Suzuki RM-Z250L9 User guide

L9
January ’19 (TK) 19
99505-01229-01E
Copyright © SUZUKI MOTOR CORPORATION 2019 All Rights Reserved
FOREWORD
This motorcycle has been designed and produced utilizing Suzuki’s most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this motorcycle.
Please read this manual and follow its instructions carefully. To emphasize special
information, the symbol and the words WARNING, CAUTION, NOTICE and
NOTE have special meanings. Pay particular attention to messages highlighted by
these signal words:

Indicates a potential hazard that could result in death or serious injury.

Indicates a potential hazard that could result in minor or moderate injury.
Indicates a potential hazard that could result in motorcycle or equipment
damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
This set-up manual is based on a motorcycle of standard specification. Some minor
differences from this manual may be found in other specifications.

1
PREPARATION
WORKSHOP
A: Packed vehicle
B: Working space
SELF PROTECTION
CAUTION
Assembling the vehicle in poor working condi-
tion can be hazardous.
Place the packed vehicle on a level floor where
it is clean and spacious.
This photograph is not for this model.
This photograph is not for this model.
CAUTION
Assembling the vehicle without proper clothes
and protective gear can be hazardous. You can
be injured if you do not wear proper clothes
and protective gear.
Be sure to wear proper clothes and shoes for
assembling and wear protective glasses, mask
or gloves as necessary.

2
UNCRATING THE MOTORCYCLE
Cut the strap by using scissors.
A: Strap
Remove the carton.
A: Crate
Remove the bolts of the bracket.
Remove the bolts to take off the rear wheel holding
bracket.
A: Bolt
B: Rear wheel holding bracket
Remove the bolts from the crate.
A: Bolt
This photograph is not for this model.
This photograph is not for this model.
CAUTION
Metal crates may have sharp edges and may
cause injury.
Wear proper protective clothes and gear.

3
Lift the steel frame to separate it from the base of the
crate.
A: Steel frame
B: Crate base
RIGHT
Open the vinyl package.
Take out the various component parts and spare parts
packaged from the crate.
A: Component parts
B: Spare parts
LEFT
CAUTION
Careless steel frame separation can injure a
person.
Lift the steel frame with two persons.
Wear proper protective clothes and gear.
NOTE:
Be careful not to damage the motorcycle when
separating the steel frame.

4
SPARE PARTS
Check all spare parts.
Item Part Name Q’ty
1Magneto cover gasket 1
2Clutch cover outer gasket 1
3Water pump case O-ring 1
4Sprocket spacer D-ring 1
5Engine oil filter comp 1
6Exhaust pipe gasket 1
7Muffler joint connector 1
8Clutch lever 1
9Brake lever 1
NOTE:
Please hand over the spare parts shown as Item 1–9in the above table to your customer together with
motorcycle.

5
LOCATION OF PARTS
Check all the components which have been removed from the base of the crate.
Parts listed above are installed respectively into the positions as follows.
Item Part Name Q’ty Remarks
A
Number plate 1
Flange bolt
(with washer) 2 6 × 12 mm
B
Handlebars assembly 1
Handlebar clamp 1
Flange bolt 4 8 × 35 mm
Screw 1
5 × 20 mm
For throttle
assembly
Strap 1 L:100
Strap 1 L:130
Fuel tank vent hose 1
Engine stop switch holder 2 Upper and Lower
Screw (with lock washer) 1 3 × 14 mm
S-HAC switch holder 2 Front and Rear
Screw (with lock washer) 1 4 × 14 mm
Clutch lever cover 1
Clutch adjuster cover 1
Item Part Name Q’ty Remarks
C Handlebar pad set 1
DHolder 1 For front brake
master cylinder
Flange bolt 2 6 × 22 mm
EStand 1
F Spoke nipple wrench 1 Tool
G Short wire (Coupler) 2 ECM setting parts
HFuel hose plug 1 Special tool
Fuel pump cap 1 Special tool
I Oil filter cap O-ring 1 Spare parts
JOwner’s service manual
set 1 With CD-ROM
NOTE:
• Please hand over the parts shown as Item E, F, G, H, I and J in the above table to your customer together
with motorcycle.
• S-HAC = SUZUKI holeshot assist control.
E
AC B D

6
The photograph shown indicates the parts dismounted
from the motorcycle in addition to the items shown in
the preceding page.
A: Front brake master cylinder
B: Throttle assembly
Engine stop switch
Clutch cable
S-HAC switch
DD
CC
AA
BB
EE
GGHHII
J
J
J
FF

7
Before assembling the motorcycle, thoroughly
understand the “Safety Check Out” described on
page 35.
After completion of assembly, carefully check the
motorcycle referring to the “Safety Check Out”,
then deliver the motorcycle to the customer.
ASSEMBLY
REMOVING THE BRACKET
Remove the bolt to take off the front brake master cyl-
inder from the bracket.
A: Front brake master cylinder
B: Bolt
C: Bracket
Remove the bolts to take off the bracket from the han-
dlebar holder.
A: Bracket
B: Bolt
NOTE:
• Keep the position of front brake master cylinder
with its cap facing upwards until it is installed.
• The bolt is not necessary to assemble the motor-
cycle.
NOTE:
• Be careful not to damage the fuel tank.
• The bracket and bolts are not necessary to
assemble the motorcycle.

8
HANDLEBARS
Loosen the throttle housing retaining screws.
Insert the throttle assembly onto the handlebars.
A: Throttle assembly
B: Handlebars
C: Spacer
Install the handlebar assembly with the clamp and the
four bolts.
A: Clamp
B: 8 × 35 mm flange bolt
C: Dot mark
D: Matching mark
Tighten the handlebar clamp bolts to the specified
torque.
Handlebar clamp bolt: 25 N·m (2.5 kgf-m)
A: 8 × 35 mm flange bolt
B: 8 × 35 mm flange bolt
NOTE:
Check the spacer is onto the handlebars.
NOTE:
• The dot mark on the clamp shows front side.
• Align the matching mark on the handlebars with
the mating surface of the left front side of the
clamp.
NOTE:
• First tighten the bolt Aof the front side with
specified torque and then tighten the bolt Bof
the rear side.
• Make sure that the clamp has no clearance at the
front side.
FRONT

9
A: Front brake hose
B: Throttle cables
C: Clutch cable
D: Engine stop switch wiring harness
E: S-HAC switch wiring harness
F: Cable guide
NOTE:
• The line drawings on page 32, 33 and 34 show
the proper routing of the control cables, hose and
wirings.
• Refer to them in addition to following the instruc-
tions carefully.

10
THROTTLE
Align the matching mark on the handlebars with mat-
ing surface of the throttle housing.
Install the throttle assembly with two screws after the
assembly is positioned so that there is approximately
0.5–1.0 mm of clearance between the grip end and the
end of the handlebars.
Throttle case screw: 3.8 N·m (0.39 kgf-m)
A: Throttle assembly
B: Matching mark
C: 5 × 20 mm screw
Fit the rubber cover onto the throttle housing.
A: Rubber cover
WARNING
Improper throttle installing can interfere with
smooth throttle grip operation. It can result in
an accident.
Check to ensure that the throttle operates
freely and closes automatically.

11
FRONT BRAKE MASTER CYLINDER
Install the front brake master cylinder onto the handle-
bars.
A: Holder
B: Front brake master cylinder
C: 6 × 22 mm flange bolt
D: Matching mark
E: Spacer
Tighten the front brake master cylinder mounting bolts
to the specified torque.
Front brake master cylinder mounting bolt:
10 N·m (1.0 kgf-m)
A: 6 × 22 mm flange bolt
B: 6 × 22 mm flange bolt
C: Holder
D: Front brake master cylinder
E: Handlebars
NOTE:
• Install the holder in position according to the
mark “UP”.
• Align the matching mark on the handlebars with
the master cylinder-to-holder fitting surface.
• Set the cut-line of spacer downward.
DOWNWARD
NOTE:
• First tighten the bolt Aof the upper side with
specified torque and then tighten the bolt Bof
the lower side.
• Make sure that the holder has no clearance at
the upper side.

12
CLUTCH CABLE
Pass the clutch cable through the adjuster cover and
lever cover.
A: Clutch cable
B: Adjuster cover
C: Lever cover
Check the clutch cable end.
Align the clutch cable end with the recess of clutch
release arm.
A: Cable end
B: Recess (Clutch release arm)
Turn the clutch lever adjuster in as far as possible and
align the slots.
Insert the inner cable end into the recess in the clutch
lever, then pull on the outer cable housing and insert it
into the adjuster.
Install the lever cover and adjuster cover.
A: Clutch cable
B: Adjuster
C: Cable end
D: Adjuster cover
E: Lever cover
NOTE:
• Before installing the cable, grease the cable end.
• Do not adjust at this time. Adjustment will be cov-
ered in the SERVICING section.

13
S-HAC SWITCH
Hook the holders on the grooves of the S-HAC switch.
A: S-HAC switch
B: Holder (Front)
C: Holder (Rear)
D: Thread cutting
Install the S-HAC switch to the left of handlebars.
S-HAC switch screw: 1.3 N·m (0.13 kgf-m)
A: S-HAC switch
B: 4 × 14 mm screw (with lock washer)
C: Matching mark
ENGINE STOP SWITCH
Hook the holders on the grooves of the engine stop
switch.
A: Engine stop switch
B: Holder (Upper)
C: Holder (Lower)
D: Thread cutting
Install the engine stop switch to the left of handlebars.
Engine stop switch screw: 1.3 N·m (0.13 kgf-m)
A: Engine stop switch
B: 3 × 14 mm screw (with lock washer)
C: Protrusion
D: Clutch lever holder
NOTE:
Use the holder with an internal thread cutting at the
front side.
NOTE:
Align the matching mark on the handlebars with
mating surface of the S-HAC switch holder.
NOTE:
Use the holder with an internal thread cutting at the
lower side.
NOTE:
• Align the engine stop switch with the S-HAC
switch.
• Set the protrusion of engine stop switch come in
contact to the clutch lever holder.

14
CLAMP
Clamp the engine stop switch wiring harness and S-
HAC switch wiring harness to the handlebars with
strap.
A: Strap L:100 mm
B: Strap L:130 mm
C: Engine stop switch wiring harness
D: S-HAC switch wiring harness
E: Handlebars
FRONT REAR
BRAKE DISC
To prevent brake squeaking and pad contamination,
carefully clean the front and rear brake disc plates with
alcohol or other non-petroleum based solvent.
This will remove the rust-preventive coating and dirt.
TAKING OUT THE MOTORCYCLE
Bind a hoist band around the handlebar clamps as
shown in the photograph.
A: Hoist band
1. Lift the front of motorcycle by using a hoist.
2. Raise the rear of motorcycle.
3. Pull the crate base forward, then balance the
motorcycle.
FRONT FRONT
This photograph is
not for this model.
This photograph is
not for this model.
This photograph is
not for this model.
This photograph is
not for this model.
NOTICE
Binding a hoist band to the handlebar or grips
can damage the motorcycle parts.
Be sure to bind a hoist band around the handle-
bar clamps.

15
STAND
Insert the boss of stand to the hole of rear axle shaft.
A: Stand
Place the motorcycle on the stand, then remove the
hoist hook.
HANDLEBAR PAD
Set the handlebar pad to the handlebar.
A: Handlebar pad
B: Handlebars
Install the handlebar pad cover as shown in the illus-
tration.
A: Handlebar pad cover
B: Handlebar pad
C: Handlebars
D: Velcro fastening
FRONT

16
NUMBER PLATE
Insert the hole of the front number plate to the boss of
front fender.
Insert the number plate to the groove of front fender.
A: Number plate
B: Hole
C: Boss
D: Groove
Install the front number plate with flange bolt.
Number plate bolt: 5.5 N·m (0.56 kgf-m)
A: Number plate
B: 6 × 12 mm flange bolt (with washer)
C: Front brake hose
D: Throttle cable
E: Clutch cable
F: S-HAC switch wiring harness
G: Engine stop switch wiring harness
Pass the strap of the number plate around the handle-
bars.
Fit the strap of the number plate into the guide.
A: Strap
B: Guide
C: Handlebar
NOTE:
• Route the brake hose in front of the number
plate.
• Route the throttle cable, clutch cable, S-HAC
switch wiring harness and engine stop switch wir-
ing harness behind the number plate as shown.

17
FUEL TANK VENT HOSE
Install the fuel tank vent hose to the fuel tank cap.
Insert the free end of fuel tank vent hose to the hole of
steering shaft.
A: Fuel tank vent hose
B: Fuel tank cap
C: Hole (Steering shaft)
REMOVING THE WRAP FILM
Remove the wrap film from the muffler.
A: Muffler
B: Wrap film
OWNER’S MANUAL
Remove the bolts to take off the seat.
A: Seat
B: 6 × 16 mm flange bolt
Spacer (Oval)
Remove the vinyl cover.
Store the owner’s manual on the seat.
Reinstall the vinyl cover.
A: Owner’s manual
B: Seat
NOTE:
Be sure not to bend or twist the hose when install-
ing.

18
Reinstall the seat.
Insert the seat hook into the seat hook retainer.
A: Seat assembly
B: Seat hook
C: Seat hook retainer
Tighten the bolts.
Seat mounting bolt: 10 N·m (1.0 kgf-m)
A: Front seat
B: 6 × 16 mm flange bolt
Spacer (Oval)

19
SERVICING
FRONT REAR
BRAKE FLUID
Hold the motorcycle vertically and keep the handlebars
straight.
Check the brake fluid level in both the front and rear
master cylinder reservoirs.
If the fluid level is below the “LOWER” level, add the
correct type of brake fluid.
Refer to the chart below for the proper selection.
Front reservoir cap screw A:
1.5 N·m (0.15 kgf-m)
Rear reservoir cap screw B:
1.5 N·m (0.15 kgf-m)
Specification and Classification
DOT 4
NOTICE
Spilled brake fluid can damage painted sur-
faces and plastic parts.
Be careful not to spill any fluid when filling the
brake fluid reservoir. Wipe spilled fluid up
immediately.
LOWER
LOWER
LOWER
LOWER