Suzuki Rm 250 2009 Factory Service Repair Manual – PDF DOWNLOAD

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Suzuki Rm 250 2009 Factory Service Repair Manual

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SUZUKI RM 250 2009 FACTORY SERVICE REPAIR MANUAL – PDF DOWNLOAD:

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Suzuki Rm 250 2009 Factory Service Repair Manual

FOREWORD:

This manual is presented as a means whereby you can maintain your RM-Z250 in top working condition 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 sincerely wish you and your Suzuki motorcycle a successful partnership for many years of happy riding. All information, illustrations, 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 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 vehicles previous built or sold.
• Suzuki Motor Corporation believes in conservation and protection of Earth’s natural resources. To that end, we encourage every vehicle owner to recycle, 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 suitable 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.

TABLE OF CONTENTS:

Suzuki Rm 250 2009 Factory Service Repair Manual

FOREWORD  .........................................................................................  1
	GENERAL CONSIDERATIONS.........................................................................  1
	SERIAL NUMBER LOCATION ........................................................................  2
	WARNINGS FOR SERVICING ........................................................................  3
	PRECAUTIONS FOR SERVICING......................................................................  4
	REPLACEMENT PARTS..............................................................................  4
GROUP INDEX .......................................................................................  5
	SYMBOL MARKS AND MATERIALS ....................................................................  6
01 GENERAL INFORMATION ............................................................................  7
	LOCATION OF PARTS .............................................................................  8
	ACCESSORY ..................................................................................... 10
		SIDE STAND ................................................................................ 10
	FUEL AND OIL RECOMMENDATION ................................................................... 10
	OPERATING INSTRUCTIONS ........................................................................ 11
		STARTING THE ENGINE ....................................................................... 11
		STOPPING THE ENGINE ....................................................................... 12
		TRANSMISSION .............................................................................. 12
	BREAK-IN (RUNNING-IN) ......................................................................... 13
		WHEN THE MOTORCYCLE IS NEW ................................................................ 13
		WHEN ENGINE PARTS ARE REPLACED ............................................................ 13
	EXTERIOR PARTS ................................................................................ 14
02 PERIODIC MAINTENANCE ........................................................................... 15
	PERIODIC MAINTENANCE .......................................................................... 17
		INSPECTION BEFORE PRACTICE ................................................................ 17
		INSPECTION BEFORE RACE (All items of inspection before practice on previous page plus) .... 18
		PERIODIC MAINTENANCE CHART ................................................................ 19
	SPARK PLUG .................................................................................... 21
	AIR CLEANER ................................................................................... 23
		AIR CLEANER ELEMENT REMOVAL ............................................................... 23
		WASHING ................................................................................... 23
		INSTALLATION .............................................................................. 23
	ENGINE OIL AND OIL FILTER ..................................................................... 24
		INSPECTION BEFORE ENGINE OIL LEVEL CHECK .................................................. 25
		ENGINE OIL LEVEL INSPECTION ............................................................... 25
		ENGINE OIL CHANGE ......................................................................... 26
		ENGINE OIL FILTER CHANGE .................................................................. 27
	OIL STRAINERS ................................................................................. 28
		INSPECTION ................................................................................ 28
	ENGINE COOLANT ................................................................................ 29
		ENGINE COOLANT LEVEL CHECK ................................................................ 29
		ENGINE COOLANT REPLENISHMENT .............................................................. 30
		COOLING SYSTEM INSPECTION ................................................................. 30
	CLUTCH CABLE .................................................................................. 31
		MAJOR ADJUSTMENT .......................................................................... 31
		MINOR ADJUSTMENT .......................................................................... 31
	THROTTLE CABLE ................................................................................ 32
		THROTTLE CABLE ADJUSTMENT ................................................................. 32
		THROTTLE CABLE LUBRICATION ................................................................ 32
	HOT STARTER ................................................................................... 33
	ENGINE IDLE SPEED ............................................................................. 34
	CRANKCASE BREATHER HOSE ....................................................................... 34
	FUEL HOSE ..................................................................................... 35
	FUEL FILTER ................................................................................... 35
	VALVE CLEARANCE ............................................................................... 36
		VALVE CLEARANCE ADJUSTMENT ................................................................ 37
	CYLINDER HEAD, CYLINDER AND PISTON ............................................................ 40
		CYLINDER HEAD INSPECTION .................................................................. 40
		CYLINDER INSPECTION ....................................................................... 40
		PISTON INSPECTION ......................................................................... 40
	MUFFLER SILENCER .............................................................................. 41
		SILENCER INSPECTION AND REPLACEMENT ....................................................... 41
	DRIVE CHAIN AND SPROCKETS ..................................................................... 42
		DRIVE CHAIN SLACK ......................................................................... 42
		CRANKCASE DRIVESHAFT OIL SEAL ............................................................. 42
		DRIVE CHAIN ADJUSTMENT .................................................................... 42
		20TH PITCH LENGTH ......................................................................... 42
		DRIVE CHAIN LUBRICATION ................................................................... 43
		SPROCKET INSPECTION ....................................................................... 43
	DRIVE CHAIN GUIDE, BUFFER AND CHAIN ROLLER .................................................... 44
		DRIVE CHAIN GUIDE INSPECTION .............................................................. 44
		DRIVE CHAIN BUFFER AND ROLLER INSPECTION .................................................. 44
	BRAKES ........................................................................................ 45
		BRAKE FLUID LEVEL ......................................................................... 45
		BRAKE PAD ................................................................................. 46
		FRONT BRAKE LEVER ADJUSTMENT .............................................................. 46
		BRAKE PEDAL HEIGHT ADJUSTMENT ............................................................. 46
	FRONT FORK .................................................................................... 47
	REAR SUSPENSION ............................................................................... 47
	WHEELS AND TIRES .............................................................................. 47
		WHEEL RIM AND TIRES INSPECTION ............................................................ 47
		SPOKE NIPPLE AND RIM LOCK INSPECTION ...................................................... 48
		TIRE PRESSURE ............................................................................. 48
	STEERING ...................................................................................... 48
	LUBRICATION ................................................................................... 49
	COMPRESSION PRESSURE CHECK .................................................................... 50
		COMPRESSION TEST PROCEDURE ................................................................ 50
	OIL PRESSURE CHECK ............................................................................ 51
		OIL PRESSURE CHECK PROCEDURE .............................................................. 51
03 TROUBLESHOOTING ................................................................................ 52
	ENGINE ........................................................................................ 53
	CARBURETOR .................................................................................... 57
	RADIATOR (COOLING SYSTEM) ..................................................................... 57
	CHASSIS ....................................................................................... 58
	BRAKES ........................................................................................ 59
	ELECTRICAL .................................................................................... 60
04 MACHINE TUNING ................................................................................. 61
	CARBURETOR TUNING ............................................................................. 62
		PRINCIPLES OF CARBURETOR TUNING ........................................................... 62
		SLOW SYSTEM ............................................................................... 63
		MAIN SYSTEM ............................................................................... 65
		INTERMEDIATE SYSTEM ....................................................................... 65
		CARBURETOR TUNING IN PRACTICE ............................................................. 67
	FRONT FORK TUNING ............................................................................. 70
		COMPRESSION DAMPING FORCE ADJUSTMENT ...................................................... 70
		REBOUND DAMPING FORCE ADJUSTMENT .......................................................... 70
		OIL QUANTITY MINOR ADJUSTMENT ............................................................. 71
		OIL CHANGE (Only for outer tube oil chamber) .............................................. 72
		SPRING CHANGE ............................................................................. 74
		FRONT FORK TUNING PROCEDURE ............................................................... 76
	REAR SUSPENSION TUNING ........................................................................ 77
		COMPRESSION DAMPING FORCE ADJUSTMENT ...................................................... 77
		REBOUND DAMPING FORCE ADJUSTMENT .......................................................... 78
		SPRING PRE-LOAD ADJUSTMENT ................................................................ 78
		REAR SUSPENSION TUNING PROCEDURE .......................................................... 79
	SUSPENSION BALANCE ............................................................................ 81
		BALANCE TEST .............................................................................. 81
		BALANCING TIPS ............................................................................ 81
05 ENGINE REMOVAL AND INSTALLATION ................................................................ 82
	ENGINE REMOVAL AND INSTALLATION ............................................................... 83
		REMOVAL ................................................................................... 83
		INSTALLATION .............................................................................. 87
06 CYLINDER HEAD, CYLINDER AND PISTON ............................................................. 90
	CONSTRUCTION .................................................................................. 91
		CYLINDER HEAD, CYLINDER AND PISTON ........................................................ 91
	ENGINE TOP SIDE ............................................................................... 92
		CYLINDER HEAD COVER REMOVAL ............................................................... 92
		CAMSHAFTS (AUTOMATIC DECOMP.) AND CAM CHAIN TENSION ADJUSTER REMOVAL ...................... 92
		CYLINDER HEAD REMOVAL ..................................................................... 93
		CYLINDER REMOVAL .......................................................................... 94
		PISTON AND PISTON RING REMOVAL ............................................................ 95
		CAM CHAIN, CAM CHAIN TENSIONER AND CAM CHAIN GUIDE REMOVAL ................................ 95
	ENGINE TOP COMPONENTS INSPECTION AND SERVICE .................................................. 96
		AUTOMATIC DECOMP. INSPECTION .............................................................. 96
		CAMSHAFT INSPECTION ....................................................................... 96
		CAM CHAIN TENSION ADJUSTER INSPECTION ..................................................... 98
		CAM CHAIN No.1 GUIDE, CAM CHAIN No.2 GUIDE AND CAM CHAIN TENSIONER INSPECTION ............. 99
		CYLINDER HEAD AND VALVE INSPECTION ........................................................ 99
		INTAKE PIPE REMOVAL .......................................................................107
		INTAKE PIPE INSTALLATION ..................................................................107
		CYLINDER INSPECTION .......................................................................108
		PISTON AND PISTON RING INSPECTION .........................................................109
		CRANKSHAFT AND CONROD INSPECTION ..........................................................111
		CAM CHAIN, CAM CHAIN TENSIONER AND CAM CHAIN GUIDE INSTALLATION ...........................112
		PISTON AND PISTON RING INSTALLATION .......................................................113
		CYLINDER AND CYLINDER HEAD INSTALLATION ...................................................115
		CAMSHAFT (AUTOMATIC DECOMP.) AND CAM CHAIN TENSION ADJUSTER INSTALLATION ..................117
		CYLINDER HEAD COVER INSTALLATION ..........................................................121
07 CLUTCH .........................................................................................122
	CONSTRUCTION ..................................................................................123
		CLUTCH ....................................................................................123
	CLUTCH PLATE ..................................................................................124
		REMOVAL ...................................................................................124
		INSPECTION ................................................................................126
		INSTALLATION ..............................................................................127
	PRIMARY DRIVE GEAR AND CLUTCH SLEEVE HUB ......................................................129
		REMOVAL ...................................................................................129
		INSPECTION ................................................................................130
		INSTALLATION ..............................................................................130
	CLUTCH RELEASE CAMSHAFT .......................................................................132
		REMOVAL ...................................................................................132
		INSPECTION ................................................................................132
		INSTALLATION ..............................................................................133
08 KICK STARTER ...................................................................................134
	CONSTRUCTION ..................................................................................135
		KICK STARTER ..............................................................................135
	KICK STARTER ..................................................................................136
		REMOVAL ...................................................................................136
		INSPECTION ................................................................................137
		INSTALLATION ..............................................................................138
09 GEARSHIFTING  ..................................................................................141
	CONSTRUCTION ..................................................................................142
		GEARSHIFT LINKAGE .........................................................................142
	GEARSHIFT LINKAGE .............................................................................143
		REMOVAL ...................................................................................143
		INSPECTION ................................................................................145
		INSTALLATION ..............................................................................145
10 TRANSMISSION AND CRANKSHAFT ....................................................................148
	CONSTRUCTION ..................................................................................149
		TRANSMISSION AND CRANKSHAFT ...............................................................149
	ENGINE BOTTOM SIDE ............................................................................150
		PRIMARY DRIVE GEAR REMOVAL ................................................................150
		CRANKCASE SEPARATION ......................................................................151
		TRANSMISSION REMOVAL ......................................................................151
		CRANKSHAFT REMOVAL ........................................................................152
		REED VALVE REMOVAL ........................................................................152
		TRANSMISSION INSPECTION ...................................................................153
		CONROD INSPECTION .........................................................................154
		CRANKSHAFT INSPECTION .....................................................................155
		OIL SEAL INSPECTION .......................................................................155
		OIL SEAL REMOVAL AND INSTALLATION .........................................................156
		BEARING INSPECTION ........................................................................156
		BEARING REMOVAL AND INSTALLATION ..........................................................157
		REED VALVE INSTALLATION ...................................................................160
		CRANKSHAFT INSTALLATION ...................................................................160
		TRANSMISSION INSTALLATION .................................................................161
		CRANKCASE INSTALLATION ....................................................................163
		PRIMARY DRIVE GEAR INSTALLATION ...........................................................164
11 LUBRICATION SYSTEM .............................................................................165
	ENGINE LUBRICATION SYSTEM .....................................................................166
		ENGINE LUBRICATION SYSTEM CHART ...........................................................166
		ENGINE OIL LEVEL INSPECTION ...............................................................167
		ENGINE OIL CHANGE .........................................................................167
		ENGINE OIL FILTER CHANGE ..................................................................167
		OIL PRESSURE CHECK ........................................................................167
		OIL STRAINERS REMOVAL .....................................................................167
		OIL STRAINERS INSPECTION ..................................................................167
		OIL STRAINERS INSTALLATION ................................................................167
		OIL SEAL REMOVAL ..........................................................................167
		OIL SEAL INSPECTION .......................................................................167
		OIL SEAL INSTALLATION .....................................................................168
		OIL PUMP REMOVAL ..........................................................................168
		OIL PUMP INSPECTION .......................................................................169
		OIL PUMP INSTALLATION .....................................................................170
12 FUEL SYSTEM ....................................................................................172
	FUEL TANK AND FUEL VALVE ......................................................................173
		CONSTRUCTION ..............................................................................173
		REMOVAL ...................................................................................173
		CLEANING AND INSPECTION ...................................................................174
		INSTALLATION ..............................................................................174
	CARBURETOR ....................................................................................175
		CONSTRUCTION ..............................................................................175
		REMOVAL ...................................................................................176
		DISASSEMBLY ...............................................................................177
		CLEANING ..................................................................................181
		INSPECTION ................................................................................181
		REASSEMBLY ................................................................................183
		INSTALLATION ..............................................................................187
	THROTTLE POSITION SENSOR ......................................................................188
		INSPECTION ................................................................................188
		REMOVAL ...................................................................................189
		INSTALLATION ..............................................................................189
13 COOLING SYSTEM .................................................................................190
	CONSTRUCTION ..................................................................................191
	ENGINE COOLANT ................................................................................192
		REPLACEMENT ...............................................................................192
	COOLING CIRCUIT ...............................................................................193
		INSPECTION ................................................................................193
	RADIATOR ......................................................................................194
		REMOVAL ...................................................................................194
		INSPECTION ................................................................................194
		INSTALLATION ..............................................................................194
	WATER PUMP ....................................................................................195
		REMOVAL ...................................................................................195
		INSPECTION ................................................................................196
		INSTALLATION ..............................................................................197
14 ELECTRICAL SYSTEM ..............................................................................199
	CAUTIONS IN SERVICING .........................................................................200
		CONNECTOR .................................................................................200
		COUPLER ...................................................................................200
		SEMI-CONDUCTOR EQUIPPED PART ..............................................................200
		USING THE MULTI-CIRCUIT TESTER ............................................................200
		SWITCH ....................................................................................200
	LOCATION OF ELECTRICAL COMPONENTS .............................................................201
	CONSTRUCTION ..................................................................................202
		ELECTRICAL SYSTEM .........................................................................202
		ELECTRICAL CIRCUIT ........................................................................202
		TROUBLESHOOTING ...........................................................................203
	IGNITION SYSTEM ...............................................................................205
		IGNITION SYSTEM PEAK VOLTAGE INSPECTION ...................................................205
		IGNITION SYSTEM COIL INSPECTION ...........................................................206
		IGNITION COIL PRIMARY PEAK VOLTAGE INSPECTION .............................................206
		IGNITION COIL/PLUG CAP INSPECTION .........................................................207
		ENGINE STOP SWITCH INSPECTION .............................................................208
	MAGNETO ROTOR .................................................................................209
		REMOVAL ...................................................................................209
		INSTALLATION ..............................................................................210
	STATOR ........................................................................................211
		REMOVAL ...................................................................................211
		INSTALLATION ..............................................................................211
15 FRONT AND REAR WHEELS ..........................................................................212
	CONSTRUCTION ..................................................................................213
	FRONT WHEEL ...................................................................................214
		REMOVAL ...................................................................................214
		INSPECTION ................................................................................214
		DUST SEAL AND BEARING REPLACEMENT .........................................................215
		DISC PLATE REPLACEMENT ....................................................................216
		INSTALLATION ..............................................................................217
	REAR WHEEL ....................................................................................218
		REMOVAL ...................................................................................218
		INSPECTION ................................................................................219
		DUST SEAL AND BEARING REPLACEMENT .........................................................219
		DISC PLATE REPLACEMENT ....................................................................221
		REAR SPROCKET REPLACEMENT .................................................................221
		INSTALLATION ..............................................................................222
		REAR WHEEL SPOKES REPLACEMENT .............................................................222
16 FRONT AND REAR BRAKES ..........................................................................223
	CONSTRUCTION...................................................................................224
	BRAKE FLUID AIR BLEEDING ......................................................................225
	BRAKE FLUID REPLACEMENT .......................................................................226
	BRAKE PADS REPLACEMENT ........................................................................227
		FRONT BRAKE PADS ..........................................................................227
		REAR BRAKE PADS ...........................................................................227
	BRAKE DISC INSPECTION .........................................................................228
	CALIPER .......................................................................................228
		FRONT CALIPER REMOVAL AND DISASSEMBLY .....................................................229
		CALIPER INSPECTION ........................................................................230
		CALIPER CLEANING ..........................................................................230
		FRONT CALIPER REASSEMBLY AND INSTALLATION .................................................230
		REAR CALIPER REMOVAL AND DISASSEMBLY ......................................................231
		REAR CALIPER REASSEMBLY AND INSTALLATION ..................................................232
	MASTER CYLINDER ...............................................................................234
		FRONT MASTER CYLINDER REMOVAL AND DISASSEMBLY .............................................234
		MASTER CYLINDER INSPECTION ................................................................235
		MASTER CYLINDER CLEANING ..................................................................235
		FRONT MASTER CYLINDER REASSEMBLY AND INSTALLATION .........................................236
		REAR MASTER CYLINDER REMOVAL AND DISASSEMBLY ..............................................237
		MASTER CYLINDER INSPECTION ................................................................238
		REAR MASTER CYLINDER REASSEMBLY AND INSTALLATION ..........................................238
	BRAKE LEVER ...................................................................................239
		REMOVAL ...................................................................................239
		INSTALLATION ..............................................................................239
	BRAKE PEDAL ...................................................................................240
		REMOVAL ...................................................................................240
		INSTALLATION ..............................................................................240
17 FRONT FORK AND STEERING ........................................................................241
	CONSTRUCTION ..................................................................................242
		FRONT FORK, STEERING.......................................................................242
		HANDLEBAR CONTROLS ........................................................................243
		REMOVAL ...................................................................................244
		DISASSEMBLY ...............................................................................245
		INSPECTION ................................................................................249
		REASSEMBLY ................................................................................251
		INSTALLATION ..............................................................................257
	STEERING ......................................................................................258
		REMOVAL ...................................................................................258
		INSPECTION ................................................................................260
		BEARING REPLACEMENT .......................................................................261
		INSTALLATION ..............................................................................262
18 REAR SUSPENSION ................................................................................267
	CONSTRUCTION ..................................................................................268
		REAR SUSPENSION ...........................................................................268
	REAR SHOCK ABSORBER ...........................................................................269
		REMOVAL ...................................................................................269
		SPRING REPLACEMENT ........................................................................270
		INSPECTION ................................................................................271
		BEARING REPLACEMENT .......................................................................272
		OIL REPLACEMENT ...........................................................................273
		DISASSEMBLY AND INSPECTION ................................................................276
		REASSEMBLY ................................................................................277
		INSTALLATION ..............................................................................278
		DISPOSAL ..................................................................................278
	SWINGARM ......................................................................................279
		REMOVAL ...................................................................................279
		INSPECTION ................................................................................281
		BEARING REPLACEMENT .......................................................................282
		INSTALLATION ..............................................................................283
	REAR SUSPENSION LINKAGE .......................................................................284
		REMOVAL ...................................................................................284
		INSPECTION ................................................................................285
		BEARING REPLACEMENT .......................................................................286
		INSTALLATION ..............................................................................287
19 SERVICING INFORMATION ..........................................................................290
	SERVICE DATA ..................................................................................291
	TIGHTENING TORQUE .............................................................................299
	SPECIAL TOOLS .................................................................................303
	WIRING DIAGRAM ................................................................................306
	CABLE ROUTING .................................................................................307
	WIRING HARNESS ROUTING ........................................................................309
	FUEL HOSE ROUTING .............................................................................310
	HOT STARTER LEVER INSTALLATION ................................................................310
	FUEL TANK CUSHION INSTALLATION ................................................................311
	RADIATOR HOSE AND CARBURETOR HOSE ROUTING .....................................................312
	RADIATOR HOSE ROUTING .........................................................................313
	CRANKCASE AND COVER INSTALLATION ..............................................................314
	MAGNETO INSTALLATION ..........................................................................315
	FRONT BRAKE HOSE ROUTING ......................................................................316
	REAR BRAKE HOSE ROUTING .......................................................................317
	REAR BRAKE PEDAL SET-UP .......................................................................318
	FRONT NUMBER PLATE INSTALLATION ...............................................................318
	HANDLEBARS SET-UP .............................................................................319
	CLUTCH CABLE ADJUSTER .........................................................................320
	REAR WHEEL SPOKES INSTALLATION ................................................................320
	EXHAUST PIPE AND MUFFLER INSTALLATION .........................................................321
	RIM LOCK INSTALLATION .........................................................................321
	FRONT FENDER INSTALLATION .....................................................................322
	REAR FENDER INSTALLATION.......................................................................322
	FRAME COVER INSTALLATION ......................................................................323
	FRAME COVER CUSHION INSTALLATION ..............................................................323
	SPECIFICATIONS ................................................................................324
	OPTIONAL PARTS ................................................................................326
	SETTING DATA ..................................................................................327

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