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Table Of Contents - Suzuki RM250 Owner's Service Manual

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Owner's service manual (270 pages)

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Owner's service manual (230 pages)

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Owner's service manual (152 pages)

Table Of Contents

Table of Contents

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Table of Contents

Component Parts And Work To Be Done4

General Information6

Warning/Caution/Note7

General Considerations10

Serial Number Location11

Location Of Parts12

Fuel And Oil Recommendation13

Operating Instructions14

Starting The Engine14

Stopping The Engine15

Break-In (Running-In)15

When The Motorcycle Is New15

Country And Area Codes16

Periodic Maintenance17

Periodic Maintenance Chart19

Inspection Before Practice21

Inspection Before Race21

Air Cleaner Element Removal23

Transmission Oil Level Inspection And Replenishment25

Transmission Oil Change26

Engine Coolant Level Check27

Engine Coolant Replenishment28

Engine Cooling System Inspection28

Clutch Major Adjustment29

Clutch Minor Adjustment29

Throttle Cable29

Cylinder Head31

Exhaust Valve31

Exhaust Silencer32

Drive Chain Slack32

Drive Chain Adjustment32

20Th Pitch Length33

Drive Chain Lubrication33

Sprocket Inspection33

Drive Chain Guide34

Drive Chain Guide Buffer34

Drive Chain Control Roller34

Brake Fluid Level34

Front Brake Lever Adjustment35

Brake Pedal Height Adjustment36

Air Pressure Adjustment36

Rear Suspension37

Wheels And Tires37

Tire Pressure37

Engine Dismounting And Mounting40

Cylinder, Cylinder Head And Piston46

Cylinder Head Removal48

Cylinder Removal48

Piston And Piston Ring49

Cylinder Head Inspection50

Cylinder Inspection50

Piston To Cylinder Clearance50

Piston And Piston Ring Inspection51

Piston And Piston Ring Installation52

Cylinder Installation53

Cylinder Head Installation54

Inspection After Installation54

Clutch Construction56

Clutch Plate Removal57

Primary Driven Gear58

Clutch Release Camshaft58

Drive Plate Inspection59

Driven Plate Inspection59

Clutch Spring Inspection59

Clutch Push Rod60

Primary Driven Gear And Clutch Sleeve Hub60

Oil Seal And Bearing60

Magneto Cover63

Kick Starter Construction65

Kick Starter Removal66

Kick Starter Inspection66

Kick Starter Reassembly67

Kick Starter Inspection After Reassembly68

Magneto Rotor And Stator69

Magneto Rotor And Stator Construction70

Magneto Rotor And Stator Removal71

Magneto Rotor And Stator Installation72

Magneto Rotor And Stator Inspection After Installation73

Transmission And Crankshaft74

Crankshaft And Crankcase Construction75

Transmission Construction76

Gearshift Linkage77

Primary Drive Gear77

Gearshift Shaft Inspection79

Gearshift Cam Driven Gear Inspection79

Transmission Inspection79

Crankshaft Inspection81

Conrod Inspection81

Crankcase Oil Seal Inspection And Removal82

Oil Seal Installation82

Bearing Inspection, Removal And Installation83

Fuel System Construction89

Carburetor Tuning90

Principles Of Carburetor Tuning90

Carburetor Components And Functions90

Carburetor Specifications90

Needle Clip Position92

Needle Number92

Throttle Stop Screw93

Throttle Valve Opening93

Carburetor Tuning In Practice94

Variation In Air (Oxygen) Concentration And Carburetor Conditions94

Judging Air/Fuel Mixture95

Included Parts And Optional Parts95

Carburetor Removal And Disassembly97

Carburetor Solenoid100

Throttle Position Sensor101

Cooling System103

Cooling System Construction104

Cooling Circuit Inspection105

Radiator Cap105

Water Pump Bearing107

Exhaust Valve Disassembly112

Exhaust Side Valve (Lh)113

Exhaust Main Valve113

Exhaust Valve Governer And Actuator117

Constructions120

Exterior Parts121

Handlebar Controls122

Seat Rail, Drive Chain Control Roller125

Front And Rear Wheels126

Front And Rear Wheels Construction127

Front Wheel Removal128

Front Wheel Reassembly128

Rear Wheel Removal And Reassembly128

Rear Wheel Removal128

Rear Wheel Reassembly129

Front And Rear Wheel Inspection129

Spacer And Dust Seal Inspection129

Axle Shaft Inspection129

Wheel Bearing Inspection130

Front Wheel Bearing Removal130

Rear Wheel Bearing Removal130

Front Wheel Bearing Reassembly131

Rear Wheel Bearing Reassembly131

Disc Plate Replacement131

Rear Sprocket Replacement132

Front And Rear Brakes133

Front And Rear Brakes Construction134

Brake Fluid Air Bleeding135

Brake Fluid Replacement136

Brake Pads Replacement137

Front Brake Pads137

Rear Brake Pads137

Brake Disc Inspection138

Front Caliper Removal And Disassembly139

Rear Caliper Removal And Disassembly140

Caliper Inspection140

Caliper Cleaning141

Front Caliper Reassembly141

Rear Caliper Reassembly142

Master Cylinder143

Front Master Cylinder Removal And Disassembly143

Rear Master Cylinder Removal And Disassembly144

Master Cylinder Inspection144

Master Cylinder Cleaning145

Front Master Cylinder Reassembly145

Rear Master Cylinder Reassembly146

Brake Pedal Removal146

Brake Pedal Reassembly146

Front Fork And Steering147

Front Fork And Steering Construction148

Front Fork Tuning149

Compression Damping Force Adjustment149

Rebound Damping Force Adjustment149

Oil Quantity Minor Adjustment150

Adding The Fork Oil150

Reducing The Fork Oil150

Spring Change153

Front Fork Tuning Procedure155

Suspension Balance156

Balance Test156

Balancing Tips156

Front Fork Removal157

Front Fork Disassembly158

Compression Damper Unit162

Inner Tube And Outer Tube163

Spring Cooler163

Slide Bushing And Guide Bushing164

Steering Removal171

Steering Inspection172

Steering Bearing Replacement172

Steering Installation173

Steering Inspection After Installation173

Rear Suspension Construction175

Rear Suspension Tuning176

Low Speed Compression Damping Force Adjustment176

High Speed Compression Damping Force Adjustment176

Spring Pre-Load Adjustment177

Rear Suspension Tuning Procedure178

Rear Shock Absorber Removal180

Rear Shock Absorber Inspection181

Rear Shock Absorber Installation183

Oil Replacement Procedure184

Rear Shock Absorber Reassembly189

Rear Shock Absorber Disposal189

Swingarm Disassembly190

Swingarm Inspection191

Rear Suspension Linkage Disassembly193

Rear Suspension Linkage Inspection193

Rear Suspension Linkage Bearing Removal194

Rear Suspension Linkage Bearing Installation194

Rear Suspension Linkage Reassembly194

Electrical System197

Electrical Circuit198

Ignition System Peak Voltage198

Ignition Coil200

Troubleshooting202

Service Data207

Tightening Torque213

Tightening Torque Chart214

Special Tools215

Wiring Diagram217

Wire, Cable And Hose Routing218

Wire Harness Routing218

Cable Routing219

Carburetor Hose And Water Hose Routing220

Front Brake Hose Routing222

Rear Brake Hose Routing223

Handlebar Set-Up224

Muffler Set-Up225

Specifications226

Dimensions And Dry Mass226

Optional Parts228

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