Suzuki RM-Z250 Application guide

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 messages
highlighted by these signal words:
This manual should be considered a permanent part of the
motorcycle and should remain with the motorcycle when resold or
otherwise transferred to a new owner or operator.
The manual contains important safety information and instructions
which should be read carefully before operating the motorcycle.
WARNING/CAUTION/NOTE
!
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
!WARNING
Indicates a potential hazard that could result in death or injury.
CAUTION
Indicates a potential hazard that could result in motorcycle damage.

FOREWORD
This manual is presented as a means whereby you
can maintain your RM-Z250 in top working condi-
tion at all times. Your riding skill and the mainte-
nance steps outlined in this manual will assure you
of top performance from your machine under any
type of competition.
We sincerely wish you and your Suzuki motorcycle
a successful partnership for many years of happy
riding.
All information, illustrations, photographs and speci-
fications contained in the manual are based on the
latest product information available at the time of
publication. Due to improvements or other changes,
there may be some discrepancies in this manual.
Suzuki reserves the right to make production
changes at any time, without notice and without
incurring any obligation to make the same or similar
changes to vehicles previous built or sold.
Suzuki Motor Corporation believes in conservation
and protection of Earth’s natural resources. To that
end, we encourage every vehicle owner to recycle,
trade in, or properly dispose of, as appropriate,
used motor oil, engine coolant, and other fluid, and
tires.
GENERAL CONSIDERATIONS
• Wear a helmet and goggles
A helmet is the most important piece of gear to
wear. Helmets do not reduce essential vision or
hearing. Generally, helmets do not cause or
intensify injury if you crash. Helmets simply help
your skull protect your intelligence, your memory,
your personality, and your life.
Your eyesight is equally valuable. Wearing suit-
able eye protection can help keep your vision
unblurred by the wind and help shield your eyes
from branches and airborne matter like bugs, dirt,
or pebbles kicked up by tires. Wear a helmet and
eye protection every time you ride.
• Wear protective gear
Wear proper clothing when you ride. Avoid loose
clothes or scarves, which could get caught in
moving parts. Abrasion injuries can be minimized
by wearing protective clothing including gloves,
strong boots that fit over the ankle, long pants,
and a long sleeve shirt or jackets. Experienced
riders often wear a kidney belt and chest or back
protector for additional comfort and protection.
• Inspect your machine before riding
Before each use, perform an inspection per “Peri-
odic Inspection” section starting on page 2-3.
• No Passengers
Suzuki RMs are designed for the rider only.
cCOPYRIGHT SUZUKI MOTOR CORPORATION 2007

• Practice on level ground
Before you begin riding, you should find a good
place to practice the skills you need to ride
safely. Find a flat, open area with enough space
to maneuver. Check with your Suzuki dealer or
call police department if you do not know where
you can ride.
Review the controls on your motorcycle before
riding.
•Knowyourlimits
Always ride within the boundaries of your own
skills. Knowing these limits and staying within
them will help you avoid accidents. Ride only in
events appropriate for your experience.
Safely competing on a motorcycle requires that
your mental and physical skills are fully part of
the experience. You should not attempt to oper-
ate a motorcycle, especially one with two wheels,
if you are tired or under the influence of alcohol
or other drugs. Alcohol, illegal drugs, and even
some prescription and over-the-counter drugs
and cause drowsiness, loss of coordination, loss
of balance, and loss of good judgement. If you
are tired or under the influence of alcohol or other
drugs, PLEASE DO NOT RIDE your motorcycle.
• Conclusion
The actions of other riders are unpredictable.
Your motorcycle’s condition can change. These
factors can best be dealt with by giving every ride
your full attention.
Circumstances beyond your control could lead to
an accident. You need to prepare for the unex-
pected by wearing a helmet and other protective
gear, and practicing safe riding techniques to
minimize the damage to you and your machine.
May all of your rides on your new Suzuki be winning
rides!
SERIAL NUMBER LOCATION
The frame number

1is stamped on the steering
head as shown in the photograph. The engine serial
number

2is stamped on the right side of the crank-
case assembly.
Write down the serial numbers here for your future
reference.
Frame No.
Engine No.

WARNINGS FOR SERVICING
!WARNING
Never run the engine indoors or in a
garage. Exhaust gas contains carbon mon-
oxide, a gas that is colorless and odorless
and can cause death or severe injury.
Only run the engine outdoors where there
is fresh air.
!WARNING
Hot engine and muffler can burn you.
Wait until the engine and muffler cools
before servicing.
!WARNING
Fuel can catch on fire if you do not handle
it properly. Gasoline vapors can catch fire
easily.
Do not smoke when servicing the machine.
Do not service the machine in an area
where there are open flames or sparks.
!WARNING
Brake fluids and engine coolant can be
hazardous to humans and pets. Brake fluid
and engine coolant are harmful or fatal if
swallowed, and harmful if it comes in con-
tact with your skin or eyes.
Keep brake fluid and engine coolant away
from children. Call your doctor immedi-
ately if swallowed, and induce vomiting.
Flush eyes or skin with water if either
brake fluid or engine coolant gets in eyes
or comes in contact with skin.

PRECAUTIONS FOR
SERVICING
• Replace gaskets, snap rings, circlips, O-rings
and cotter pins with new ones.
• Take care not to expand the end gap larger than
required to slip the circlip over the shaft when
installing a circlip.
• Use special tools where specified.
• Use genuine SUZUKI parts and recommended
oil.
• When two or more persons work together, pay
attention to the safety of each other.
• After reassembly, inspect parts for tightness and
operation.
REPLACEMENT PARTS
Use only genuine SUZUKI replacement parts or
their equivalent. Genuine SUZUKI parts are high
quality parts which are designed and built specially
for SUZUKI vehicles.
NOTE:
Use of replacement parts which are not equivalent
in quality to genuine SUZUKI parts can lead to per-
formance problems and damage.
!WARNING
Servicing the machine with engine running
can be hazardous. You can be caught in
the moving parts such as the drive chain,
sprockets etc.
Be sure to stop the engine when servicing
the machine.
!WARNING
Servicing the machine without proper
clothes and protective gear can be hazard-
ous. You can be injured if you do not wear
proper clothes and protective gear.
Be sure to wear proper clothes and shoes
for servicing and wear protective glasses,
mask or gloves as necessary.

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
FUEL SYSTEM 12
COOLING SYSTEM 13
ELECTRICAL SYSTEM 14
FRONT AND REAR WHEELS 15
FRONT AND REAR BRAKES 16
FRONT FORK AND STEERING 17
REAR SUSPENSION 18
SERVICING INFORMATION 19

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”.
99000-32130
Apply oil. Use engine oil or transmission
oil unless otherwise specified.
Use SUZUKI FORK OIL SS-05 or
equivalent fork oil.
99000-99001-SS5
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKI
MOLY PASTE in a ratio of 1:1)
Use SUZUKI REAR SUSPENSION OIL
SS-25 or equivalent rear suspension oil.
99000-99001-S25
Apply SUZUKI SUPER GREASE “A”
or equivalent grease.
99000-25010
Use engine coolant.
Apply SUZUKI SILICONE GREASE.
99000-25100
Apply or use brake fluid. (DOT 4)
Apply SUZUKI MOLY PASTE.
99000-25140
Measure in voltage range.
Apply SUZUKI BOND “1215”
or equivalent bond.
99000-31110
Measure in resistance range.
Apply SUZUKI BOND “1207B”.
99000-31140
Use special tool.
Apply THREAD LOCK SUPER “1303”.
99000-32030
Indication of service data.
Apply THREAD LOCK SUPER “1322”
or equivalent thread lock.
99000-32110
Replace a part with a new one when
reassembling.
Apply THREAD LOCK “1342”.
99000-32050

GENERAL INFORMATION 1-1
CONTENTS
GENERAL INFORMATION
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
JS1RJ41A000 500001 –
JS1RJ41C 82 100001 –
JS1RJ41C000 500001 –
JS1RJ41C 82 100001 –
1
LOCATION OF PARTS ............................................................................... 1- 2
ACCESSORY ............................................................................................... 1- 3
SIDE STAND ......................................................................................... 1- 3
FUEL AND OIL RECOMMENDATION ........................................................ 1- 3
OPERATING INSTRUCTIONS .................................................................... 1- 4
STARTING THE ENGINE ...................................................................... 1- 4
STOPPING THE ENGINE ..................................................................... 1- 5
TRANSMISSION ................................................................................... 1- 5
BREAK-IN (RUNNING-IN) ........................................................................... 1- 6
WHEN THE MOTORCYCLE IS NEW ................................................... 1- 6
WHEN ENGINE PARTS ARE REPLACED ........................................... 1- 6
EXTERIOR PARTS ...................................................................................... 1- 7

1-2 GENERAL INFORMATION
LOCATION OF PARTS

1Clutch lever

2Hot starter lever

3Engine stop switch

4Front brake lever

5Throttle grip

6Fuel tank cap

7Carburetor starter knob

8Gearshift lever

9Front suspension compression damp-
ing adjuster

0Front suspension rebound damping
adjuster

AKick starter lever

BRear brake pedal

CRear suspension compression damp-
ing adjuster

DRear suspension rebound damping
adjuster