Suzuki RM250 Application guide

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FOREWORO
This manual is presented as a means whereby
you can maintain your RM250 in top working
c ondition at all times . Your riding skill and the
maintenance steps outlined in this manual will
assure you of top performance from your
machine under any type of competition.
We sinc erely wish you and your Suzuki motor -
cycle a successful partnership for many years
of happy riding.
All information, illustration , photographs and
specifications 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 discrepan-
cies in this manual. Suzuki reserves
the right to
make production changes at any time , witihout
notice and without incurring any obligation to
make the same or similar changes to vehicles
previously built or sold.
Suzuki Motor Corpor ation believes in conserva-
tion and protection of Earth 's natural resources.
To that end, we encourage every vehicle own-
er to recycle , trade in, or properly dispose of ,
as appropriate, used motor oil, engine coolant,
and other fluid , and tires .
WARNING / CAUTION / NOTE
Please read this manual and follow its instruc -
tions car efully . To emphasize special informa -
tion , the symbol £ and the words WARNING,
CAUTION, and NOTE have special meanings.
Pay special attention to the messages highlight -
ed by these signal words :
A WARNING Indicates a potentia l hazard
that cou ld result in death or injury .
.4. CAUTION Indicates a potential hazard
that could result in motorcycle damage .
NOTE: Indicates special information to make
maintenance easier or instructions clearer.
COMPETITION MOTORCYCLES
The Suzuki RM250 is a high-perfo r mance ,
competition - only motorcycle . It is not designed
or approved for gene ral o ff -highway riding , as
it does not meet U.S. Environmental Protection
Agency off - highway motorcycle noise standars
and does not have a U.S. Forest Service ap-
proved spark arrester . It is also not designed or
approved for riding on publ ic roads, as it does
not meet Federal Motor Vehicle Safety Stan-
dards for on- highway motorcyc les.
General considerations:
• Before each use, perform an inspection per
"Periodic Inspection" section starting on
page 2- 1.
• Suzuki RMs are designed for the rider only
- NO PASSENGERS.
• Always ride within the boundaries of your
own skills. Knowing these l imits and staying
within them wi ll help you avoid accidents.
Ride only in events appr op riate for your ex -
perience.
• Safely competing on a mo t orcycle requires
that your mental and physical skills are fully
part of the experience . You should not at -
tempt to operate a motor vehicle , especially
one with two wheels , if you are tired or un -
der the influence of alcohol or other drugs.
Alcohol , illegal dru gs , and even some
prescription and ove r -the-counte r drugs can
cause dr owsiness , loss of coordination . loss
of balance, and loss of good judgement. If
you are tired or under the influence of alco -
hol or other drugs, PLEASE DO NOT RIDE
your motorcycle .
Mayall of your rides on your new Suzuki be win -
ning rides!
,.

WARNINGS FOR SERVICING
A WARNING
Never run the engine indoors or in a garage.
Exhaust gas contains carbon monoxide. a gas
that is colorless and odorless and can cause
death or severe injury.
Only run the engine outdoors where there is
fresh air.
A WARNING
Hot engine and muffler can burn you.
Wait until the engine and muffler cools before
servicing.
A 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.
A WARNING
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Brake fluids and engine coolant can be
hazardous
to humans and pets. Brake fluid
and engine coolant are harmful or fatal if swal-
lowed, and harmful if it comes in contact with
your skin or eyes.
Keep brake
fluid and engine coolant away
from children. Call your doctor immediately
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.

A WARNING
Servicing the machine with engine running
can be hazardous . You can be caught in the
moving parts such as the drive chain, sprock ·
ets etc.
Be sure to s top the engine when servicing the
machine.
PRECAUTIONS FOR SERVICING
• Replace gaskets, ei relips, a-rings and cotter
pins with new ones.
• Take care not to expand the end gap larger
than required to slip the circl ip over the shaft
when installing a c ir clip.
• Use special tools where specified.
• Use genuine SUZUKI parts and recommend-
ed oil.
• When two or more persons work together ,
pay attention to the safety of each other.
• After reassembly, inspect parts for tightness
and ope ration.
A WARNING
Servicing the machine without proper clothes
and protective gear can be hazardous . You
can be injured if you do not wear Rroper
clothes and protective gear.
Be sure to wear proper clothes and shoes for
servicing and wear protective glasses. mask
or gloves as necessary .
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REPLACEMENT PARTS
Use only genuine SUZUKI replacement parts or
thei r equivalent . Genuine SUZUKI parts are high
quality parts which are designed and built spe-
cially for SUZUKI vehicles .
NOTE: Use of replacement parts which are not
equivalentin quality to genuine SUZUKIparts can
lead to performance problems and damage.

SYMBOL MARKS AND MATERIALS
SYMBOL MARK MATERIALS
SUZUKI SUPER GREASE" A"
99000 - 25030
;_
....
.. .
-
SUZUKI SILICONE GREASE
99000 - 25100
THREAD LOCK SUPER" 1303"
99000 - 32030
SUZUKI BOND 1207B
99104-31140
Use or apply OOT4 brake fluid.
FROtIT
FIIIKDlL
SUZUKI FORK O IL 55 - 05
99000-99001-555

SYMBOL MARK MATERIALS
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SUZUKI REAR SUSPENSION OIL 55 - 25
99000-99001 - 525
Use engine coolant.
Apply engine
oil or transmission oil.
Tighten a nut or bolt to the specified
torque.
Replace a part with a new one when
ressembling.
J

-MEMO-

TABLE OF CONTENTS
,----------------------------- ---- -------
GENERAL INSTRUCTIONS
PERIODIC MAINTENANCE
TROUBLESHOOTING
MACHINE TUNING
ENGINE DISMOUNTING AND MOUNTING
CYLINDER, PISTON AND EXHAUST VALVE
CLUTCH
KICK STARTER
TRANSMISSION AND CRANKSHAFT
FUEL SYSTEM
COOLING SYSTEM
ELECTRICAL SYSTEM
FRONT AND REAR WHEELS
FRONT AND REAR BRAKES
FRONT FORK AND STEERING
REAR SUSPENSION
SERVICE DA TA
SPECIAL TOOLS
WIRE, CABLE AND HOSE ROUTING
SPECIFICA TIONS

1·1 GEN E RAL INSTRUCTIONS
LOCATION OF PARTS
CD Clutch lever
@ Engine kill switch
@ Throttle grip
@ Front brake lever
® Fuel tank cap
® Choke/idle adjust knob
Q) Gearshift lever
® Kick starter lever
® Rear brake pedal