Suzuki RM-Z250 Factory Service Repair Manual 2004-2006

99500-42182-01E RM-Z250

FOREWORD This manual contains an introductory description on the SUZUKI RM-Z250 and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections as a guide for proper inspection and service. This manual will help you know the motorcycle better so that you can assure your customers of fast and reliable service. Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider. * This manual has been prepared on the basis of the latest specifications at the time of publication. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle. * Illustrations in this manual are used to show the basic principles of operation and work procedures.They may not represent the actual motorcycle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. CODE MODEL COUNTRY or AREA EFFECTIVE FRAME NO. COUNTRY AND AREA CODES The following codes stand for the applicable country(-ies) and area(-s). E-03 E-28 E-19 E-24 E-03 E-28 E-19 E-24 E-03 E-28 E-19 E-24 JKSKXCPC 4A000001 – JKSKXCPC 4A000001 – JKSKX250NPA000001 – JKSKXCPC 4A000001 – JKSKXCPC 5A009001 – JKSKXCPC 5A009001 – JKSKX250NPA009001 – JKSKXCPC 5A009001 – JKSKXCPC 6A015001 – JKSKXCPC 6A015001 – JKSKX250NPA015001 – JKSKXCPC 6A015001 – U.S.A. Canada EU Australia U.S.A. Canada EU Australia U.S.A. Canada EU Australia K4 K5 K6

List of corresponding materials and tools Select applicable model, lubricant, adhesive, sealing agent, oil or special tools referring to this list when reading this manual. Lubricant Bond, Sealant and Oil Symbol mark or defi- nition in this manual Suzuki recomended lubrcant, bond sealant G: Apply grease 99000-25010 Suzuki Super grease “A” or equivalent L: Apply a non-perma- nent locking agent 99000-32110 Suzuki Thread Lock Super “1322” or equivalent 56019-1063 Kawasaki Bond (Liquid Gasket-Gray) 99000-31230 Suzuki Bond “1216B” Front fork oil KAYABA 01 or SAE 5W 99000-99044-L01 Suzuki fork oil L01 or an equivalent fork oil Rear shock absorber oil KYB K2-C or an equivalent Rear shock absorber oil Rear shock absorber oil KYB K2-C or an equivalent Rear shock absorber oil

SPECIAL TOOLS Base Manual Tools SUZUKI Recommend tools Base Manual Tools SUZUKI Recommend tools 57001-122 Fuel level gauge, M18 × 1.0 KK570-01122 Fuel level gauge, M18 × 1.0 57001-137 Steering stem bearing driver 09941-74910 Steering bearing installer 09915-74511 Oil pressure gauge 57001-143 Inside circlip pliers 09900-06108 Snap ring pliers 57001-125 Oil pressure gauge 5 kgf/cm 2 09915-74550 Oil pressure gauge adapter 57001-144 Outside circlip pliers 09900-06107 Snap ring pliers 57001-135 Bearing puller KK570-01135 Bearing puller 57001-221 Compression gauge 20 kgf/cm 2 09915-64512 Compression gauge

Base Manual Tools SUZUKI Recommend tools Base Manual Tools SUZUKI Recommend tools 57001-241 Valve spring compressor assembly 09916-14510 Valve lifter 09923-74511 Bearing remover 57001-1063 Rim protector 09941-94510 Rim protector 09930-30104 Slide shaft 57001-1072 Bead breaker assembly KK570-11072 Bead breaker assembly 57001-1058 Oil seal & Bearing remover 09941-64511 Bearing & Oil seal remover 57001-1095 Piston ring compressor grip 09916-74512 Piston ring compressor 57001-1097 Piston ring compressor belt !67 – !79 09916-74550 Piston ring holder band

Base Manual Tools SUZUKI Recommend tools Base Manual Tools SUZUKI Recommend tools 57001-1074 Steering stem bearing driver adapter ø34.5 57001-1100 Steering stem nut wrench K5700-11100 Steering stem nut wrench 57001-1075 Head pipe race press shaft 57001-1101 Hook wrench K5700-11101 Hook wrench 57001-1076 Head pipe outer race driver 57001-1107 Head pipe outer race remover 09941-54911 Head pipe outer race remover 57001-1077 Head pipe outer race driver 09941-34513 Bearing installer 57001-1114 Valve seat cutter 45° – !27.5 KK5700-11114 Valve seat cutter 45° – !27.5

Base Manual Tools SUZUKI Recommend tools Base Manual Tools SUZUKI Recommend tools 57001-1115 Valve seat cutter 45° – !32 KK5700-11115 Valve seat cutter 45° – !32 57001-1129 Bearing driver set 09913-70210 Bearing installer set 57001-1116 Valve seat cutter 45° – !35 KK5700-11116 Valve seat cutter 45° – !35 57001-1154 Valve spring compressor adapter !20 09916-14530 Valve spring compressor attachment 57001-1119 Valve seat cutter 32° – !28 KK5700-11119 Valve seat cutter 32° – !28 57001-1174 Crankshaft jig K5700-11174 Crankshaft jig 57001-1128 Valve seat cutter holder bar K5700-11128 Valve seat cutter holder bar 57001-1199 Valve seat cutter 32° – !33 K5700-11199 Valve seat cutter 32° – !33

Base Manual Tools SUZUKI Recommend tools Base Manual Tools SUZUKI Recommend tools 57001-1218 Fork outer tube weight 09940-52861 Front fork oil seal installer set 57001-1262 Spark plug wrench, Hex16 09930-10121 Spark plug wrench set 57001-1238 Jack K5700-11238 Jack 57001-1265 Bearing remover shaft !9 57001-1241 Timing light K5700-11241 Timing light 57001-1267 Bearing removal head !15 × !17 09941-50111 Wheel bearing remover set 57001-1243 Clutch holder 09920-53740 Clutch sleeve hub holder 57001-1290 Fork oil level gauge 09943-74111 Oil level gauge

Base Manual Tools SUZUKI Recommend tools Base Manual Tools SUZUKI Recommend tools 57001-1292 Pilot screw adjuster, C 57001-1330 Valve seat cutter holder, !4.5 K5700-11330 Valve seat cutter holder, !4.5 57001-1371 Pilot screw adjuaster Adapter, !4 09913-10130 Carburetor adjust driver 57001-1331 Valve guide arbor !4.5 K5700-11331 Valve guide arbor !4.5 57001-1317 Compression gauge M10 × 1.0 09915-63310 Compression pressure gauge adapter 57001-1333 Valve guide reamer !4.5 K5700-11333 Valve guide reamer !4.5 57001-1328 Valve seat cutter, 60° – !28 K5700-11328 Valve seat cutter, 60° – !28 57001-1334 Valve seat cutter, 60° – !33 K5700-11334 Valve seat cutter, 60° – !33

Base Manual Tools SUZUKI Recommend tools Base Manual Tools SUZUKI Recommend tools 57001-1362 Crankshaft splitting tool assembly 09920-13120 Crankcase separat- ing tool 57001-1454 Filter cap driver K5700-11454 Driver filter cap 57001-1394 Hand tester 57001-1457 Needle adapter set 09900-25009 Needle pointed probe set 57001-1415 Peak voltage adapter 09900-25008 Multi circuit tester 57001-1509 Fork oil seal driver !48 K5700-11509 Fork oil seal driver !48 57001-1400 Throttle sensor adapter K5700-11400 Throttle sensor adaptor 57001-1557 Gear holder K5700-11557 Gear holder

Suzuki RM-Z250 Factory Service Repair Manual 2004-2006

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