Suzuki RM-Z250L9 Easy Set-Up Manual
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Suzuki RM-Z250L9 Easy Set-Up Manual

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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.
99505-01229-01E
L9
January '19 (TK) 19
Copyright © SUZUKI MOTOR CORPORATION 2019 All Rights Reserved

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Summary of Contents for Suzuki RM-Z250L9

  • Page 1 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.
  • Page 2 PREPARATION WORKSHOP This photograph is not for this model. This photograph is not for this model.  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. A: Packed vehicle B: Working space SELF PROTECTION...
  • Page 3 UNCRATING THE MOTORCYCLE Cut the strap by using scissors. This photograph is not for this model. This photograph is not for this model. A: Strap Remove the carton.  CAUTION Metal crates may have sharp edges and may cause injury. Wear proper protective clothes and gear.
  • Page 4 Lift the steel frame to separate it from the base of the crate.  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.

  • Page 5: Spare Parts

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

  • Page 6: Location Of Parts

    • 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. Parts listed above are installed respectively into the positions as follows.
  • Page 7 J J J 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...

  • Page 8: Removing The Bracket

    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.
  • Page 9 HANDLEBARS Loosen the throttle housing retaining screws. Insert the throttle assembly onto the handlebars. NOTE: Check the spacer is onto the handlebars. A: Throttle assembly B: Handlebars C: Spacer Install the handlebar assembly with the clamp and the four bolts. NOTE: •...
  • Page 10 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. A: Front brake hose B: Throttle cables C: Clutch cable D: Engine stop switch wiring harness E: S-HAC switch wiring harness...
  • Page 11 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.

  • Page 12: Front Brake Master Cylinder

    FRONT BRAKE MASTER CYLINDER Install the front brake master cylinder onto the handle- bars. NOTE: DOWNWARD • 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. •...

  • Page 13: Clutch Cable

    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.
  • Page 14 S-HAC SWITCH Hook the holders on the grooves of the S-HAC switch. NOTE: Use the holder with an internal thread cutting at the front side. A: S-HAC switch B: Holder (Front) C: Holder (Rear) D: Thread cutting Install the S-HAC switch to the left of handlebars. NOTE: Align the matching mark on the handlebars with mating surface of the S-HAC switch holder.

  • Page 15: Brake Disc

    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 FRONT FRONT...
  • Page 16 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.

  • Page 17: Number Plate

    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. NOTE: •...
  • Page 18 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. NOTE: Be sure not to bend or twist the hose when install- ing.
  • Page 19 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)

  • Page 20: Brake Fluid

    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.
  • Page 21 FRONT BRAKE AIR BLEEDING This photograph is not for this model. This photograph is not for this model. Any air which may have been trapped in the brake fluid circuit must be bled completely. If the brake lever or brake pedal feels spongy or weak, then most likely there is air in the brake fluid circuit.

  • Page 22: Front Brake Lever

    FRONT BRAKE LEVER Check the brake lever play at the adjuster bolt. Front brake lever adjuster bolt length: 11–15 mm If adjustment is necessary, carry out the following pro- cedure. 1. Loosen the lock nut A. 2. Turn the adjuster B to obtain the correct length. 3.

  • Page 23: Rear Brake Pedal

    CLUTCH CABLE Check the clutch lever play at the clutch lever clear- ance when squeezing the lever until pressure is felt. Clutch lever play: 2.0–3.0 mm NOTE: Minor adjustments can now be made by using the clutch lever adjuster B provided with the adjuster cover A.

  • Page 24: Front Suspension

    FRONT SUSPENSION Move the front forks up and down several times. Inspect for smooth movement and oil leakage. REAR SUSPENSION Move the rear suspension up and down several times. Inspect for smooth movement and oil leakage.

  • Page 25: Drive Chain

    DRIVE CHAIN Check the drive chain slack. Drive chain slack: 35–45 mm If adjustment is necessary, carry out the following pro- cedure. 1. Loosen the axle nut. 2. Loosen the lock nut. 3. Adjust the slack in the drive chain by turning the right and left chain adjuster bolts.

  • Page 26: Tire Pressure

    Verify that the chain joint clip is installed properly. The opening of the chain joint clip faces away from the direction of travel. A: Chain joint clip Direction of travel TIRE PRESSURE Check the air pressure of the front and rear tires by using an accurate air gauge.

  • Page 27: Engine Oil

    ENGINE OIL NOTE: This motorcycle is shipped from factory with the engine filled with engine oil. NOTICE Operating the engine with too little or too much oil can damage the engine. Hold the motorcycle vertically. Check the oil level with the engine oil level bolt before each use of the motorcycle.
  • Page 28 Engine oil Suzuki recommends the use of SAE 10W-40 engine oil. Oil quality is a major contributor to your engine’s per- formance and life. Always select good quality engine oil. Use oil with an API classification of SG, SH, SJ, SL, SM or SN with a JASO classification of MA.

  • Page 29: Engine Coolant

    1. Add the engine coolant to the correct level from radiator inlet hole. 2. Close the radiator cap securely. NOTE: • Use an “SUZUKI SUPER LONG LIFE COOL- ANT” (Blue). • “SUZUKI SUPER LONG LIFE COOLANT” is pre- mixed to the proper ratio.
  • Page 30 FUEL NOTE: • Use only premium unleaded gasoline with an octane rating of 95 or higher (Research method) or use only premium unleaded gasoline of at least 90 pump octane (R/2+M/2 method). • Oxygenated fuel can be used, if the ethanol (grain alcohol) contain is not greater than 10%.

  • Page 31: Tightening Torque List

    TIGHTENING TORQUE TIGHTENING TORQUE LIST Item Part Name N·m kgf-m Item Part Name N·m kgf-m FRONT FORK BRAKE Handlebar clamp bolt Rear brake push rod lock nut 0.61 Handlebar holder nut Brake caliper air bleeder valve 0.61 Steering stem head nut 11.2 AXLE Front fork upper bracket bolt...

  • Page 32: Tightening Torque Chart

    TIGHTENING TORQUE CHART Thread diameter Unit Bolt type (Nominal diameter) N·m kgf-m lbf-ft “ A ” [mm] 0.15 0.30 0.55 21.0 32.5 47.0 10.5 76.0 A equivalent of 4T strength bolt without flange 16.0 115.5 Thread diameter Unit Bolt type (Nominal diameter) N·m kgf-m...

  • Page 33: Harness Routing

    HARNESS ROUTING Clutch cable Throttle cable Clamp (Blue tape position) Engine stop switch lead wire S-HAC switch lead wire Clamp S-HAC switch lead wire Clamp Engine stop switch lead wire Engine stop switch lead wire...

  • Page 34: Cable Routing

    CABLE ROUTING Pass the throttle cables and clutch cable between the number plate mounting bolts. Pass the clutch cable in front of the throttle cables. Clutch cable Throttle cable (Returning) Throttle cable (Returning) Throttle cable (Pulling) Clutch cable (White tape position) Clamp Cable guide Clamp...
  • Page 35 Fix the clutch cable aligning the punch mark Clutch cable bracket on the clutch cable with the convex mark of the clutch cable bracket. Throttle cable (Returning) Clamp Cable guide Clutch cable Throttle cable (Pulling) Pass the throttle cables and clutch cable under the radiator joint upper hose and radiator overflow hose.

  • Page 36: Safety Check-Out

    SAFETY CHECK OUT NOTE: COLD TIRE INFLATION PRESSURE • After completion of the setting-up the motorcycle FRONT REAR all the following items should be double-checked 70–110 kPa 70–110 kPa to confirm that the operation and function of the 0.7–1.1 kgf/cm 0.7–1.1 kgf/cm motorcycle are satisfactory.

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