Suzuki RM-Z250 User manual

© COPYRIGHT SUZUKI MOTOR CORPORATION 2009
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
1Rear disc plate
2Rear wheel (1.85 ×19)
3Spacer
4Disc cover
5Bead stopper
6Rear sprocket
7Rear axle shaft
8Front axle shaft
9Front wheel (1.60 ×21)
0Front disc plate
ARear axle nut
BDisc plate bolt (Rear)
CRear sprocket nut
DDisc plate bolt (Front)
EFront axle nut

ITEM N·m
kgf-m lbf-ft
A90 9.0 65.0
B26 2.6 19.0
C30 3.0 21.5
D11 1.1 8.0
E35 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.