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.