Suzuki RM-Z250 User manual

99011-49H51-01ARM-Z250
Part No. 99011-49H51-01A April, 2010 EN Printed in Japan
RM-Z250
TK
L1
OWNER’S MANUAL AND
RACE PREPARATION MANUAL
VWARNING
Failure to follow these safety
precautions may increase your risk
of injury:
•Wear a helmet, eye protection,
 and bright, protective clothing.
•Don’t ride after consuming alcohol
 or other drugs.
•This competition vehicle is
 designed and manufactured for use
 in closed course competition only -
 do not use on public streets, roads,
 or highways. This vehicle does not
 meet safety (and other) standards
 for street use or recreational off-
 road use.
•Single rider only.
•Slow down on slippery surfaces,
 unfamiliar terrain, or when visibility
 is reduced.
•Read owner’s manual carefully.

VWARNING/VCAUTION/NOTICE/NOTE
Please read this manual and follow its instructions carefully. To emphasize
special information, the symbol Vand the words WARNING, CAUTION,
NOTICE and NOTE have special meanings. Pay particular attention to
messages highlighted by these signal words:
NOTE:
Indicates special information to make maintenance easier or instructions
clearer.
V CAUTION
Indicates a potential hazard that could result in minor or moderate
injury.
NOTICE
Indicates a potential hazard that could result in vehicle or equipment
damage.
V WARNING
Indicates a potential hazard that could result in death or serious injury.
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.

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 motorcycle previous built or sold.
Suzuki Motor Corporation believes in conservation
and protection of Earth’s natural resources. To that
end, we encourage every motorcycle owner to recy-
cle, 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 RM-Zs are designed for the rider only.
cCOPYRIGHT SUZUKI MOTOR CORPORATION 2010

• 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.
• Know your limits
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 illustration. 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.
CAUTION
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
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.
NOTICE
Performing the maintenance improperly
can cause damage to the parts or the
motorcycle.
To prevent the parts or the motorcycle
from damage, be sure to take the following
precautions:
* 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 recom-
mended oil.
* When two or more persons work
together, pay attention to the safety of
each other.
* After reassembly, inspect parts for tight-
ness and operation.

NOTE:
* Clean a motorcycle from dirt and/or dust before
servicing.
* Avoid spraying or allowing water to flow over the
following places:
- Spark plug
- Fuel tank cap
- Throttle body
- Fuel injection system
- Brake master cylinders
- Air cleaner inlet
* Be sure to dry the motorcycle after washing the
motorcycle. Blow off water from parts by applying
air blow if it is necessary to remove parts just after
washing the motorcycle.
REPLACEMENT PARTS
NOTE:
Use of replacement parts which are not equivalent
in quality to genuine SUZUKI parts can lead to per-
formance problems and damage.
Use only genuine SUZUKI replacement parts or
their equivalent. Genuine SUZUKI parts are high
quality parts which are designed and built specially
for SUZUKI motorcycle.
NOTICE
High pressure washers such as those
found at coin-operated car washes have
enough pressure to damage the parts of
your motorcycle. It may cause rust, corro-
sion and increase wear. Parts cleaner can
also damage motorcycle parts.
Do not use high pressure washers to clean
your motorcycle. Do not use parts cleaner
on throttle body and fuel injection sensors.

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 FORK OIL SS-19
or equivalent.
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.
1360
OIL
FORK
M/O
RS
A
LLC
SBF
MV
1215
1207B
1303
TOOL
1322
1342

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
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