE

or equivalent.

99000-25140

Measure in voltage range.

Apply SUZUKI BOND “1215”

or equivalent.

99000-31110

Measure in resistance range.

Apply SUZUKI BOND “1207B”

or equivalent.

99000-31140

Measure in diode test range.

Apply THREAD LOCK SUPER “1303”

or equivalent.

99000-32030

Use special tool.

Apply THREAD LOCK SUPER “1322”

or equivalent.

99000-32110

Indication of service data.

Apply THREAD LOCK “1342”

or equivalent.

99000-32050

Replace a part with a new one when

reassembling.

ABBREVIATIONS USED IN THIS

MANUAL

A

AC : Alternating Current

API : American Petroleum Institute

B

BTDC : Before Top Dead Center

B+ : Battery Positive Voltage

C

CKP Sensor : Crankshaft Position Sensor

(CKPS)

D

DC : Direct Current

DTC : Diagnostic Trouble Code

E

ECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp.

Sensor (WTS)

F

FI : Fuel Injection, Fuel Injector

FP : Fuel Pump

FP Relay : Fuel Pump Relay

G

GND : Ground

GP Switch : Gear Position Switch

I

IAP Sensor : Intake Air Pressure Sensor (IAPS)

(MAP Sensor)

IAT Sensor : Intake Air Temperature Sensor

(IATS)

J

JASO : Japanese Automobile Standards

Organization

L

LH : Left Hand

M

Max : Maximum

Min : Minimum

R

RH : Right Hand

S

SAE : Society of Automotive Engineers

SDS : Suzuki Diagnosis System

T

TO Sensor : Tip-Over Sensor (TOS)

TP Sensor : Throttle Position Sensor (TPS)

WIRE COLOR

B : Black Lg : Light green

Bl : Blue O : Orange

Br : Brown P : Pink

Dg : Dark green R : Red

G : Green Y : Yellow

Gr : Gray

B/Bl : Black with Blue tracer

B/Br : Black with Brown tracer

B/R : Black with Red tracer

B/W : Black with White tracer

B/Y : Black with Yellow tracer

Bl/B : Blue with Black tracer

Bl/G : Blue with Green tracer

Bl/R : Blue with Red tracer

Bl/W : Blue with White tracer

Bl/Y : Blue with Yellow tracer

Br/W : Brown with White tracer

G/B : Green with Black tracer

G/W : Green with White tracer

Gr/W : Gray with White tracer

R/B : Red with Black tracer

R/Bl : Red with Blue tracer

R/W : Red with White tracer

W/Bl : White with Blue tracer

W/R : White with Red tracer

Y/B : Yellow with Black tracer

Y/R : Yellow with Red tracer

SAE-TO-FORMER SUZUKI TERM

This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in

this manual in compliance with SAE recommendations, as well as their former SUZUKI names.

SAE TERM

FORMER SUZUKI TERM

FULL TERM ABBREVIATION

A

Air Cleaner ACL Air Cleaner, Air Cleaner Box

B

Battery Positive Voltage B+ Battery Voltage, +B

C

Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),

Crank Angle

D

Data Link Connector DLC Mode Select Coupler

Diagnostic Test Mode DTM ––––

Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code

E

Electronic Ignition El ––––

Engine Control Module ECM Engine Control Module (ECM)

Fl Control Unit, Engine Control Unit (ECU)

Engine Coolant Level ECL Coolant Level

Engine Coolant Temperature ECT Coolant Temperature, Engine Coolant Tem-

perature, Water Temperature

Engine Speed RPM Engine Speed (RPM)

F

Fan Control FC ––––

Fuel Level Sensor –––– Fuel Level Sensor, Fuel Level Gauge

Fuel Pump FP Fuel Pump (FP)

G

Generator GEN Generator

Ground GND Ground (GND, GRD)

I

Ignition Control IC Electronic Spark Advance (ESA)

Ignition Control Module ICM ––––

Intake Air Temperature IAT

Intake Air Temperature (IAT), Air Temperature

M

Malfunction Indicator Lamp MIL Lamp

Malfunction Indicator Lamp (MIL)

Manifold Absolute Pressure MAP Intake Air Pressure (IAP), Intake Vacuum

SAE TERM

FORMER SUZUKI TERM

FULL TERM ABBREVIATION

O

On-Board Diagnostic OBD Self-Diagnosis Function

Diagnostic

P

Programmable Read Only Memory PROM ––––

R

Random Access Memory RAM ––––

Read Only Memory ROM ROM

T

Throttle Body TB Throttle Body (TB)

Throttle Body Fuel Injection TBI Throttle Body Fuel Injection (TBI)

Throttle Position Sensor TP Sensor TP Sensor (TPS)

V

Voltage Regulator VR Voltage Regulator

GENERAL INFORMATION 1-1

GENERAL INFORMATION

CONTENTS

1

WARNING/CAUTION/NOTE .........................................................................1- 2

GENERAL PRECAUTIONS...........................................................................1- 2

SUZUKI RM-Z250L0 (’10-MODEL) ...............................................................1- 4

SERIAL NUMBER LOCATION......................................................................1- 4

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION........................1- 5

FUEL (FOR USA AND CANADA)...........................................................1- 5

FUEL (FOR OTHER COUNTRIES).........................................................1- 5

ENGINE OIL (FOR USA).........................................................................1- 5

ENGINE OIL (FOR OTHER COUNTRIES) .............................................1- 5

BRAKE FLUID.........................................................................................1- 5

FRONT FORK OIL ..................................................................................1- 5

REAR SUSPENSION OIL .......................................................................1- 5

ENGINE COOLANT ................................................................................1- 6

BREAK-IN (RUNNING-IN).............................................................................1- 6

WHEN THE MOTORCYCLE IS NEW .....................................................1- 6

WHEN ENGINE PARTS ARE REPLACED.............................................1- 6

INFORMATION LABELS...............................................................................1- 7

SPECIFICATIONS .........................................................................................1- 8

DIMENSIONS AND CURB MASS...........................................................1- 8

ENGINE ...................................................................................................1- 8

TRANSMISSION .....................................................................................1- 8

CHASSIS .................................................................................................1- 9

ELECTRICAL ..........................................................................................1- 9

CAPACITIES ...........................................................................................1- 9

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

CODE COUNTRY or AREA EFFECTIVE FRAME NO.

000

E-03

E-19

E-28

Japan

U.S.A.

E.U.

Canada

JS1RJ42A000 500001 –

JS1RJ42C A2 100001 –

JS1RJ42A000 500001 –

JS1RJ42C A2 100001 –

1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol

and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-

sages highlighted by these signal words.



Indicates a potential hazard that could result in death or injury.



Indicates a potential hazard that could result in motorcycle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all

potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-

INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you

are unsure about how to perform a particular service operation, ask a more experienced mechanic for

advice.

GENERAL PRECAUTIONS



* Proper service and repair procedures are important for the safety of the service mechanic and

the safety and reliability of the motorcycle.

* When 2 or more persons work together, pay attention to the safety of each other.

* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-

doors.

* When working with toxic or flammable materials, make sure that the area you work in is well-

ventilated and that you follow all of the material manufacturer’s instructions.

* Never use gasoline as a cleaning solvent.

* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system

until they have cooled.

* After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings

related to the system for leaks.

GENERAL INFORMATION 1-3



* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-

lent.

* When removing parts that are to be reused, keep them arranged in an orderly manner so that

they may be reinstalled in the proper order and orientation.

* Be sure to use special tools when instructed.

* Make sure that all parts used in reassembly are clean. Lubricate them when specified.

* Use the specified lubricant, bond, or sealant.

* When removing the battery, disconnect the negative cable first and then the positive cable.

* When reconnecting the battery, connect the positive cable first and then the negative cable,

and replace the terminal cover on the positive terminal.

* When performing service to electrical parts, if the service procedures do not require use of

battery power, disconnect the negative cable from the battery.

* When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first.

Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci-

fied tightening torque.

* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking

nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with

new ones. Also, before installing these new parts, be sure to remove any left over material

from the mating surfaces.

* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger

than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is

completely seated in its groove and securely fitted.

* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a

thread is smeared with them.

* After reassembling, check parts for tightness and proper operation.

* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and

other fluids: batteries and tires.

* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

1-4 GENERAL INFORMATION

SUZUKI RM-Z250L0 (’10-MODEL)

• Difference between photograph and actual motorcycle may exist depending on the markets.

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the

steering head pipe. The engine serial number 2 is located on the rear side of the crankcase. These num-

bers are required especially for registering the machine and ordering spare parts.

RIGHT SIDE

LEFT SIDE

GENERAL INFORMATION 1-5

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION

FUEL (FOR USA AND CANADA)

Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2).

FUEL (FOR OTHER COUNTRIES)

Use only unleaded gasoline of at least 95 octane (Research Method).

ENGINE OIL (FOR USA)

Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. Use of

SG/SH/SJ/SL in API with JASO MA/MA1/MA2.

Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an

alternative according to the following chart.

ENGINE OIL (FOR OTHER COUNTRIES)

MOTUL 300V 10W-40 (recommendation) or use a premium qual-

ity 4-stroke motor oil to ensure longer service life of your motorcy-

cle. Use of SG/SH/SJ/SL in API with JASO MA/MA1/MA2. The

recommended viscosity is SAE 10W-40. If an SAE 10W-40 motor

oil is not available, select an alternative according to the right

chart.

BRAKE FLUID

Specification and classification: DOT 4



FRONT FORK OIL

Use SUZUKI FORK OIL SS-05 or an equivalent fork oil.

REAR SUSPENSION OIL

Use REAR SUSPENSION OIL SS-25 or an equivalent suspension oil.

* Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the man-

ufacturer, do not use or mix different types of fluid such as silicone-based and petro-

leum-based fluid for refilling the system, otherwise serious damage will result.

* Do not use any brake fluid taken from old or used or unsealed containers.

* Never re-use brake fluid left over from a previous servicing, which has been stored for a long

period.

1-6 GENERAL INFORMATION

ENGINE COOLANT

Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only.



WATER FOR MIXING

Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator.

ANTI-FREEZE/ENGINE COOLANT

The engine coolant performs as a corrosion and rust inhibitor as well as anti-freeze. Therefore, the engine

coolant should be used at all times even though the atmospheric temperature in your area does not go down

to freezing point.

Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use

an equivalent which is compatible with an aluminum radiator.

LIQUID AMOUNT OF WATER/ENGINE COOLANT

Solution capacity (total): Approx. 950 ml (1.0/0.8 US/Imp qt)

For engine coolant mixture information, refer to page 2-18.



BREAK-IN (RUNNING-IN)

WHEN THE MOTORCYCLE IS NEW

1) Warm up the engine before starting off.

2) Ride for 60 minutes using less than 1/2 throttle opening.

3) Ride for 60 minutes using less than 3/4 throttle opening.

NOTE:

* The break-in (running-in) period is the period of greatest wear.

* The bolts and nuts of the new machine can loosen quickly. Be

sure to retighten the bolts and nuts during the break-in (run-

ning-in) period.

WHEN ENGINE PARTS ARE REPLACED

Follow the same procedure when any of the following parts are

replaced:

Piston

Piston ring

Cylinder

Crankshaft

Crankshaft bearing

Leaving the engine at idling speed after riding will cause engine overheat as this competition

motorcycle does not have the radiator cooling fan and coolant reservoir. Riding the motorcycle

under severe conditions such as muddy or sandy terrain with high ambient temperature can

shorten time to be overheated.

Mixing of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it would reduce

its efficiency. If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting perfor-

mance is greatly reduced. Be sure to mix it above 50% even though the atmospheric tempera-

ture does not go down to the freezing point.

1/2

FULL

OPEN

CLOSED

GENERAL INFORMATION 1-7

INFORMATION LABELS

E: English F: French

A: Attached

No. LABEL or PLATE NAME

APPLIED SPECIFICATION

E-03 E-19 E-28

1 General warning label E A

2 General warning label E AA

3 General warning label F AA

4 EC approval mark label A

5 ICES Canada label E/F A

6 EPA plate E A

7 Manufacture label E AAA

For E-03

For E-19, 28

1-8 GENERAL INFORMATION

SPECIFICATIONS

DIMENSIONS AND CURB MASS

Overall length....................................................... 2 170 mm (85.4 in)

Overall width ........................................................ 830 mm (32.7 in)

Overall height ...................................................... 1 270 mm (50.0 in)

Wheelbase........................................................... 1 475 mm (58.1 in)

Ground clearance ................................................ 345 mm (13.6 in)

Seat height........................................................... 955 mm (37.6 in)

Curb mass............................................................ 105 kg (231 lbs)

ENGINE

Type ..................................................................... Four-stroke, liquid-cooled, DOHC

Number of cylinders ............................................. 1

Bore ..................................................................... 77.0 mm (3.03 in)

Stroke................................................................... 53.6 mm (2.11 in)

Displacement ....................................................... 249 cm

3

(15.2 cu. in)

Compression ratio................................................ 13.5 : 1

Fuel system.......................................................... Fuel injection

Air cleaner............................................................ Polyurethane foam element

Starter system...................................................... Primary kick

Lubrication system ............................................... Semi-dry sump

Idle speed ............................................................ 2 100 ± 50 r/min

TRANSMISSION

Clutch................................................................... Wet multi disc

Transmission ........................................................ 5-speed constant mesh

Gearshift pattern .................................................. 1-down, 4-up

Primary reduction ratio......................................... 3.316 (63/19)

Gear ratios, Low ................................................... 2.153 (28/13)

2nd.................................................... 1.764 (30/17)

3rd .................................................... 1.470 (25/17)

4th..................................................... 1.238 (26/21)

Top.................................................... 1.090 (24/22)

Final reduction ratio ............................................. 3.769 (49/13)

Drive chain ........................................................... DID 520DMA2 114 links

GENERAL INFORMATION 1-9

CHASSIS

Front suspension................................................. Upside-down telescopic fork

Rear suspension ................................................. Swingarm type

Front suspension stroke ...................................... 310 mm (12.2 in)

Rear wheel travel ................................................ 310 mm (12.2 in)

Caster.................................................................. 30° 20’

Trail...................................................................... 140 mm (5.5 in)

Steering angle ..................................................... 45° (right & left)

Front brake .......................................................... Disc brake

Rear brake........................................................... Disc brake

Front tire size....................................................... 80/100-21 51M, tube type

Rear tire size ....................................................... 100/90-19 57M, tube type

ELECTRICAL

Ignition type......................................................... Electronic Ignition (CDI)

Ignition timing ...................................................... 8° B.T.D.C. at 2 100 r/min

Spark plug ........................................................... NGK CR8EIA-10

CAPACITIES

Fuel tank, including reserve ................................ 6.5 L (1.7/1.4 US/Imp gal)

Gear ratios, oil change ....................................... 850 ml (0.9/0.7 US/Imp qt)

with filter change............................. 900 ml (1.0/0.8 US/Imp qt)

overhaul .......................................... 1 000 ml (1.1/0.9 US/Imp qt)

Coolant................................................................ 950 ml (1.0/0.8 US/Imp qt)

These specifications are subject to change without notice.

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-1

2

CONTENTS

PERIODIC MAINTENANCE ........................................................................ 2- 3

INSPECTION BEFORE PRACTICE ...................................................... 2- 3

INSPECTION BEFORE RACE

(All items of inspection before practice on previous page plus) .... 2- 4

PERIODIC MAINTENANCE CHART .................................................... 2- 5

SPARK PLUG .............................................................................................. 2- 7

AIR CLEANER ............................................................................................. 2- 9

AIR CLEANER ELEMENT REMOVAL ................................................. 2- 9

WASHING .............................................................................................. 2- 9

INSTALLATION ..................................................................................... 2-10

ENGINE OIL AND OIL FILTER ................................................................... 2-11

INSPECTION BEFORE ENGINE OIL LEVEL CHECK ......................... 2-11

ENGINE OIL LEVEL INSPECTION ....................................................... 2-12

ENGINE OIL CHANGE .......................................................................... 2-13

ENGINE OIL FILTER CHANGE ............................................................ 2-14

OIL STRAINERS .......................................................................................... 2-15

OIL STRAINER (No.1) REMOVAL ....................................................... 2-15

OIL STRAINER (No.2) REMOVAL ....................................................... 2-15

INSPECTION ......................................................................................... 2-16

OIL STRAINER (No.2) INSTALLATION ............................................... 2-17

OIL STRAINER (No.1) INSTALLATION ............................................... 2-17

ENGINE COOLANT ..................................................................................... 2-18

ENGINE COOLANT LEVEL CHECK .................................................... 2-18

ENGINE COOLANT REPLENISHMENT ............................................... 2-19

COOLING SYSTEM INSPECTION ....................................................... 2-19

CLUTCH CABLE ......................................................................................... 2-20

MAJOR ADJUSTMENT ........................................................................ 2-20

MINOR ADJUSTMENT ......................................................................... 2-20

THROTTLE CABLE ..................................................................................... 2-21

THROTTLE CABLE ADJUSTMENT ..................................................... 2-21

THROTTLE CABLE OIL SUPPLY ........................................................ 2-22

HOT STARTER ............................................................................................ 2-23

THROTTLE BODY ................................................................................ 2-23

ENGINE IDLE SPEED ................................................................................. 2-24

CRANKCASE BREATHER HOSE .............................................................. 2-24

FUEL HOSE ................................................................................................. 2-24

VALVE CLEARANCE .................................................................................. 2-25

VALVE CLEARANCE ADJUSTMENT .................................................. 2-26

PERIODIC MAINTENANCE

2-2 PERIODIC MAINTENANCE

CONTENTS

CYLINDER HEAD, CYLINDER AND PISTON ............................................ 2-29

CYLINDER HEAD INSPECTION .......................................................... 2-29

CYLINDER INSPECTION ..................................................................... 2-29

PISTON INSPECTION .......................................................................... 2-29

DRIVE CHAIN AND SPROCKETS .............................................................. 2-30

DRIVE CHAIN SLACK .......................................................................... 2-30

CRANKCASE DRIVESHAFT OIL SEAL .............................................. 2-30

DRIVE CHAIN ADJUSTMENT .............................................................. 2-31

20TH PITCH LENGTH .......................................................................... 2-31

DRIVE CHAIN LUBRICATION ............................................................. 2-32

SPROCKET INSPECTION .................................................................... 2-32

DRIVE CHAIN GUIDE, BUFFER AND TENSIONER ROLLER .................. 2-33

DRIVE CHAIN GUIDE INSPECTION .................................................... 2-33

DRIVE CHAIN BUFFER AND ROLLER INSPECTION ........................ 2-33

BRAKES ...................................................................................................... 2-34

BRAKE FLUID LEVEL .......................................................................... 2-34

BRAKE PAD ......................................................................................... 2-35

FRONT BRAKE LEVER ADJUSTMENT .............................................. 2-35

BRAKE PEDAL HEIGHT ADJUSTMENT ............................................ 2-35

FRONT FORK .............................................................................................. 2-36

REAR SUSPENSION .................................................................................. 2-36

WHEELS AND TIRES ................................................................................. 2-36

WHEEL RIM AND TIRES INSPECTION ............................................... 2-36

SPOKE NIPPLE AND RIM LOCK INSPECTION ................................. 2-37

TIRE PRESSURE .................................................................................. 2-37

STEERING ................................................................................................... 2-37

LUBRICATION ............................................................................................ 2-38

CHASSIS BOLTS AND NUTS .................................................................... 2-39

COMPRESSION PRESSURE CHECK ........................................................ 2-41

COMPRESSION TEST PROCEDURE ................................................. 2-41

OIL PRESSURE CHECK ............................................................................. 2-42

OIL PRESSURE TEST PROCEDURE .................................................. 2-42

PERIODIC MAINTENANCE 2-3

PERIODIC MAINTENANCE

INSPECTION BEFORE PRACTICE

WHAT TO CHECK CHECK FOR

Spark plug • Heat range, fouled electrode, tightness

• Loose high-tension cord

Air cleaner element • Dust

• Lubrication

Engine oil Oil level

Coolant Coolant level

Cooling system • Radiator hose damage

• Engine coolant leak

Clutch • Play

• Smooth operation

Throttle • Play

• Smooth operation

Crankcase breather hose Breather hose clogging and bend

Engine idle speed Revolution speed

Brake fluid Fluid level

Brakes • Brake lever position

• Brake pedal height

• Operation

Drive chain Slack, lubrication

Drive chain guide/buffer Wear, damage

Suspension • Smooth operation

• Front fork air pressure

Wheels • Spoke tension

• Rim lock tightness or damage

Tires Tire pressure

Steering Smoothness, play

Exhaust pipe and muffler • Exhaust gas leakage

• Tightening torque

Bolts and nuts Tightening torque

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

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Suzuki RM-Z250 User manual

Suzuki RM-Z250 User manual

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