Suzuki RM250 Application guide

r l,

FOREWORO

This manual is presented

a means

whereby

you

can

maintain

your

RM250

top

working

ondition

all

times

Your

riding

skill and

the

maintenance steps outlined in this manual

will

assure

you

top

performance

from

your

machine

under

any

type

competition.

We sinc

erely

wish

you

and

your

Suzuki

motor

cycle

successful

partnership

for

many

years

happy

riding.

All

information,

illustration

photographs

and

specifications contained in the manual

are

based

the latest product information available at the

time

publication. Due

improvements

other changes, there

may

some discrepan-

cies in this manual. Suzuki reserves

the

right

make production changes

any

time

witihout

notice

and

without

incurring

any

obligation

make

the

same

similar

changes

vehicles

previously

built

sold.

Suzuki

Motor

Corpor

ation

believes in conserva-

tion and

protection

Earth

natural resources.

that

end,

encourage

every

vehicle

own-

recycle

trade

in, or

properly

dispose

appropriate,

used

motor

oil, engine

coolant,

and

other

fluid

, and

tires

WARNING

CAUTION

NOTE

Please read

this

manual

and

its

instruc

tions

car

efully

emphasize

special

informa

tion

the

symbol

£ and

the

words

WARNING,

CAUTION, and NOTE

have

special

meanings.

Pay special

attention

the

messages

highlight

these

signal

words

WARNING

Indicates

potentia

l hazard

that

cou

result

death

injury

.4.

CAUTION

Indicates

potential

hazard

that

could

result

motorcycle

damage

NOTE: Indicates special information to

make

maintenance

easier or instructions clearer.

COMPETITION MOTORCYCLES

The

Suzuki

RM250

is a

high-perfo

mance

competition

only

motorcycle

. It is

not

designed

approved

for

gene

ral o

-highway

riding

, as

does

not

meet

U.S.

Environmental

Protection

Agency

off

highway

motorcycle

noise standars

and

does

not

have a U.S.

Forest

Service ap-

proved

spark

arrester

is also

not

designed or

approved

for

riding

publ

ic roads, as

does

not

meet

Federal

Motor

Vehicle

Safety

Stan-

dards

for

on-

highway

motorcyc

les.

General

considerations:

• Before

each

use,

perform

inspection

per

"Periodic

Inspection"

section

starting

page 2- 1.

• Suzuki RMs are

designed

for

the

rider

only

PASSENGERS.

•

Always

ride

within

the

boundaries

your

own

skills.

Knowing

these

imits

and

staying

within

them

help

you

avoid

accidents.

Ride

only

events

appr

riate

for

your

perience.

•

Safely

competing

orcycle

requires

that

your

mental

and

physical

skills are

fully

part

the

experience

. You

should

not

tempt

operate

motor

vehicle

especially

one

with

two

wheels

you

are

tired

der

the

influence

alcohol

other

drugs.

Alcohol

, illegal dru

, and

even

some

prescription

and

ove

-the-counte

drugs

can

cause dr

owsiness

, loss

coordination

. loss

balance, and loss

good

judgement.

you

are

tired

under

the

influence

alco

hol

other

drugs,

PLEASE DO NOT RIDE

your

motorcycle

Mayall

your rides

your

new

Suzuki be

win

ning

rides!

WARNINGS

FOR

SERVICING

WARNING

Never run

the

engine indoors or

a garage.

Exhaust gas contains carbon monoxide. a gas

that

is colorless and odorless and can cause

death or severe injury.

Only run

the

engine

outdoors

where

there is

fresh air.

A WARNING

Hot engine

and

muffler

can

burn you.

Wait until the engine and muffler cools before

servicing.

WARNING

Fuel can

catch

on fire

you

not

handle it

properly. Gasoline

vapors

can

catch

fire

easily.

not

smoke

when

servicing

the

machine.

not

service

the

machine in an area

where

there are open flames or sparks.

A WARNING

\')

Brake fluids and engine coolant can be

hazardous

humans and pets. Brake

fluid

and engine coolant are harmful or fatal

swal-

lowed, and harmful

comes

contact

with

your

skin or eyes.

Keep brake

fluid

and engine coolant

away

from

children. Call

your

doctor

immediately

swallowed, and induce vomiting, Flush eyes

or skin

with

water

either brake

fluid

engine

coolant

gets in eyes or comes

contact

with

skin.

A WARNING

Servicing

the

machine

with

engine

running

can

hazardous

. You

can

caught

the

moving

parts

such

the

drive

chain,

sprock

ets

etc.

sure

top

the

engine

when

servicing

the

machine.

PRECAUTIONS

FOR

SERVICING

• Replace gaskets,

relips,

a-rings

and

cotter

pins

with

new

ones.

• Take care

not

expand

the

end gap larger

than required

slip the circl

over the shaft

when

installing

a c

clip.

• Use special

tools

where

specified.

• Use genuine SUZUKI parts and recommend-

ed oil.

•

When

two

persons

work

together

pay

attention

the

safety

each other.

•

After

reassembly, inspect parts for tightness

and

ope

ration.

A WARNING

Servicing

the

machine

without

proper

clothes

and

protective

gear can be

hazardous

. You

can be

injured

you

not

wear

Rroper

clothes

and

protective

gear.

Be sure

wear

proper

clothes

and shoes

for

servicing

and

wear

protective

glasses. mask

gloves

necessary

~:P/

III

REPLACEMENT PARTS

Use only

genuine

SUZUKI

replacement

parts

thei

equivalent

. Genuine SUZUKI

parts

are high

quality

parts

which

are

designed

and

built

spe-

cially

for

SUZUKI

vehicles

NOTE: Use

replacement

parts

which

are

not

equivalentin quality to genuine SUZUKIparts can

lead

performance

problems

and

damage.

SYMBOL MARKS AND MATERIALS

SYMBOL MARK MATERIALS

SUZUKI

SUPER

GREASE"

99000

25030

....

.. .

SUZUKI SILICONE GREASE

99000

25100

THREAD LOCK

SUPER"

1303"

99000

32030

SUZUKI BOND

1207B

99104-31140

Use

apply OOT4 brake fluid.

FROtIT

FIIIKDlL

SUZUKI

FORK

99000-99001-555

SYMBOL MARK MATERIALS

I I

___

-.l

SUZUKI

REAR

SUSPENSION OIL

99000-99001

525

Use engine coolant.

Apply engine

oil

transmission oil.

Tighten a nut

bolt to the specified

torque.

Replace a part with a

new

one when

ressembling.

-MEMO-

TABLE

CONTENTS

,-----------------------------

----

-------

GENERAL

INSTRUCTIONS

PERIODIC

MAINTENANCE

TROUBLESHOOTING

MACHINE

TUNING

ENGINE

DISMOUNTING

AND

MOUNTING

CYLINDER,

PISTON

AND

EXHAUST

VALVE

CLUTCH

KICK

STARTER

TRANSMISSION

AND

CRANKSHAFT

FUEL

SYSTEM

COOLING

SYSTEM

ELECTRICAL

SYSTEM

FRONT

AND

REAR

WHEELS

FRONT

AND

REAR

BRAKES

FRONT

FORK

AND

STEERING

REAR

SUSPENSION

SERVICE

SPECIAL

TOOLS

WIRE,

CABLE

AND

HOSE

ROUTING

SPECIFICA

TIONS

1·1

GEN

RAL

INSTRUCTIONS

LOCATION

PARTS

Clutch lever

@ Engine

kill

switch

@ Throttle grip

@ Front brake lever

® Fuel tank cap

® Choke/idle adjust knob

Gearshift lever

® Kick starter lever

® Rear brake pedal

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