Suzuki RM-Z250 Manuale utente

GROUP INDEX

GENERAL INFORMATION 1

PERIODIC MAINTENANCE 2

TROUBLESHOOTING 3

MACHINE TUNING 4

ENGINE REMOVAL AND INSTALLATION

CYLINDER HEAD, CYLINDER AND PISTON

CLUTCH 7

KICK STARTER 8

GEARSHIFTING 9

TRANSMISSION AND CRANKSHAFT 10

LUBRICATION SYSTEM 11

FI SYSTEM DIAGNOSIS 12

FUEL SYSTEM AND THROTTLE BODY 13

COOLING SYSTEM 14

ELECTRICAL SYSTEM 15

FRONT AND REAR WHEELS 16

FRONT AND REAR BRAKES 17

FRONT FORK AND STEERING 18

REAR SUSPENSION 19

SERVICING INFORMATION 20

FOREWORD

This manual contains an introductory description on

the SUZUKI RM-Z250 and procedures for its

inspection, service and overhaul of its main compo-

nents.

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 sec-

tions as a guide for proper inspection and service.

This manual will help you know the motorcycle bet-

ter so that you can assure your customers of fast

and reliable service.



* This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modifications have been made since

then, differences may exist between the con-

tent 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 motorcy-

cles. If you do not have the proper knowledge

and tools, ask your authorized SUZUKI

motorcycle dealer to help you.

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.

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX.

3. Holding the manual as shown at the right will allow you to find

the first page of the section easily.

4. The contents are listed on the first page of each section to

help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service information

such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front and rear wheels

1Rear disc plate

2Rear wheel (1.85 ×19)

3Spacer

4Disc cover

5Bead stopper

6Rear sprocket

7Rear axle shaft

8Front axle shaft

9Front wheel (1.60 ×21)

0Front disc plate

ARear axle nut

BDisc plate bolt (Rear)

CRear sprocket nut

DDisc plate bolt (Front)

EFront axle nut



ITEM N·m

kgf-m

lbf-ft

A90 9.0 65.0

B26 2.6 19.0

C30 3.0 21.5

D11 1.1 8.0

E35 3.5 25.5

FWD

SYMBOL MARKS AND MATERIALS

Listed in the table below are the symbols indicating instructions and other information. The meaning of each

symbol is also included in the table.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Data beside it indicates specified

torque.

Apply THREAD LOCK SUPER “1360”

or equivalent.

99000-32130

Apply oil. Use engine oil or transmission

oil unless otherwise specified.

Use SUZUKI FORK OIL SS-05

or equivalent.

99000-99001-SS5

Apply molybdenum oil solution.

(Mixture of engine oil and SUZUKI

MOLY PASTE in a ratio of 1:1)

Use REAR SUSPENSION OIL SS-25 or

equivalent.

Apply SUZUKI SUPER GREASE “A”

or equivalent.

99000-25010

Use engine coolant or equivalent.

Apply SUZUKI SILICONE GREASE

or equivalent.

99000-25100

Apply or use brake fluid. (DOT 4)

Apply SUZUKI MOLY PASTE

or equivalent.

99000-25140

Measure in voltage range.

Apply SUZUKI BOND “1215”

or equivalent.

99000-31110

Measure in resistance range.

Apply SUZUKI BOND “1207B”

or equivalent.

99000-31140

Measure in diode test range.

Apply THREAD LOCK SUPER “1303”

or equivalent.

99000-32030

Use special tool.

Apply THREAD LOCK SUPER “1322”

or equivalent.

99000-32110

Indication of service data.

Apply THREAD LOCK “1342”

or equivalent.

99000-32050

Replace a part with a new one when

reassembling.

ABBREVIATIONS USED IN THIS

MANUAL

AC : Alternating Current

API : American Petroleum Institute

BTDC : Before Top Dead Center

B+ : Battery Positive Voltage

CKP Sensor : Crankshaft Position Sensor

(CKPS)

DC : Direct Current

DTC : Diagnostic Trouble Code

ECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp.

Sensor (WTS)

FI : Fuel Injection, Fuel Injector

FP : Fuel Pump

FP Relay : Fuel Pump Relay

GND : Ground

GP Switch : Gear Position Switch

IAP Sensor : Intake Air Pressure Sensor (IAPS)

(MAP Sensor)

IAT Sensor : Intake Air Temperature Sensor

(IATS)

JASO : Japanese Automobile Standards

Organization

LH : Left Hand

Max : Maximum

Min : Minimum

RH : Right Hand

SAE : Society of Automotive Engineers

SDS : Suzuki Diagnosis System

TO Sensor : Tip-Over Sensor (TOS)

TP Sensor : Throttle Position Sensor (TPS)

WIRE COLOR

B : Black Lg : Light green

Bl : Blue O : Orange

Br : Brown P : Pink

Dg : Dark green R : Red

G : Green Y : Yellow

Gr : Gray

B/Bl : Black with Blue tracer

B/Br : Black with Brown tracer

B/R : Black with Red tracer

B/W : Black with White tracer

B/Y : Black with Yellow tracer

Bl/B : Blue with Black tracer

Bl/G : Blue with Green tracer

Bl/R : Blue with Red tracer

Bl/W : Blue with White tracer

Bl/Y : Blue with Yellow tracer

Br/W : Brown with White tracer

G/B : Green with Black tracer

G/W : Green with White tracer

Gr/W : Gray with White tracer

R/B : Red with Black tracer

R/Bl : Red with Blue tracer

R/W : Red with White tracer

W/Bl : White with Blue tracer

W/R : White with Red tracer

Y/B : Yellow with Black tracer

Y/R : Yellow with Red tracer

SAE-TO-FORMER SUZUKI TERM

This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in

this manual in compliance with SAE recommendations, as well as their former SUZUKI names.

SAE TERM FORMER SUZUKI TERM

FULL TERM ABBREVIATION

Air Cleaner ACL Air Cleaner, Air Cleaner Box

Battery Positive Voltage B+ Battery Voltage, +B

Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),

Crank Angle

Data Link Connector DLC Mode Select Coupler

Diagnostic Test Mode DTM ––––

Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code

Electronic Ignition El ––––

Engine Control Module ECM Engine Control Module (ECM)

Fl Control Unit, Engine Control Unit (ECU)

Engine Coolant Level ECL Coolant Level

Engine Coolant Temperature ECT Coolant Temperature, Engine Coolant Tem-

perature, Water Temperature

Engine Speed RPM Engine Speed (RPM)

Fan Control FC ––––

Fuel Level Sensor –––– Fuel Level Sensor, Fuel Level Gauge

Fuel Pump FP Fuel Pump (FP)

Generator GEN Generator

Ground GND Ground (GND, GRD)

Ignition Control IC Electronic Spark Advance (ESA)

Ignition Control Module ICM ––––

Intake Air Temperature IAT

Intake Air Temperature (IAT), Air Temperature

Malfunction Indicator Lamp MIL Lamp

Malfunction Indicator Lamp (MIL)

Manifold Absolute Pressure MAP Intake Air Pressure (IAP), Intake Vacuum

SAE TERM FORMER SUZUKI TERM

FULL TERM ABBREVIATION

On-Board Diagnostic OBD Self-Diagnosis Function

Diagnostic

Programmable Read Only Memory PROM ––––

Random Access Memory RAM ––––

Read Only Memory ROM ROM

Throttle Body TB Throttle Body (TB)

Throttle Body Fuel Injection TBI Throttle Body Fuel Injection (TBI)

Throttle Position Sensor TP Sensor TP Sensor (TPS)

Voltage Regulator VR Voltage Regulator

GENERAL INFORMATION 1-1

GENERAL INFORMATION

CONTENTS

WARNING/CAUTION/NOTE .........................................................................1- 2

GENERAL PRECAUTIONS...........................................................................1- 2

SUZUKI RM-Z250L0 (’10-MODEL) ...............................................................1- 4

SERIAL NUMBER LOCATION......................................................................1- 4

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION........................1- 5

FUEL (FOR USA AND CANADA)...........................................................1- 5

FUEL (FOR OTHER COUNTRIES).........................................................1- 5

ENGINE OIL (FOR USA).........................................................................1- 5

ENGINE OIL (FOR OTHER COUNTRIES) .............................................1- 5

BRAKE FLUID.........................................................................................1- 5

FRONT FORK OIL ..................................................................................1- 5

REAR SUSPENSION OIL .......................................................................1- 5

ENGINE COOLANT ................................................................................1- 6

BREAK-IN (RUNNING-IN).............................................................................1- 6

WHEN THE MOTORCYCLE IS NEW .....................................................1- 6

WHEN ENGINE PARTS ARE REPLACED.............................................1- 6

INFORMATION LABELS...............................................................................1- 7

SPECIFICATIONS .........................................................................................1- 8

DIMENSIONS AND CURB MASS...........................................................1- 8

ENGINE ...................................................................................................1- 8

TRANSMISSION .....................................................................................1- 8

CHASSIS .................................................................................................1- 9

ELECTRICAL ..........................................................................................1- 9

CAPACITIES ...........................................................................................1- 9

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

CODE COUNTRY or AREA EFFECTIVE FRAME NO.

000

E-03

E-19

E-28

Japan

U.S.A.

E.U.

Canada

JS1RJ42A000 500001 –

JS1RJ42C A2 100001 –

JS1RJ42A000 500001 –

JS1RJ42C A2 100001 –

1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol

and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-

sages highlighted by these signal words.



Indicates a potential hazard that could result in death or injury.



Indicates a potential hazard that could result in motorcycle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all

potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-

INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you

are unsure about how to perform a particular service operation, ask a more experienced mechanic for

advice.

GENERAL PRECAUTIONS



* Proper service and repair procedures are important for the safety of the service mechanic and

the safety and reliability of the motorcycle.

* When 2 or more persons work together, pay attention to the safety of each other.

* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-

doors.

* When working with toxic or flammable materials, make sure that the area you work in is well-

ventilated and that you follow all of the material manufacturer’s instructions.

* Never use gasoline as a cleaning solvent.

* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system

until they have cooled.

* After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings

related to the system for leaks.

GENERAL INFORMATION 1-3



* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-

lent.

* When removing parts that are to be reused, keep them arranged in an orderly manner so that

they may be reinstalled in the proper order and orientation.

* Be sure to use special tools when instructed.

* Make sure that all parts used in reassembly are clean. Lubricate them when specified.

* Use the specified lubricant, bond, or sealant.

* When removing the battery, disconnect the negative cable first and then the positive cable.

* When reconnecting the battery, connect the positive cable first and then the negative cable,

and replace the terminal cover on the positive terminal.

* When performing service to electrical parts, if the service procedures do not require use of

battery power, disconnect the negative cable from the battery.

* When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first.

Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci-

fied tightening torque.

* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking

nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with

new ones. Also, before installing these new parts, be sure to remove any left over material

from the mating surfaces.

* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger

than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is

completely seated in its groove and securely fitted.

* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a

thread is smeared with them.

* After reassembling, check parts for tightness and proper operation.

* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and

other fluids: batteries and tires.

* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

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