Suzuki RM 250 2003 Manuals

Manuals and User Guides for Suzuki RM 250 2003. We have 1 Suzuki RM 250 2003 manual available for free PDF download: Owner's Service Manual

Suzuki RM 250 2003 Owner's Service Manual

Suzuki RM 250 2003 Owner's Service Manual (225 pages)

Brand: Suzuki | Category: Motorcycle | Size: 11.91 MB

Table of Contents

General Information 1

6
- Table of Contents
  6
- Warning/Caution/Note
  7
- Warning/Cautions for Servicing
  7
- General Considerations
  10
- Serial Number Location
  11
- Location of Parts
  12
- Fuel and Oil Recommendation
  13
- Operating Instructions
  14
  - Starting the Engine
    14
  - Stopping the Engine
    15
  - Transmission
    15
- Break-In (Running-In)
  15
  - When the Motorcycle Is New
    15
  - When Engine Parts Are Replaced
    15
- Country and Area Codes
  16
Periodic Maintenance 2

17
- Periodic Maintenance
  19
- Spark Plug
  22
- Air Cleaner
  23
  - Air Cleaner Element Removal
    23
  - Washing
    23
  - Installation
    23
- Transmission Oil
  25
  - Transmission Oil Level Inspection and Replenishment
    25
  - Transmission Oil Change
    26
- Engine Coolant
  27
- Clutch
  29
  - Major Adjustment
    29
  - Minor Adjustment
    29
- Throttle Cable
  29
- Fuel Hose
  30
- Fuel Valve
  30
- Cylinder Head, Cylinder and Piston
  31
  - Cylinder Head
    31
  - Cylinder
    31
  - Piston
    31
- Exhaust Valve
  31
- Drive Chain and Sprockets
  32
  - Drive Chain Slack
    32
  - Drive Chain Adjustment
    32
  - 20Th Pitch Length
    33
  - Drive Chain Lubrication
    33
  - Sprocket Inspection
    33
- Exhaust Silencer
  32
- Brakes
  34
  - Brake Fluid Level
    34
- Drive Chain Guide, Buffer, Control Roller
  34
  - Drive Chain Guide
    34
  - Drive Chain Guide Buffer
    34
  - Drive Chain Control Roller
    34
- Rear Suspension
  35
- Steering
  35
Cylinder, Cylinder Head and Piston

42
- Construction
  43
- Removal
  44
  - Cylinder Head
    44
  - Cylinder
    44
  - Piston and Piston Ring
    45
- Inspection
  46
  - Cylinder Head
    46
  - Cylinder
    46
  - Piston to Cylinder Clearance
    46
  - Conrod
    47
  - Piston and Piston Ring
    47
- Installation
  48
  - Piston and Piston Ring
    48
  - Cylinder
    49
  - Cylinder Head
    50
- Inspection after Installation
  50
Clutch

51
- Construction
  52
- Removal
  53
  - Clutch Plate
    53
  - Primary Driven Gear
    54
  - Clutch Release Camshaft
    54
- Inspection
  55
  - Drive Plate
    55
  - Driven Plate
    55
  - Clutch Spring
    55
  - Clutch Push Rod
    56
  - Primary Driven Gear Andclutch Sleeve Hub
    56
  - Bearing and Spacer
    56
  - Clutch Release Camshaft
    56
  - Oil Seal and Bearing
    56
- Installation
  57
  - Primary Driven Gear
    57
  - Clutch Plate
    58
  - Clutch Cover
    58
  - Magneto Cover
    59
- Inspection after Installation
  59
Kick Starter

60
- Construction
  61
- Inspection
  62
- Removal
  62
- Reassembly
  63
- Inspection after Reassembly
  64
Magneto Rotor and Stator

65
- Construction
  66
- Removal
  67
- Installation
  68
- Inspection after Installation
  69
Transmission and Crankshaft

70
- Construction
  71
  - Crankshaft and Crankcase
    71
  - Transmission
    72
- Removal
  73
  - Gearshift Linkage
    73
  - Primary Drive Gear
    73
  - Crankcase
    74
  - Transmission
    74
  - Crankshaft
    75
- Inspection
  75
  - Gearshift Shaft
    75
  - Gearshift Cam Driven Gear
    75
  - Transmission
    75
  - Crankshaft
    77
  - Conrod
    77
- Crank Case
  78
- Installation
  80
  - Crankshaft
    80
  - Transmission
    80
  - Crankcase
    81
  - Gearshift Linkage
    82
- Inspection after Installation
  83
Fuel System

84
- Construction
  85
- Carburetor Tuning
  86
  - Principles of Carburetor Tuning
    86
  - Carburetor Tuning in Practice
    90
- Carburetor
  93
  - Removal and Disassembly
    93
  - Inspection
    95
  - Reassembly and Remounting
    95
- Carburetor Solenoid
  96
  - Removal and Inspection
    96
  - Reassembly
    96
- Throttle Position Sensor
  97
  - Inspection
    97
  - Removal and Remounting
    98
- Reed Valve
  98
  - Removal
    98
  - Inspection
    98
  - Reassembly
    98
Cooling System

99
- Construction
  100
- Cooling Circuit Inspection
  101
  - Cooling Circuit
    101
  - Radiator Cap
    101
- Removal
  101
  - Radiator
    101
  - Water Pump
    102
- Inspection
  102
  - Radiator
    102
  - Impeller and Gear Shaft
    103
  - Water Pump Bearing
    103
  - Oil Seal
    103
  - Reassembly
    104
- Inspection after Reassembly
  105
Exhaust Valve

106
- Construction
  107
- Exhaust Valve
  108
  - Disassembly
    108
  - Inspection
    110
  - Reassembly
    110
- Exhaust Valve Governer and Actuator
  113
  - Disassembly
    113
  - Inspection
    114
  - Reassembly
    114
- Inspection after Installation
  115
Constructions

116
- Exterior Parts
  117
- Handlebar Controls
  118
  - Removal
    118
  - Remounting
    119
- Seat Rail, Drive Chain Control Roller
  121
Front and Rear Wheels

122
- Construction
  123
- Front Wheel Removal and Reassembly
  124
  - Front Wheel Removal
    124
  - Front Wheel Reassembly
    124
- Rear Wheel Removal and Reassembly
  124
  - Rear Wheel Removal
    124
  - Rear Wheel Reassembly
    125
- Front and Rear Wheel Inspection
  125
  - Spacer and Dust Seal Inspection
    125
  - Axle Shaft Inspection
    125
  - Wheel Rim Inspection
    125
  - Wheel Bearing Inspection
    126
- Wheel Bearing Removal and Reassembly
  126
  - Front Wheel Bearing Removal
    126
  - Rear Wheel Bearing Removal
    126
  - Front Wheel Bearing Reassembly
    127
  - Rear Wheel Bearing Reassembly
    127
- Disc Plate Replacement
  127
- Rear Sprocket Replacement
  128
Front and Rear Brakes

129
- Construction
  130
- Brake Fluid Air Bleeding
  131
- Brake Fluid Replacement
  132
- Brake Pads Replacement
  133
  - Front Brake Pads
    133
  - Rear Brake Pads
    133
- Brake Disc Inspection
  134
- Caliper
  134
  - Front Caliper Removal and Disassembly
    135
  - Rear Caliper Removal and Disassembly
    136
  - Caliper Inspection
    136
  - Caliper Cleaning
    137
  - Front Caliper Reassembly
    137
  - Rear Caliper Reassembly
    138
- Master Cylinder
  139
- Brake Pedal
  142
  - Removal
    142
  - Reassembly
    142
Front Fork and Steering

143
- Construction
  144
- Front Fork Tuning
  145
  - Compression Damping Force Adjustment
    145
  - Rebound Damping Force Adjustment
    145
  - Oil Quantity Minor Adjustment
    146
  - OIL CHANGE (Only for Outer Tube Oil Chamber)
    147
  - Spring Change
    149
  - Front Fork Tuning Procedure
    151
  - Suspension Balance
    152
- Front Fork
  153
  - Removal
    153
  - Disassembly
    154
  - Inspection
    158
  - Reassembly
    160
  - Installation
    165
- Steering
  167
  - Removal
    167
  - Inspection
    168
  - Bearing Replacement
    168
  - Installation
    169
- Inspection after Installation
  169
Rear Suspension

170
- Construction
  171
- Rear Suspension Tuning
  172
  - Low Speed Compression Damping Force Adjustment
    172
  - High Speed Compression Damping Force Adjustment
    172
  - Rebound Damping Force Adjustment
    173
  - Spring Pre-Load Adjustment
    173
  - Rear Suspension Tuning Procedure
    174
  - Rear Suspension
    175
  - Suspension Balance
    176
- Rear Shock Absorber
  176
  - Rear Shock Absorber Removal
    176
  - Spring Removal
    177
  - Rear Shock Absorber Inspection
    177
  - Bearing Replacement
    178
  - Spring Installation
    179
  - Rear Shock Absorber Installation
    179
  - Oil Replacement Procedure
    180
  - Rear Shock Absorber Disassembly and Inspection
    183
  - Rear Shock Absorber Reassembly
    185
  - Rear Shock Absorber Disposal
    185
- Swingarm
  186
  - Disassembly
    186
  - Inspection
    187
  - Bearing Replacement
    188
  - Reassembly
    188
- Rear Suspension Linkage
  189
  - Disassembly
    189
  - Inspection
    189
  - Bearing Removal
    190
  - Bearing Installation
    190
  - Reassembly
    190
Electrical System

193
- Electrical Circuit
  194
- Inspection
  194
  - Ignition System Peak Voltage
    194
  - Ignition Coil
    196
  - CDI Unit
    196
  - Stator Coil
    197
Service Data

203
- Service Data
  204
  - Cylinder + Piston + Piston Ring
    204
  - Conrod + Crankshaft
    204
  - Clutch
    204
  - Radiator + Coolant
    205
  - Transmission + Drive Chain
    205
  - Carburetor
    205
  - Electrical
    206
  - Brake + Wheel
    206
  - Tire
    207
  - Suspension
    207
  - Fuel + Oil
    208
- Tightening Torque
  209
  - Engine
    209
  - Tightening Torque Chart
    210
- Special Tools
  211
- Wiring Diagram
  213
- Wire, Cable and Hose Routing
  214
  - Wire Harnes Routing
    214
  - Cable Routing
    215
  - Carburetor Hose and Water Hose Routing
    216
  - Front Brake Hose Routing
    218
  - Rear Brake Hose Routing
    219
- Handlebar Set-Up
  220
- Muffler Set-Up
  221
- Specifications
  222
  - Dimensions and Dry Mass
    222
  - Engine
    222
  - Transmission
    222
  - Chassis
    223
  - Electrical
    223
  - Capacities
    223
- Optional Parts
  224
  - Rear Sproket
    224
- Spare Parts
  224

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