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Suzuki RM-Z250 Owner's Manual

Other manuals for RM-Z250: Owner's Service Manual

Summary of RM-Z250

  • Page 1

    99 01 1- 49 h 51 -0 1a r m -z 25 0 part no. 99011-49h51-01a april, 2010 en printed in japan rm-z250 tk l1 owner’s manual and race preparation manual v warning failure to follow these safety precautions may increase your risk of injury: • wear a helmet, eye protection, and bright, protective clothing...

  • Page 2

    Vwarning/vcaution/notice/note please read this manual and follow its instructions carefully. To emphasize special information, the symbol v and the words warning, caution, notice and note have special meanings. Pay particular attention to messages highlighted by these signal words: note: indicates s...

  • Page 3: Foreword

    Foreword this manual is presented as a means whereby you can maintain your rm-z250 in top working condi- tion at all times. Your riding skill and the mainte- nance steps outlined in this manual will assure you of top performance from your machine under any type of competition. We sincerely wish you ...

  • Page 4: Serial Number Location

    • practice on level ground before you begin riding, you should find a good place to practice the skills you need to ride safely. Find a flat, open area with enough space to maneuver. Check with your suzuki dealer or call police department if you do not know where you can ride. Review the controls on...

  • Page 5: Warnings For Servicing

    Warnings for servicing  warning never run the engine indoors or in a garage. Exhaust gas contains carbon mon- oxide, a gas that is colorless and odorless and can cause death or severe injury. Only run the engine outdoors where there is fresh air.  caution hot engine and muffler can burn you. Wait ...

  • Page 6: Precautions For

    Precautions for servicing  warning servicing the machine with engine running can be hazardous. You can be caught in the moving parts such as the drive chain, sprockets etc. Be sure to stop the engine when servicing the machine.  warning servicing the machine without proper clothes and protective g...

  • Page 7: Replacement Parts

    Note: * clean a motorcycle from dirt and/or dust before servicing. * avoid spraying or allowing water to flow over the following places: - spark plug - fuel tank cap - throttle body - fuel injection system - brake master cylinders - air cleaner inlet * be sure to dry the motorcycle after washing the...

  • Page 8: Symbol Marks and Materials

    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 supe...

  • Page 9

    Abbreviations used in this manual a ac : alternating current api : american petroleum institute b btdc : before top dead center b+ : battery positive voltage c ckp sensor : crankshaft position sensor (ckps) d dc : direct current dtc : diagnostic trouble code e ecm : engine control module, engine con...

  • Page 11: Group Index

    Group index general information 1 periodic maintenance 2 machine tuning 3 disassembly and assembly 4 servicing information 5.

  • Page 13: General Information

    General information 1 general information 1-1 location of parts ................................................................................. 1-2 accessory ................................................................................................ 1-3 side stand ...............................

  • Page 14: Location of Parts

    1-2 general information location of parts 1 clutch lever 2 hot starter lever 3 engine stop switch 4 front brake lever 5 throttle grip 6 fuel tank cap 7 starter knob/idle screw 8 gearshift lever 9 front suspension compression damping adjuster 0 front suspension rebound damping adjuster a kick starter...

  • Page 15: Accessory

    General information 1-3 accessory side stand this motorcycle is not equipped with a side stand. To support the motorcycle for a short period of time, use the accessory side stand that comes supplied with the motorcycle. When servicing the motorcycle, use a service stand and support the underneath of...

  • Page 16: Operating Instructions

    1-4 general information operating instructions starting the engine inspect the engine oil level, coolant level and air cleaner condi- tion before starting the engine. Note: check that the fuel tank has enough fuel for practice or race before starting the engine. When the engine is cold regardless of...

  • Page 17

    General information 1-5 when the engine is already warm or restarts: 1) pull the hot starter lever 1. 2) kick down the kick starter lever slowly from the top position until engine compression resistance is felt, release the kick starter lever from this position and allow it to return to the top. Whi...

  • Page 18

    1-6 general information when the motorcycle is not used for long time: due to deterioration of fuel remaining in the fuel line for long period, engine will be difficult to start until the deteriorated (stale) fuel is discharged from the fuel line. Repeated kick operation is required for flushing the...

  • Page 19: Break-In (Running-In)

    General information 1-7 break-in (running-in) when the motorcycle is new 1) warm up the engine before starting off. 2) ride for 60 minutes using less than 1/2 throttle opening. 3) ride for 60 minutes using less than 3/4 throttle opening. Note: * the break-in (running-in) period is the period of grea...

  • Page 21: Periodic Maintenance

    Periodic maintenance periodic maintenance 2-1 2 periodic maintenance .......................................................................... 2-3 inspection before practice ....................................................... 2-3 inspection before race (all items of inspection before practice o...

  • Page 22: Periodic Maintenance

    Periodic maintenance 2-2 periodic maintenance fuel hose ................................................................................................ 2-26 valve clearance ................................................................................. 2-27 valve clearance adjustment ...............

  • Page 23: Periodic Maintenance

    Periodic maintenance 2-3 periodic maintenance inspection before practice what to check check for spark plug • heat range, fouled electrode, tightness • loose high-tension cord air cleaner element • dust • lubrication engine oil oil level coolant coolant level cooling system • radiator hose damage • ...

  • Page 24

    2-4 periodic maintenance inspection before race (all items of inspection before practice on previous page plus) what to check check for clutch clutch disk plates wear and distortion brake pads wear sprockets wear fuel tank leakage fuel hose • damage • hoses are connected exhaust pipe and muffler dam...

  • Page 25

    Periodic maintenance 2-5 periodic maintenance chart it is very important to inspect and maintain the machine regularly. Follow the guideline in the chart. The life of parts varies depending on the riding conditions. Perform more often than shown in the chart if you use the motorcycle under severe co...

  • Page 26

    2-6 periodic maintenance note: r = replace, c = clean, t = tighten, i = inspect and clean, adjust lubricate or replace if necessary, l = lubricate tire i — — spoke nipple i — — inspect every 20 min. Up to initial 2 hours then check before each ride. Steering i — — frame i — — swingarm i — — bolts an...

  • Page 27: Spark Plug

    Periodic maintenance 2-7 spark plug • remove the seat. ( 4-2) • remove the radiator covers and fuel tank. ( 4-2) • hold the cylinder head cover bolt immovable with the wrench. • disconnect the lead wire coupler from the ignition coil/plug cap. • remove the ignition coil/plug cap. • clean the ignit...

  • Page 28

    2-8 periodic maintenance • measure the spark plug gap a with a wire gauge. • if it is not within the specification, replace the spark plug.  spark plug gap: 0.9 – 1.0 mm (0.035 – 0.039 in)  standard spark plug • tighten the spark plug with specified tightening torque after tightening the spark plu...

  • Page 29: Air Cleaner

    Periodic maintenance 2-9 air cleaner air cleaner element removal • remove the seat. ( 4-2) • remove the wing bolt 1. • remove the element 2 from the element holder. Washing • fill a washing pan large enough to hold the element with a non-flammable cleaning solvent a. Immerse the element in the solv...

  • Page 30

    2-10 periodic maintenance installation • apply filter oil to the element base where it contacts the air cleaner box. • fit the element 2 onto the element holder 1. Note: fit the projection a of the element holder to the hole of the ele- ment 2. • install them in the air cleaner box by engaging the p...

  • Page 31: Engine Oil and Oil Filter

    Periodic maintenance 2-11 engine oil and oil filter note: * do not mix engine oil. Use only good quality engine oil. * be careful that dirt does not enter into crankcase through engine oil filler. * wipe off spilled engine oil. * improper engine oil level can affect engine performance. Note: recycle...

  • Page 32

    2-12 periodic maintenance inspection before engine oil level check • before starting the engine, check that there is sufficient oil for operating the engine. • remove the oil check bolt 1. • tilt the motorcycle to the right and check that engine oil comes out from oil level check hole. • tighten the...

  • Page 33

    Periodic maintenance 2-13 engine oil level inspection • during inspection, hold the motorcycle in an upright position on a level surface. Note: the oil level measurement may become inaccurate unless the motorcycle is held upright as the motorcycle inclination affects the oil level. • warm up the eng...

  • Page 34

    2-14 periodic maintenance engine oil change • during inspection, hold the motorcycle in an upright position on a level surface. • warm up the engine. • remove the filler cap, tdc plug 1, drain plug 2 and drain no.2 plug 3. Drain engine oil. • replace the o-ring with a new one and tighten the tdc plu...

  • Page 35

    Periodic maintenance 2-15 engine oil filter change • drain the engine oil as described in the engine oil replace- ment procedure. • remove the oil filter cap 1 and spring 2 with oil filter 3. • apply engine oil lightly to the gasket of new oil filter before installation. • install the new oil filter...

  • Page 36: Oil Strainers

    2-16 periodic maintenance oil strainers oil strainer (no.1) removal • hold the motorcycle upright. • clean the engine to avoid engine trouble. • drain engine oil. ( 2-14) • remove the oil strainer cap. Note: hold the motorcycle upright while replacing the oil strainer. • pull out the oil strainer 1...

  • Page 37

    Periodic maintenance 2-17 inspection • check the oil strainers for any damage or clogging. • if the oil strainer is clogging, clean the oil strainer with a com- pressed air. A oil strainer no.1 b oil strainer no.2 • clean the oil nozzle by applying compressed air. Oil strainer (no.2) installation • ...

  • Page 38

    2-18 periodic maintenance oil strainer (no.1) installation • install the oil strainer and then tighten the oil strainer cap to the specified torque. Note: replace the gasket washer with a new one.  engine oil strainer cap: 21 n·m (2.1 kgf-m, 15.0 lbf-ft) • add new engine oil and check the oil level...

  • Page 39: Engine Coolant

    Periodic maintenance 2-19 engine coolant engine coolant level check • remove the radiator cap 1 and air bleeder bolt 2. • check that the engine coolant level is at the bottom of the inlet hole. If not, replenish the radiator with specified engine cool- ant. • tighten the air bleeder bolt 2 to the sp...

  • Page 40

    2-20 periodic maintenance engine coolant replenishment • use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50:50. Note: the radiator, cylinder and cylinder head are made of aluminum alloy. Using non-recommended engine coolant may corrode a...

  • Page 41: Clutch Cable

    Periodic maintenance 2-21 clutch cable adjust the clutch cable play as follows: major adjustment • loosen the lock-nut 1. • turn adjuster 2 so the clutch lever clearance a measured at the lever holder obtains 2 – 3 mm (0.08 – 0.12 in) when squeezing the lever until pressure is felt. • tighten the lo...

  • Page 42: Throttle Cable

    2-22 periodic maintenance throttle cable adjust the throttle cable play a as follows: throttle cable adjustment • loosen the lock-nut 1. • turn adjuster 2 so the throttle grip has 2 – 4 mm (0.08 – 0.16 in) play in circumference. • tighten the lock-nut 1.  throttle cable play a: 2 – 4 mm (0.08 – 0.1...

  • Page 43

    Periodic maintenance 2-23 throttle cable oil supply • remove the throttle case 1. • apply oil to the throttle cable. • apply grease to the throttle cable spool. 99000-25010: suzuki super grease “a” or equivalent.

  • Page 44: Hot Starter

    2-24 periodic maintenance hot starter adjust the hot starter cable play as follows: note: be careful not to damage the lever cover when installing. ( 5-18) • loosen the lock-nut 1. • turn adjuster 2 so the hot starter lever clearance a mea- sured at the lever holder obtains 2 –3 mm (0.08 – 0.12 in)...

  • Page 45: Engine Idle Speed

    Periodic maintenance 2-25 engine idle speed • adjust the throttle cable play. ( 2-22) • warm up the engine. Note: make this adjustment when the engine is hot. • insert the needle-pointed probe to the lead wire coupler (w/bl). Note: use the special tool (needle-pointed probe), to prevent the rub- be...

  • Page 46: Crankcase Breather Hose

    2-26 periodic maintenance crankcase breather hose • inspect the crankcase breather hose for damage, clogging and bend. If any defects are found, the breather hose must be replaced. Fuel hose • inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced...

  • Page 47: Valve Clearance

    Periodic maintenance 2-27 valve clearance • remove the seat. ( 4-2) • remove the radiator covers and fuel tank. ( 4-2) • remove the ignition coil/plug cap and spark plug. ( 2-7) • remove the cylinder head cover 2 and gasket 3 by remov- ing their bolts 1. The valve clearance specification is diffe...

  • Page 48

    2-28 periodic maintenance valve clearance adjustment the clearance is adjusted by replacing the existing tappet shim with a thicker or thinner one. • remove the intake or exhaust camshafts. ( 4-12) • remove the tappet 1 and shim 2 by fingers or magnetic hand. • check the figures printed on the shim...

  • Page 49

    Periodic maintenance 2-29 (intake side) 0.015 – 0.039 0.040 – 0.064 0.065 – 0.089 0.090 – 0.160 0.000– 0.014 0.161 – 0.185 0.186 – 0.210 0.211 – 0.235 0.236 – 0.260 0.261 – 0.285 0.286 – 0.310 0.311 – 0.335 0.336 – 0.360 0.361 – 0.385 0.386 – 0.410 0.411 – 0.435 0.436 – 0.460 0.461 – 0.485 0.486 – 0...

  • Page 50

    2-30 periodic maintenance (exhaust side) 0.070 – 0.094 0.095 – 0.119 0.120 – 0.144 0.145 – 0.169 0.045 – 0.069 0.020 – 0.044 0.000 – 0.019 0.170 – 0.240 0.241 – 0.265 0.266 – 0.290 0.291 – 0.315 0.316 – 0.340 0.341– 0.365 0.366 – 0.390 0.391 – 0.415 0.416 – 0.440 0.441 – 0.465 0.466 – 0.490 0.491 – ...

  • Page 51

    Periodic maintenance 2-31 cylinder head, cylinder and piston cylinder head inspection • remove the cylinder head. ( 4-15) • decarbonize the combustion chambers. • inspect for pinholes, cracks and other damage. • if any defects are found, replace the cylinder head with a new one. Cylinder inspection...

  • Page 52: Drive Chain and Sprockets

    2-32 periodic maintenance drive chain and sprockets drive chain slack • place the motorcycle on a block to lift the rear wheel off the ground. • inspect the drive chain slack at the middle point between the drive chain buffer and rear sprocket.  drive chain slack a: 35 – 45 mm (1.4 – 1.8 in) crankc...

  • Page 53

    Periodic maintenance 2-33 drive chain adjustment • loosen the axle nut 1. • loosen the lock-nuts 2 and adjust the drive chain slack to the specification by turning the adjusters 3. Make sure that the right and left adjuster washers 4 are at the same position on scales 5. • with the adjusters 3 held ...

  • Page 54

    2-34 periodic maintenance drive chain lubrication • remove the chain clip and master link from the drive chain and remove the drive chain. Note: be careful not to bend the chain clip. • inspect for wear and damage of the drive chain and replace it if necessary. • clean the drive chain with non-flamm...

  • Page 55

    Periodic maintenance 2-35 drive chain guide, buffer and tensioner roller drive chain guide inspection • inspect the drive chain guide 1 for bends and damage. Note: the drive chain can hit a bent guide causing noise and drive chain wear. • inspect the chain guide defense 2 for wear. • if necessary, r...

  • Page 56: Brakes

    2-36 periodic maintenance brakes brake fluid level • inspect the brake fluid level in both front and rear reservoirs. If the brake fluid level is lower than lower mark a, replenish the reservoir with the specified brake fluid to the upper line. Inspect brake pad wear and brake fluid leakage if the b...

  • Page 57

    Periodic maintenance 2-37 brake pad • inspect the brake pads for wear. If the brake pads are worn, replace them with new ones. ( 4-64) a wear limit note: * pump the brake lever and pedal several times to restore the brake pads after replacing the brake pads. * replace both right and left pads toget...

  • Page 58

    2-38 periodic maintenance front brake lever adjustment adjust the brake lever position as follows: • loosen the lock-nut 1. • turn in or out adjuster 2 to obtain the proper brake lever position. • the standard adjuster length a is from 11 – 15 mm (0.4 – 0.6 in). • tighten the lock-nut 1.  adjuster ...

  • Page 59: Front Fork

    Periodic maintenance 2-39 front fork • move the front fork up and down several times and inspect for smooth movement. • inspect for damage and oil leaks. • inspect the bolts and nuts for tightness. • if any defects are found, replace the front fork with a new one. • place a stand under the chassis t...

  • Page 60: Wheels and Tires

    2-40 periodic maintenance wheels and tires wheel rim and tires inspection • inspect the wheel and tires for damage. • inspect the wheel bearing for rattles. ( 4-55) • inspect the wheel rim runout. ( 4-55) • if necessary, replace the defective parts with a new one. Spoke nipple and rim lock inspect...

  • Page 61: Steering

    Periodic maintenance 2-41 steering • inspect the steering by moving the front forks up and down, and back and forward. If the steering has play or binds, inspect steering stem head nut tightness and steering bear- ings. ( 4-92, -93) frame • inspect the frame periodically. Swingarm • inspect the swi...

  • Page 62: Lubrication

    2-42 periodic maintenance lubrication apply grease or oil to the moving parts to increase durability and prevent wear. The following materials are necessary: a. Lightweight oil such as wd-40 or penetrating oil b. Aerosol type chain lube c. Suzuki super grease “a” (or equivalent grease) or water-proo...

  • Page 63

    Periodic maintenance 2-43 follow the schedule closely. The disassembly necessary to lubricate many components is in itself valuable preventative maintenance. It allows you to inspect for wear, fatigue, adjustment and fastener tightness and it allows you to clean out the grit which otherwise cannot b...

  • Page 65: Machine Tuning

    Machine tuning machine tuning 3-1 3 selection of ecm tuning map ............................................................ 3-2 short wire connecting procedure ........................................ 3-3 front fork tuning ...............................................................................

  • Page 66: Selection of Ecm Tuning Map

    3-2 machine tuning selection of ecm tuning map in the ecm of this model, there are three different maps pro- vided, a standard map and two modified maps (injection map for slightly leaner mixture and that for slightly richer mixture). Select the appropriate short wire among those that come sup- plie...

  • Page 67

    Machine tuning 3-3 short wire connecting procedure • disconnect the mode select coupler 2 from the bracket 1. • disconnect the mode select coupler cap 3. • connect the short wire 4 to the mode select coupler 2. • reinstall the mode select coupler. • start the engine. Note: keep dry when connecting t...

  • Page 68: Front Fork Tuning

    3-4 machine tuning front fork tuning the front fork compression and rebound damping force, and oil capacity are adjustable for rider’s preference, rider’s weight and course condition. Note: * break-in new front forks before attempting adjustment. * be sure to adjust both right and left front forks e...

  • Page 69

    Machine tuning 3-5 oil quantity minor adjustment adding the fork oil • remove the air bleeder valve 1. • add the fork oil with a injector from the air bleed hole. Reducing the fork oil • remove the front forks. ( 4-72) • remove the air bleeder valve. • leaning the front fork, reduce the fork oil fr...

  • Page 70

    3-6 machine tuning oil change (only for outer tube oil chamber) • remove the front forks. ( 4-72) • thoroughly clean the fork before disassembly. • clamp the outer tube with a vise. Protect the outer tube with a rag when using a vise. ( 4-73) • loosen and remove the fork cap bolt (sub-tank) from t...

  • Page 71

    Machine tuning 3-7 note: be sure to adjust the fork oil quantity within the above-mentioned range. Note: identification slit mark on the spring end is for spare parts only. The spring assembled at the factory does not have identification slit mark. • raise the outer tube and temporarily tighten the ...

  • Page 72

    3-8 machine tuning spring change • remove the front forks. ( 4-72) • thoroughly clean the fork before disassembly. • remove the fork cap bolt and drain fork oil. ( 4-73) • loosen the center bolt completely. ( 4-74) • compress the outer tube by hands and install the piston holder (special tool) be...

  • Page 73

    Machine tuning 3-9 • replace the spring. • tighten the lock nut 2. Note: thread length a should be approx. 10 mm (0.39 in). 2 lock-nut a approx. 10 mm (0.39 in) • install the damper rod assembly. ( 4-85) • insert the push rod 4 into the inner rod. • insert the shaped projection a of center bolt 5 i...

  • Page 74

    3-10 machine tuning • check or adjust the clearance between the lock-nut 2 and center bolt 5 to provide more than 1 mm (0.04 in) and more. ( 4-86) • tighten the lock-nut/center bolt to the specified torque.  lock-nut/center bolt: 22 n·m (2.2 kgf-m, 16.0 lbf-ft) • tighten the center bolt to the spe...

  • Page 75

    Machine tuning 3-11 front fork tuning procedure test ride the motorcycle and find out how the front suspension reacts on various types of surface. According to the symptom noticed, adjust the front fork to the best setting for rider and race track conditions. To adjust, attempt changing fork oil cap...

  • Page 76: Rear Suspension Tuning

    3-12 machine tuning rear suspension tuning the rear suspension compression and rebound damping force, and spring pre-load are adjustable for rider’s preference, rider’s weight and course condition. Note: * break-in the rear suspension when riding with a new rear cushion unit. ( 1-7) * inspect the f...

  • Page 77

    Machine tuning 3-13 rebound damping force adjustment note: to set the adjuster, you must gently turn the adjust screw clock- wise until it stops, then back it out the recommended number of turns. Do not force the adjust screw past the stopped position, or you may damage the adjuster. • turn the adju...

  • Page 78

    3-14 machine tuning rear suspension tuning procedure • remove the rear shock absorber. ( 4-98) • remove the rear shock absorber spring. ( 4-100) • adjust the rear suspension according to the rider’s weight and preference by referring to the table below. Note: identification marking paint on the sp...

  • Page 79

    Machine tuning 3-15 after the sag measurement has been set 105 mm (4.13 in), test ride the motorcycle and adjust the suspen- sion for the rider and track conditions referring to the guide below. Note: when adjusting the damping force setting, attempt turning the adjuster 1 to 2 click stops at a time...

  • Page 80: Suspension Balance

    3-16 machine tuning suspension balance balancing the front to rear suspension properly is the most critical adjustment for suspension performance. If the front forks are adjusted harder than the rear suspension, such as changing to heavier front fork oil, stiffer compression and rebound setting, air...

  • Page 81: Disassembly and Assembly

    Disassembly and assembly disassembly and assembly 4-1 4 engine removal and installation .................................................. 4-2 removal ............................................................................................... 4-2 installation .......................................

  • Page 82

    4-2 disassembly and assembly engine removal and installation removal • drain engine oil. ( 2-14) • drain engine coolant. ( 4-49) • remove the seat 1. • remove the radiator covers 2, left and right. • remove the right frame cover 3. • place the jack under the frame to support the motorcycle. • remo...

  • Page 83

    Disassembly and assembly 4-3 note: when removing the fuel tank, do not leave the fuel hose 7 on the fuel tank side. • remove the fuel tank assembly. • loosen the muffler connector clamp bolt 8. • remove the muffler 0 by removing their bolts 9. • remove the exhaust pipe b by removing their nuts a. • ...

  • Page 84

    4-4 disassembly and assembly • remove the front protectors e by removing their bolts d. • remove the radiator louvers f, left and right. • remove the radiator mounting bolts g, left and right. • loosen the radiator hose clamps h. • disconnect the radiator hoses i and j. • remove the radiator hose k....

  • Page 85

    Disassembly and assembly 4-5 • remove the clutch cable bracket bolt q and disconnect the clutch cable r. Note: loosen the clutch cable adjuster when disconnecting. • remove the throttle body s. ( 4-45) • remove the ignition coil/plug cap t. ( 2-7) • remove the cotter pin u, washer v and clip w. • ...

  • Page 86

    4-6 disassembly and assembly • remove the gearshift lever ]. Note: mark a the gearshift shaft head at which the gearshift lever slit set for correct reinstallation. • remove the engine sprocket cover ^ and front chain guide plate a. • remove the drive chain clip b, and release the drive chain c. • r...

  • Page 87

    Disassembly and assembly 4-7 installation install the engine in the reverse order of removal. Pay attention to the following points: • fit the swingarm in its position and hold it with the swingarm pivot shaft. • mount the engine on the frame. • tighten the engine mounting bolts, nuts and swingarm p...

  • Page 88

    4-8 disassembly and assembly • install the engine sprocket 1 and snap ring 2. Note: replace the snap ring 2 with a new one. Seat the snap ring 2 in the groove and locate its end as shown in the illustration.  09900-06107: snap ring remover (open type) a thrust b sharp edge • reassemble the drive ch...

  • Page 89

    Disassembly and assembly 4-9 • install the clip a, washer b and cotter pin c. Note: replace the cotter pin c with a new one. • install the kick starter lever d in the correct position. ( 4-44) • tighten the kick starter lever bolt e to the specified torque.  kick starter lever bolt: 29 n·m (2.9 kg...

  • Page 90

    4-10 disassembly and assembly • install the muffler joint connector k and exhaust pipe gasket l. Note: replace the connector k and gasket l with new ones to pre- vent exhaust gas leakage. Note: when installing a new connector k, clean the exhaust pipe and joint of the muffler. • temporarily tighten ...

  • Page 91

    Disassembly and assembly 4-11 • temporarily tighten the muffler connector clamp bolt p. Note: when installing the connector clamp, fit the convex part i of the connector clamp onto the concave part of muffler. • check the clearance between exhausted pipe and radiator hose. • be sure to tighten the b...

  • Page 92

    4-12 disassembly and assembly cylinder head, cylinder and piston engine top side disassembly cylinder head cover removal • remove the seat. ( 4-2) • remove the radiator covers and fuel tank. ( 4-2) • remove the ignition coil/plug cap and spark plug. ( 2-7) • remove the cylinder head cover 2 and g...

  • Page 93

    Disassembly and assembly 4-13 • place a wrench over the crankshaft and turn it counter clock- wise to align the tdc mark a with the center of the groove b of the timing inspection hole. Note: * the piston must be at tdc on the compression stroke. * make sure that the cylinder is at tdc on compressio...

  • Page 94

    4-14 disassembly and assembly • remove the cam chain tension adjuster cap bolt 5, gasket 6, bar 7 and spring 8. • remove the cam chain tension adjuster 0 by removing their bolts 9. • remove the camshaft journal holder a. Note: be sure to loosen the camshaft journal holder bolts evenly by shifting th...

  • Page 95

    Disassembly and assembly 4-15 cylinder head removal • remove the camshafts. ( 4-12) • remove the spark plug. ( 2-7) • remove the throttle body. ( 4-45) • drain engine coolant. ( 4-49) • loosen the muffler connector clamp bolt 1. • remove the nuts 2. • remove the exhaust pipe 3. • remove the exha...

  • Page 96

    4-16 disassembly and assembly • remove the cylinder head base nuts c. • loosen the cylinder base bolt d. • remove the cylinder head bolts e. Note: when loosening the cylinder head bolts e, loosen each bolt lit- tle by little diagonally. • remove the cylinder head f. Note: if the cylinder head does n...

  • Page 97

    Disassembly and assembly 4-17 cylinder removal • remove the cylinder head. ( 4-15) • remove the cylinder 2 by removing the cylinder base bolt 1. Note: do not drop the cam chain 3 into the crankcase. Note: if the cylinder does not come off easily, lightly tap it using a plas- tic hammer. • remove th...

  • Page 98

    4-18 disassembly and assembly piston and piston ring removal • remove the cylinder. ( 4-17) • place a clean rag over the cylinder base to prevent the piston pin circlip 1 from dropping into the crankcase. • remove the piston pin circlip 1. • remove the piston pin 2 and piston 3. • carefully spread ...

  • Page 99

    Disassembly and assembly 4-19 engine top side assembly piston and piston ring installation install the piston and piston ring in the reverse order of removal. Pay attention to the following points: piston ring • install the piston rings in the order of oil ring and 1st ring. • the first member to go...

  • Page 100

    4-20 disassembly and assembly piston • install the piston 1 with the punch mark a facing towards the exhaust side. • before installing the piston pin 2, apply molybdenum oil solution onto its surface.  molybdenum oil solution • place a clean rag over the cylinder base to prevent the piston pin circ...

  • Page 101

    Disassembly and assembly 4-21 cam chain, cam chain tensioner and cam chain no.1 guide removal • remove the cylinder head. ( 4-15) • remove the magneto cover and magnet rotor. ( 4-51, -52) • remove the cam chain no.1 guide 1. • remove the cam chain guide retainer 3 by removing its bolt 2. • remove ...

  • Page 102

    4-22 disassembly and assembly installation install the cam chain and cam chain tensioner in the reverse order of removal. Pay attention to the following points: • install the cam chain tensioner 1, spacer 2 and cam chain tensioner bolt 3. • tighten the cam chain tensioner bolt 3 to the specified tor...

  • Page 103

    Disassembly and assembly 4-23 cylinder and cylinder head installation install the cylinder and cylinder head in the reverse order of removal. Pay attention to the following points: cylinder • thoroughly wipe off oil from the fitting surface of the crank- case. • apply suzuki bond “1215” to the crank...

  • Page 104

    4-24 disassembly and assembly cylinder head • install the dowel pins 1 into the cylinder and then install the cylinder head gasket 2 onto the cylinder. Note: replace the cylinder head gasket 2 with a new one. • place the cylinder head 3 on the cylinder. Note: do not drop the cam chain 4 into the cra...

  • Page 105

    Disassembly and assembly 4-25 • with the cylinder head snugly seated on the cylinder, secure it by tightening the cylinder head bolts 5 in diagonal stages. • tighten the cylinder head bolts 5 to the specified torque.  cylinder head bolt: initial 25 n·m (2.5 kgf-m, 18.0 lbf-ft) final 51 n·m (5.1 kgf...

  • Page 106

    4-26 disassembly and assembly camshaft (automatic decomp.) and cam chain tension adjuster installation install the camshaft and cam chain tension in the reverse order of removal. Pay attention to the following points: camshaft (automatic decomp.) • place a wrench over the crankshaft and turn it coun...

  • Page 107

    Disassembly and assembly 4-27 • pull the exhaust side of the cam chain taut to install the camshaft sprocket (exhaust side). • turn the exhaust camshaft so that the timing mark c is aligned with the gasket surface of the cylinder head. Engage the cam chain with the exhaust camshaft sprocket. • the o...

  • Page 108

    4-28 disassembly and assembly • apply grease to the new o-ring 5 and install it to the cam- shaft journal holder 6. Note: replace the o-ring 5 with a new one.  99000-25010: suzuki super grease “a” or equivalent • install the camshaft journal holder 6. • have the camshaft journal holder evenly by ti...

  • Page 109

    Disassembly and assembly 4-29 cam chain tension adjuster • retract the push rod by pushing the stopper 1. • apply grease to the o-ring 2. Note: replace the o-ring 2 with a new one.  99000-25010: suzuki super grease “a” or equivalent • install the cam chain tension adjuster 3 as shown. A upward • ti...

  • Page 110

    4-30 disassembly and assembly • install the gasket 7 and cam chain tension adjuster cap bolt 8. Note: replace the gasket 7 with a new one. Note: click sound is heard when the cam chain tension adjuster cap bolt 8 is installed. • tighten the cam chain tension adjuster cap bolt 8 to the specified torq...

  • Page 111

    Disassembly and assembly 4-31 cylinder head cover installation install the cylinder head cover in the reverse order of removal. Pay attention to the following points: • install the new cylinder head cover gasket 1 to the cylinder head cover 2. Note: * check to be sure that the cam chain no.2 guide 3...

  • Page 112: Clutch

    4-32 disassembly and assembly clutch clutch plate removal • drain engine oil. ( 2-14) • remove the brake pedal. ( 4-71) • remove the clutch cover 1 and its gasket 2. • remove the clutch spring set bolts 3 and clutch springs. Note: loosen the clutch spring set bolts 3 little by little and diagonall...

  • Page 113

    Disassembly and assembly 4-33 • remove the clutch drive plates 9 and driven plates 0. Note: mark the paint mark a to the clutch driven no. 2 plate. A clutch driven no. 2 plate b clutch driven no. 1 plate c direction of outside • remove the spring washer a and spring washer seat b..

  • Page 114

    4-34 disassembly and assembly inspection drive plate • measure the drive plate thickness.  drive plate thickness service limit: 2.42 mm (0.095 in)  09900-20101: vernier calipers • inspect the drive plates for wear, distortion and discoloration. • if the drive plate thickness is found to have reach...

  • Page 115

    Disassembly and assembly 4-35 push rod • inspect the push rod for wear and damage. • if any defects are found, replace the push rod with a new one. Release bearing • inspect the clutch release bearing 1 for any abnormality, par- ticularly cracks, to decide whether it can be reused or should be repla...

  • Page 116

    4-36 disassembly and assembly • apply engine oil to the drive plates 3 and driven plates 4. • install the clutch drive plates and driven plates one by one into the clutch sleeve hub in the prescribed order as show in illustration. • install the push rod and push piece 5. • apply engine oil to the re...

  • Page 117

    Disassembly and assembly 4-37 • install the clutch springs and clutch spring set bolts 9. • tighten the clutch spring set bolts 9 to the specified torque. Note: tighten the clutch spring set bolts 9 diagonally.  clutch spring set bolt: 10 n·m (1.0 kgf-m, 7.0 lbf-ft) • install the gasket 0 and clutc...

  • Page 118

    4-38 disassembly and assembly primary driven gear and clutch sleeve hub removal • remove the clutch cover. ( 4-32) • remove the pressure plate and clutch plates. ( 4-32, -33) • flatten the lock washer 1. • hold the clutch sleeve hub 3 with the special tool and loosen the clutch sleeve hub nut 2. ...

  • Page 119

    Disassembly and assembly 4-39 inspection • inspect the clutch sleeve hub and primary driven gear for wear and cracks. • if any defects are found, replace the sleeve hub or driven gear with a new one. • inspect the needle bearing and spacer for damage and wear. • if any defects are found, replace the...

  • Page 120

    4-40 disassembly and assembly • fit the clutch sleeve hub 5, new lock washer 6 and clutch sleeve hub nut 7. Note: replace the lock washer 6 with a new one. • tighten the clutch sleeve hub nut 7 with the special tool to the specified torque.  09920-53740: clutch sleeve hub holder 09920-31020: extens...

  • Page 121

    Disassembly and assembly 4-41 • reassemble the clutch plates and pressure plate. ( 4-35 to -37) • install the gasket 8 and clutch cover 9. Note: replace the gasket with a new one. • tighten the clutch cover bolts (a, b) diagonally to the speci- fied torque.  clutch cover bolt: 11 n·m (1.1 kgf-m, 8...

  • Page 122

    4-42 disassembly and assembly clutch release camshaft removal • remove the clutch cover and its gasket. ( 4-32) • remove the pressure plate and push rod. ( 4-32) • remove the retainer 2 by removing its bolt 1. • disconnect the clutch cable 3. • pull the clutch release camshaft 4 out of crankcase. ...

  • Page 123

    Disassembly and assembly 4-43 installation install the clutch release camshaft 1 in the reverse order of removal. Pay attention to the following points: • apply suzuki moly paste to the clutch release camshaft.  99000-25140: suzuki moly paste or equivalent • apply grease to the oil seal lip.  9900...

  • Page 124

    4-44 disassembly and assembly kick starter removal • remove the kick starter lever 1 by removing its bolt 2. Installation • install the kick starter lever 1 onto the kick starter shaft. Note: when installing the kick starter lever 1, align the wide spline teeth a and b. • tighten the kick starter le...

  • Page 125: Throttle Body

    Disassembly and assembly 4-45 throttle body removal • remove the seat and radiator covers. ( 4-2) • remove the fuel tank. ( 4-2) note: be sure to follow the notice in fuel tank section when remov- ing the fuel tank. • disconnect the tp sensor coupler 1 and condenser coupler 2. • remove the condens...

  • Page 126

    4-46 disassembly and assembly • remove the throttle cable cover 9 by removing their bolts 8. • loosen the lock-nuts 0. • disconnect the throttle cables from their pulley. • remove the throttle body assembly. Note: do not apply pressured water to the throttle body cover drain as muddy water can get i...

  • Page 127

    Disassembly and assembly 4-47 installation install the throttle body assembly in the reverse order of removal. Pay attention to the following points: • connect the throttle pulling cable 1 and throttle returning cable 2 to the pulley. • turn in each throttle cable adjuster fully and locate each oute...

  • Page 128

    4-48 disassembly and assembly tp sensor adjustment 1. Connect a 12 volt battery to the service coupler 1 using the battery lead wire 2. 36890-28h00: battery lead wire (option) 2. Loosen the screw 3 with the special tool. 3. Turn the tp sensor 4. 4. Insert the needle-point probes to the tp sensor lea...

  • Page 129: Engine Coolant

    Disassembly and assembly 4-49 engine coolant replacement • open the radiator cap 1. • remove the engine coolant drain bolt 2 and drain engine coolant. • install the gasket washer and tighten the engine coolant drain bolt 2 to the specified torque. Note: replace the gasket washer with a new one.  en...

  • Page 130

    4-50 disassembly and assembly • tighten the air bleeder bolt 3 to the specified torque.  radiator air bleeder bolt: 6 n·m (0.6 kgf-m, 4.5 lbf-ft) • add engine coolant up to the radiator inlet. • tighten the radiator cap securely. • after warming up and cooling down the engine, add the spec- ified e...

  • Page 131: Electrical System

    Disassembly and assembly 4-51 electrical system magneto rotor removal • drain engine oil. ( 2-14) • disconnect the magneto lead wire coupler 1. • remove the clamp 2. • remove the gearshift lever. • remove the magneto cover 4 by removing their bolts 3. • remove the gasket 5 and dowel pins 6. • hold ...

  • Page 132

    4-52 disassembly and assembly • remove the magneto rotor 8 with the special tool.  09930-34951: rotor remover • remove the magneto rotor key 9. Installation • remove any grease from the tapered portion a of the mag- neto rotor and crankshaft b. • fit the magneto rotor key 1 to the crankshaft. • ins...

  • Page 133

    Disassembly and assembly 4-53 • install the dowel pins 3 and gasket 4. Note: replace the gasket 4 with a new one. • install the magneto cover 5. • tighten the magneto cover bolts (a,b,c) to the specified torque. Note: * the bolts a are 5 mm longer than the others. * fit the clutch cable bracket to t...

  • Page 134: Front and Rear Wheels

    4-54 disassembly and assembly front and rear wheels front wheel removal • remove the front axle nut 1. • loosen the left axle holder bolts 2. • place the motorcycle on a block to lift front wheel off the ground. • loosen the right axle holder bolts 3. • remove the front axle 4. • remove the front wh...

  • Page 135

    Disassembly and assembly 4-55 axle shaft • support the axle shaft with the v blocks and measure the axle shaft runout. • if the runout exceeds the limit, replace the axle shaft with a new one.  axle runout service limit: 0.25 mm (0.010 in)  09900-20607: dial gauge 09900-20701: dial gauge chuck 099...

  • Page 136

    4-56 disassembly and assembly disk plate replacement • remove the disk plate 2 by removing their bolts 1. • apply thread lock super to the disk plate bolts 1.  99000-32110: thread lock super “1322” or equivalent • tighten the disk plate bolts 1 to the specified torque.  disk plate bolt: 11 n·m (1....

  • Page 137

    Disassembly and assembly 4-57 rear wheel removal • loosen the rear axle nut 1. • place the motorcycle on a block to lift the rear wheel off the ground. • remove rear axle nut 1 and washer 2. • remove the rear axle shaft 3 and chain adjuster washers 4. • disengage the drive chain 5. • remove the rear...

  • Page 138

    4-58 disassembly and assembly inspection wheel spacer • remove the wheel spacers from the rear wheel. • inspect the rear wheel spacers 1 and dust seals 2 for wear and cracks. • if any defects are found, replace the spacer 1 together with the dust seal 2. Note: apply grease on the spacers 1 and dust ...

  • Page 139

    Disassembly and assembly 4-59 disk plate replacement • remove the disk plate 2 by removing their bolts 1. • apply thread lock super to the disk plate bolts 1.  99000-32110: thread lock super “1322” or equivalent • tighten the disk plate bolts 1 to the specified torque.  disk plate bolt: 26 n·m (2....

  • Page 140

    4-60 disassembly and assembly installation • install the rear wheel, chain adjuster washers 1 and axle shaft. • adjust the drive chain slack. ( 2-33) a fwd b left c right • tighten the rear axle nut 2 to the specified torque.  rear axle nut: 100 n·m (10.0 kgf-m, 72.5 lbf-ft) rear wheel spokes repl...

  • Page 141: Front and Rear Brakes

    Disassembly and assembly 4-61 front and rear brakes brake fluid air bleeding • remove the reservoir cap 2 by removing their bolts 1.  warning brake fluid can be hazardous to humans and pets. Brake fluid is harmful or fatal if swallowed, and harm- ful if it comes in contact with your skin or eyes. K...

  • Page 142

    4-62 disassembly and assembly • pour brake fluid up to the upper line a.  specification and classification: dot 4 • connect a transparent tube to the bleeder valve and set the other end into a receptacle. • pump the brake lever/pedal until air bubbles stop coming out from the reservoir. • hold the ...

  • Page 143

    Disassembly and assembly 4-63 brake fluid replacement • remove the reservoir cap. ( 4-61) • suck up the brake fluid as much as possible. • drain the old brake fluid as much as possible. • fill the reservoir with new brake fluid. • connect a transparent tube to the bleeder valve and set the other en...

  • Page 144

    4-64 disassembly and assembly brake pads replacement front brake pads • remove the cap 1 and pad mounting pin 2. • remove the brake pads 3. Note: replace the two brake pads as a set. • fit the new brake pads into the caliper. • tighten the pad mounting pin 2 to the specified torque.  brake pad moun...

  • Page 145

    Disassembly and assembly 4-65 caliper  warning the use of any fluid except dot 4 brake fluid from a sealed container can damage the brake system and lead to an accident. Use only dot 4 brake fluid from sealed container. Never use or mix different types of brake fluid.  warning brake fluid can be h...

  • Page 146

    4-66 disassembly and assembly front caliper removal and disassembly • place a rag under the brake hose union bolt 1 to catch spilled brake fluid. • disconnect the brake hose 2 by removing the union bolt 1. • remove the caliper mounting bolts 3. • remove the caliper. • remove the brake pads. ( 4-64)...

  • Page 147

    Disassembly and assembly 4-67 • remove the dust seals 0 and piston seals a. • remove the front brake caliper axle bolt (caliper) b. Front caliper reassembly and installation reassemble and install the brake caliper in the reverse order of removal and disassembly. Pay attention to the following point...

  • Page 148

    4-68 disassembly and assembly • tighten the caliper mounting bolts 2 to the specified torque.  front brake caliper mounting bolt: 26 n·m (2.6 kgf-m, 19.0 lbf-ft) • tighten the brake pad mounting pin 3 to the specified torque.  brake pad mounting pin: 18 n·m (1.8 kgf-m, 13.0 lbf-ft) • set the brake...

  • Page 149

    Disassembly and assembly 4-69 • remove the brake pad. ( 4-64) • remove the spring 7. • remove the caliper bracket 8 from the caliper 9. • remove the boots 0 and a. • remove the spring b. • remove the rear brake caliper axle bolt (bracket) c. • wrap the caliper with a rag to prevent brake fluid scat...

  • Page 150

    4-70 disassembly and assembly rear caliper reassembly and installation reassemble and install the brake caliper in the reverse order of removal and disassembly. Pay attention to the following points: • apply brake fluid to the new dust seal and piston. • apply suzuki silicone grease to the new pisto...

  • Page 151

    Disassembly and assembly 4-71 brake pedal removal • remove the clip 1. • remove the cotter pin 2 and washer 3. • remove the master cylinder rod pin 4. • remove the brake pedal pivot bolt 5 and return spring 6. Installation • apply grease to the oil seals and brake pedal pivot bolt.  99000-25010: su...

  • Page 152: Front Fork and Steering

    4-72 disassembly and assembly front fork and steering front fork removal • place the motorcycle on a block to lift front wheel off the ground. • remove the front wheel. ( 4-54) • remove the front number plate 2 by removing its bolt 1. • remove the handlebar pad 3. • remove the handlebars 5 by remov...

  • Page 153

    Disassembly and assembly 4-73 • hold the fork body and loosen the front fork lower clamp bolts a. • remove the front fork. Disassembly • set rebound and compression damper settings to the mini- mum settings (softest) before disassembling. Record the set- ting before turning the adjuster. • thoroughl...

  • Page 154

    4-74 disassembly and assembly • place a drain pan under the front fork and drain fork oil. Note: face the oil hole a on the sub-tank downward. • raise the outer tube and temporarily install the fork cap bolt 1 (sub-tank) to the outer tube. • clamp the axle holder 3 with a vise. Protect the axle hold...

  • Page 155

    Disassembly and assembly 4-75 • hold the lock-nut 5 with a wrench and remove the center bolt 4. • remove the push rod 6. • with the outer tube compressed by hands, remove the special tool. Notice if the lock nut 5 is removed, the inner rod can slip into the damper rod and damper rod threaded can dam...

  • Page 156

    4-76 disassembly and assembly • loosen the fork cap bolt 1 (sub-tank) and remove the sub-tank 7 along with the damper rod assembly 8. • remove the fork spring 9. Note: do not attempt to disassemble the damper rod assembly 8. The damper rod assembly 8 is available only as an assembly. • remove the du...

  • Page 157

    Disassembly and assembly 4-77 inner tube • separate the inner tube 1 out of the outer tube 2. • remove the slide bushing 3 from the inner tube 1. • remove the following parts from the inner tube 1. • guide bushing 4 • seal retainer 5 • oil seal 6 • stopper ring 7 • dust seal 8.

  • Page 158

    4-78 disassembly and assembly damper rod assembly and compression damper unit • clamp the bottom (flat part) of the sub-tank with a vise. Note: do not clamp the sub-tank too tight. • loosen the compression damper unit 1. • remove the compression damper unit 1 from the sub-tank 2. Note: slowly compre...

  • Page 159

    Disassembly and assembly 4-79 inspection center bolt • inspect the adjuster rod of the center bolt for damage. If it is damaged, replace it with a new one. Compression damper unit • inspect the compression damper unit for damage. If it is dam- aged, replace it with a new one. Note: disassembling the...

  • Page 160

    4-80 disassembly and assembly damper rod assembly • inspect the damper rod assembly for scratches or bending. If it has scratches or is bent, replace it with a new one. Fork spring • measure the free length of front fork spring. • if it is shorter than service limit, replace it with a new one.  ser...

  • Page 161

    Disassembly and assembly 4-81 reassembly note: * clean all fork parts before reassembling. * replace the o-rings, oil seal and dust seal with new ones. * apply specified front fork oil when installing the o-rings, slide bushing, guide bushing, damper unit and sliding parts. Inner tube • apply fork o...

  • Page 162

    4-82 disassembly and assembly • install a new oil seal 3 with the special tool until the stopper ring groove of the outer tube can be seen.  09940-52861: front fork oil seal installer set • attach the stopper ring securely to the stopper ring groove of the outer tube. • attach the dust seal 1. Note...

  • Page 163

    Disassembly and assembly 4-83 • with the damper rod in fully extended position, pour the spec- ified amount of fork oil.  fork oil quantity (inside the damper rod): 193 ml (6.5/6.8 us/lmp oz)  fork oil ss-19 or equivalent • apply fork oil to the o-ring 4. Note: replace the o-ring 4 with a new one....

  • Page 164

    4-84 disassembly and assembly • tighten the lock-nut 7 by hand completely. • with the damper rod held in vertical position, compress the damper rod fully to discharge an excess of oil. Note: protect the inner rod end with a rag when compressing the damper rod. Note: set the compression damper settin...

  • Page 165

    Disassembly and assembly 4-85 • tighten the lock nut 7. Note: thread length b should be approx. 10 mm (0.39 in). B approx. 10 mm (0.39 in) • completely wipe off the fork oil from the spring and damper rod assembly. • apply fork oil to the bushing 8. • insert the spring and damper rod assembly into t...

  • Page 166

    4-86 disassembly and assembly • insert the push rod a into the inner rod. • replace the o-ring with a new one. • apply fork oil to the o-ring. • insert the shaped projection a of center bolt b into the push rod b. • slowly tighten the center bolt b until resistance is felt and check the clearance be...

  • Page 167

    Disassembly and assembly 4-87 • loosen and remove the fork cap bolt 9 (sub-tank) from the outer tube with the special tool and slowly slide down the outer tube.  09941-53630: front fork cap socket wrench (50 mm) • pour the specified amount of fork oil into the outer tube.  oil quantity (when stand...

  • Page 168

    4-88 disassembly and assembly • tighten the fork cap bolt 2 (sub-tank) to the specified torque with the special tool.  09941-53630 : front fork cap socket wrench (50 mm)  fork cap bolt: 34 n·m (3.4 kgf-m, 24.5 lbf-ft) • tighten the fork upper clamp bolts 3 to the specified torque.  fork upper cla...

  • Page 169

    Disassembly and assembly 4-89 steering removal handlebars • place the motorcycle on a block to lift front wheel off the ground. • remove the front number plate and handlebar pad. ( 4-72) • remove the clamps 1. • remove the engine stop switch 3 by removing its screw 2. • remove the clutch lever hold...

  • Page 170

    4-90 disassembly and assembly • slightly loosen the handlebar holder set nuts 9. • remove the handlebars a by removing the handlebar clamp bolts 0. Note: mark the paint mark d to the matching surface of handlebar holder and handlebars before removing. Steering stem • remove the front wheel 1. ( 4-5...

  • Page 171

    Disassembly and assembly 4-91 • remove the steering stem head nut 6 and washer 7. • remove the steering stem upper bracket 8. • remove the handlebar holder set bolts and nuts 9. • remove the handlebar holders, damper bushings and spac- ers. • remove the steering stem nut 0 with the special tools. No...

  • Page 172

    4-92 disassembly and assembly • remove the washer b, upper dust seal c and upper bearing d. Inspection • inspect the removed parts for the following abnormalities. • distortion of the steering stem • bearing wear or damage • abnormal bearing noise • race wear or damage • damper bushing wear or damag...

  • Page 173

    Disassembly and assembly 4-93 installation install the steering in the reverse order of steering removal. Pay attention to the following points: steering stem • apply grease to the bearings.  99000-25010: suzuki super grease “a” or equivalent • fit the steering stem lower bracket, upper bearing, up...

  • Page 174

    4-94 disassembly and assembly • fit the steering stem upper bracket 2 and washer 3 • temporarily tighten the steering stem head nut 4. Note: pay attention to the direction of the washer 3. • temporarily install the front forks to the steering stem, and tighten the lower clamp bolts. • tighten the st...

  • Page 175

    Disassembly and assembly 4-95 • set the “ ” mark on the handlebar holder 9 forward. • align the matching mark b on the handlebars with the match- ing surface of the handlebar holder 9. • tighten the handlebar clamp bolts 0 to the specified torque. Note: when tightening the handlebar clamp bolts 0, f...

  • Page 176

    4-96 disassembly and assembly • align the matching mark d on the handlebars with the throttle holder matching surface. • tighten the screws b securely. Note: make sure that the cut-line e of collar c to lower side. • align the matching mark f on the handlebars with the master cylinder matching surfa...

  • Page 177

    Disassembly and assembly 4-97 • align the “ ” mark on the left grip with the matching mark b on the left handlebar end. • align the matching mark c on the handlebars with the match- ing surface clutch lever holder. • tighten the upper bolt d first temporarily to provide clearance on the lower side a...

  • Page 178: Rear Suspension

    4-98 disassembly and assembly rear suspension rear shock absorber removal • place the motorcycle on a block to lift rear wheel off the ground. • remove the seat and right frame cover. ( 4-2) • loosen the air cleaner clamp screw 1. • remove the rubber band 2. • disconnect the iat sensor coupler 3 an...

  • Page 179

    Disassembly and assembly 4-99 • remove the rear shock absorber upper mounting bolt and nut 0. • remove the rear shock absorber lower mounting bolt and nut a. Note: if necessary, move the swingarm up or down to facilitate this mounting bolt/nut removal. • remove the rear shock absorber..

  • Page 180

    4-100 disassembly and assembly spring replacement • loosen the lock-nut 1 with the special tool and turn it fully to the end of the thread. • turn the adjuster 2 as well as the lock-nut 1.  09910-60611: universal clamp wrench • depress the spring seat 3 and remove the stopper ring 4. • remove the s...

  • Page 181

    Disassembly and assembly 4-101 • adjust the spring set length and tighten the lock-nut.  standard spring set length: 4.2 mm (0.17 in) compressed from the free length spring set length adjustable range: 245 – 263 mm (9.64 – 10.35 in) [at spring free length 265 mm (10.43 in)] a: hardest spring settin...

  • Page 182: Swingarm

    4-102 disassembly and assembly swingarm removal • place the motorcycle on a block to lift rear wheel off the ground. • remove the rear wheel. ( 4-57) • remove the chain guide bolts and nuts 1. • remove the chain guide plate 2 and chain guide 3. • remove the rear master cylinder mounting bolts 4 and...

  • Page 183

    Disassembly and assembly 4-103 • down the rear brake pedal a and remove the pivot shaft b. • remove the swingarm. • remove the chain buffer d by removing its screws c. • remove the plates f by removing its screws e. • remove the following parts from the swingarm. Spacer g oil seal h washer i thrust ...

  • Page 184

    4-104 disassembly and assembly installation install the swingarm in the reverse order of removal. Pay atten- tion to the following points: • install the following parts into the swingarm. 1 oil seal 5 washer 2 spacer 6 dust seal 3 washer 7 spacer 4 thrust bearing 8 washer • apply grease to the dust ...

  • Page 185: Rear Suspension Linkage

    Disassembly and assembly 4-105 rear suspension linkage removal • place a block under the chassis tubes. • remove the rear cushion rod bolts and nuts 1. • remove the cushion lever bolt and nut 2. • remove the shock absorber lower bolt and nut 3. • remove the collars, dust seals, washers and spacers..

  • Page 186

    4-106 disassembly and assembly installation install the rear suspension linkage in the reverse order of removal. Pay attention to the following points: • install the washers 1. • position the dust seals 2 so that the manufacturer’s code indicated side of the seals face outside. • apply grease to the...

  • Page 187

    Disassembly and assembly 4-107 • tighten the cushion lever, cushion rod and swingarm nuts to the specified torque. 3: rear suspension linkage bolt  tightening torque: a: 50 n·m (5.0 kgf-m, 36.0 lbf-ft) d: 80 n·m (8.0 kgf-m, 58.0 lbf-ft) a: 6.25 mm (0.25 in) b: 50 n·m (5.0 kgf-m, 36.0 lbf-ft) e: 80 ...

  • Page 188

    4-108 disassembly and assembly 4: stamped mark d: 4.0 mm (0.16 in)  tightening torque: f: 70 n·m (7.0 kgf-m, 50.5 lbf-ft) left right notice improperly reassembled rear suspension linkage bolts can interfere with suspension move- ment and damage the rear suspension linkage. Make sure that the rear s...

  • Page 189: Servicing Information

    Servicing information servicing information 5-1 5 tightening torque ................................................................................ 5-2 engine ................................................................................................... 5-2 fi system and intake air system .......

  • Page 190: Tightening Torque

    5-2 servicing information tightening torque engine item n·m kgf-m lbf-ft cylinder head cover bolt 14 1.4 10.0 spark plug 11 1.1 8.0 cylinder head bolt (initial) 25 2.5 18.0 (final) 51 5.1 37.0 cylinder head base nut 10 1.0 7.0 cylinder base bolt 12 1.2 8.5 camshaft journal holder bolt 10 1.0 7.0 pri...

  • Page 191

    Servicing information 5-3 fi system and intake air system cooling system engine mounting nut (front) 66 6.6 47.5 engine mounting bracket nut (upper) 40 4.0 29.0 engine mounting bracket nut (front) 40 4.0 29.0 engine sprocket cover bolt 11 1.1 8.0 kick starter lever bolt 29 2.9 21.0 kick starter leve...

  • Page 192

    5-4 servicing information chassis item n·m kgf-m lbf-ft handlebar clamp bolt 25 2.5 18.0 handlebar holder set nut 44 4.4 32.0 front fork upper clamp bolt (right and left) 23 2.3 16.5 front fork lower clamp bolt (right and left) 23 2.3 16.5 steering stem head nut 100 10.0 72.5 front fork cap bolt 34 ...

  • Page 193

    Servicing information 5-5 seat rail bolt and nut (upper and lower) 23 2.3 16.5 footrest bolt 35 3.5 25.5 cable adjuster lock-nut (throttle, clutch and hot starter) 2.2 0.22 1.60 clutch cable bracket bolt 6 0.6 4.5 radiator cover upper bolt 10 1.0 7.0 radiator cover bolt 10 1.0 7.0 item n·m kgf-m lbf...

  • Page 194

    5-6 servicing information each fastener should be tightened to the torque specified in “tightening list”. If no description or speci- fication is provided, refer to the following tightening torque chart for the applicable torque for each fastener. *1: small crown shape bolt (crown shape bolt with fl...

  • Page 195: Special Tools

    Servicing information 5-7 special tools 09900-06107 snap ring remover (open type) 09900-20101 vernier calipers (150 mm) 09900-20607 dial gauge 09900-20701 dial gauge chuck 09900-20803 thickness gauge 09900-21304 v blocks 09900-25008 multi circuit tester set 09900-25009 needle-pointed probe set 09900...

  • Page 196

    5-8 servicing information 09930-34951 rotor remover 09930-44560 rotor holder 09940-14911 steering stem nut socket wrench 09940-14960 steering stem nut socket wrench 09940-34581 front fork assem- bling attachment (f) 09940-52861 front fork oil seal installer set 09941-53630 front fork cap socket wren...

  • Page 197: Wiring Diagram

    Servicing information 5-9 wiring diagram ru n b/w b/y b/w b/y w/bl b/w b/br br/w r/b b/w r b b/r br/w g/w p y g/b bl/w b/w bl gr bl/b r/bl b/r r/b gr/w w/bl lg g w/r b/bl bl/r b/br dg bl/y w/g bl/g y/b b b/y b/w b/w b/w bl/w w/g bl/g bl/r bl/y r/bl lg b/r g y/b w/r gr b/w r/bl b/w b/w b/r b/w o bl g...

  • Page 198: Cable Routing

    5-10 servicing information cable routing 1 throttle cable (pulling cable) 5 radiator overflow hose 2 throttle cable (returning cable) 6 cable guide 3 hot starter cable a 2 – 3 mm (0.08 – 0.12 in) 4 clutch cable b 14 – 16 mm (0.55 – 0.63 in) *2 *1 *3 *8 *9 *7 *4 *5 *6 *1 bind the engine stop switch l...

  • Page 199

    Servicing information 5-11 1 throttle cable (pulling cable) 5 wiring harness 2 throttle cable (returning cable) a 2 – 3 mm (0.08 – 0.12 in) 3 hot starter cable b 0 – 1.5 mm (0 – 0.06 in) 4 radiator overflow hose *2 *5 *6 *4 *4 *1 *3 *1 pass the throttle cables over the radiator and radiator overflow...

  • Page 200: Fuel Hose Routing

    5-12 servicing information fuel hose routing 1 fuel hose 8 fuel tank 2 throttle body 9 tp sensor 3 air cleaner 0 condenser 4 iat sensor a ect sensor 5 intake pipe clamp b breather hose 6 air cleaner outlet pipe clamp c air cleaner box 7 fuel pump a upward *1 gray button *2 yellow button *3 do not sl...

  • Page 201: Radiator Hose Routing

    Servicing information 5-13 radiator hose routing *1 *3 *2 *3 *2 *5 *6 *4 1 radiator lh 2 radiator rh 3 radiator overflow hose a 15 ± 10° *1 bind the radiator overflow hose. *2 face the white mark to the backward. *3 face the yellow mark to the backward. *4 pass the radiator overflow hose between eng...

  • Page 202

    5-14 servicing information crankcase and cover installation.

  • Page 203

    Servicing information 5-15 a right crankcase cover bolt l: 30 mm (1.2 in) l magneto cover bolt l: 35 mm (1.4 in) b right crankcase cover bolt l: 25 mm (1.0 in) m magneto cover bolt l: 30 mm (1.2 in) c clutch cover bolt l: 60 mm (2.4 in) n crankcase bolt l: 40 mm (1.6 in) d clutch cover bolt l: 25 mm...

  • Page 204

    5-16 servicing information exhaust pipe and muffler installation a muffler mounting bolt b muffler connector clamp bolt c exhaust pipe cover bolt item n·m kgf-m lbf-ft a 23 2.3 16.5 b 18 1.8 13.0 c 11 1.1 8.0

  • Page 205: Clutch Cable Adjuster

    Servicing information 5-17 clutch cable adjuster *3 *1 *2 1 clutch cable adjuster a turn to tighten the clutch cable tension. B turn to loosen the clutch cable tension. *1 when the movement is felt heavier, clean this and apply grease. *2 do not apply grease to the rubber covers. Fit the cover posit...

  • Page 206

    5-18 servicing information hot starter lever installation *1 *5 *3 *4 *2 *1 pass the hot starter cable into the lever cover. *2 connect the hot starter cable to the master cylinder holder and hot starter lever. *3 pass the hot starter lever into the lever cover. *4 tighten the lower bolt first tempo...

  • Page 207: Rear Brake Pedal Set-Up

    Servicing information 5-19 rear brake pedal set-up 1 rear master cylinder 2 return spring 3 brake pedal a 0 – 10 mm (0 – 0.4 in).

  • Page 208: Front Brake Hose Routing

    5-20 servicing information front brake hose routing *1 *4 *2 *3 1 front brake hose 5 front fork protector 2 front brake master cylinder 6 clamp 3 stopper 7 front brake caliper 4 hose guide *1 set the brake hose end between the hose stopper, then tighten the brake hose union bolt. *2 clamp the upper ...

  • Page 209: Rear Brake Hose Routing

    Servicing information 5-21 rear brake hose routing *1 *1 *2 a a a – a 1 rear brake hose 3 rear brake caliper 2 rear brake master cylinder 4 hose guide *1 set the brake hose end between the hose stopper, then tighten the brake hose union bolt. *2 outside.

  • Page 210: Handlebar Set-Up

    5-22 servicing information handlebar set-up 1 throttle cable (pulling cable) b 190 mm (7.48 in) 2 throttle cable (returning cable) c 2 – 3 mm (0.08 – 0.12 in) a marking d 121 mm (4.76 in) b forward e 175 mm (6.89 in) a 145 mm (5.71 in) f 14 – 16 mm (0.55 – 0.63 in) *1 align the matching surface of m...

  • Page 211

    Servicing information 5-23 rear wheel spokes installation 1 spoke (inner) l: 206.5 mm (8.13 in) 2 spoke (outer) l: 204.5 mm (8.05 in).

  • Page 212: Specifications

    5-24 servicing information specifications dimensions and curb mass overall length ....................................................... 2 170 mm (85.4 in) overall width ........................................................ 830 mm (32.7 in) overall height ...........................................

  • Page 213

    Servicing information 5-25 chassis front suspension................................................. Upside-down telescopic fork rear suspension ................................................. Swingarm type front suspension stroke ...................................... 310 mm (12.2 in) rear wheel ...

  • Page 214: Spare Parts List

    5-26 servicing information spare parts list item part name part number q’ty 1 parts set, spare 19900-49h00 1 1 gasket, magneto cover 11483-49h00 1 2 gasket, clutch cover outer 11484-10h00 1 3 gasket, exhaust pipe 14181-49h00 1 4 connector, muf jt 14771-29f00 1 5 filter comp, engine oil 16510-35g00 1...

  • Page 215: Optional Parts

    Servicing information 5-27 optional parts front fork spring: 3-7 rear suspension spring: 3-14 part no. Number of teeth comments rear sprocket 64511-29f00 47 112 l 64511-37e00 48 114 l 64511-36e00 50 114 l 64511-40261 51 116 l fi indicator light assy 36380-28h00 — battery lead wire 36890-28h00 — fr...

  • Page 216: Setting Data

    5-28 servicing information setting data *make copies. Event date/ location date / / / / / / race/course / / / temp./humidity / / / weather course coudition engine fi system spark plug chassis front fork oil capacity ml ml ml comp. Adj. Position re-bound adj. Position spring rear suspension spring sp...

  • Page 219: Owner’S Manual And

    99 01 1- 49 h 51 -0 1a r m -z 25 0 part no. 99011-49h51-01a april, 2010 en printed in japan rm-z250 tk l1 owner’s manual and race preparation manual v warning failure to follow these safety precautions may increase your risk of injury: • wear a helmet, eye protection, and bright, protective clothing...