Suzuki RM 250 2003 Owner'S Service Manual Download Page 36

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ENGINE DISMOUNTING AND MOUNTING 3-1

CONTENTS

ENGINE DISMOUNTING AND MOUNTING

ENGINE DISMOUNTING ............................................................................. 3- 2

ENGINE MOUNTING ................................................................................... 3- 5

INSPECTION AFTER ENGINE MOUNTING ............................................... 3- 6

Summary of Contents for RM 250 2003

Page 1: ...OWNER S SERVICE MANUAL...

Page 2: ...of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator The manual contains important safety information and instructions which should...

Page 3: ...the manual are based on the latest product information available at the time of publication Due to improvements or other changes there may be some discrepancies in this manual Suzuki reserves the rig...

Page 4: ...page of the section easily 4 The contents are listed on the first page of each section to help find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit...

Page 5: ...fied Use SUZUKI FORK OIL SS 05 or equivalent fork oil 99000 99001 SS5 Apply SUZUKI SUPER GREASE A 99000 25030 USA 99000 25010 Others Use SUZUKI REAR SUSPENSION OIL SS 25 or equivalent rear suspension...

Page 6: ...RAL CONSIDERATIONS 1 5 SERIAL NUMBER LOCATION 1 6 LOCATION OF PARTS 1 7 FUEL AND OIL RECOMMENDATION 1 8 OPERATING INSTRUCTIONS 1 9 STARTING THE ENGINE 1 9 STOPPING THE ENGINE 1 10 TRANSMISSION 1 10 BR...

Page 7: ...ance easier or instructions clearer WARNING CAUTIONS FOR SERVICING WARNING Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in m...

Page 8: ...olant away from children Call your doctor immedi ately if swallowed and induce vomiting Flush eyes or skin with water if either brake fluid or engine coolant gets in eyes or comes in contact with skin...

Page 9: ...when instructed Make sure that all parts used in reassembly are clean Lubricate them when specified Use the specified lubricant bond or sealant Whenever you remove oil seals gaskets packing O rings lo...

Page 10: ...hould 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 wh...

Page 11: ...ON The frame number 1 is stamped on the steering head as shown in the photograph The engine serial num ber 2 is stamped on the right side of the crankcase assembly Write down the serial numbers here f...

Page 12: ...1 7 LOCATION OF PARTS 1 Clutch lever 2 Engine stop switch 3 Clutch cable adjuster 4 Throttle grip 5 Front brake lever 6 Fuel tank cap 7 Starter knob 8 Gearshift lever 9 Fuel valve 0 Kick starter lever...

Page 13: ...the engine oil thoroughly when the tempera ture is below 0 C 32 F Vegetable based oils can separate easier than mineral oils Use premixture oil as soon as possible after mixing or lubrica tion perfor...

Page 14: ...eady speed When the engine is warm 1 Turn the fuel valve lever to the ON position 2 Shift the transmission into neutral 3 Open the throttle 1 8 1 4 turn A and depress the kick starter lever forcefully...

Page 15: ...ne before starting off 2 Ride for 1 hour using less than 1 2 throttle opening with vari ous throttle opening 3 Ride for 1 hour using less than 3 4 throttle opening with vari ous throttle opening NOTE...

Page 16: ...GENERAL INFORMATION 1 11 COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s CODE COUNTRY or AREA 000 E 03 E 28 Japan U S A Canada...

Page 17: ...ANSMISSION OIL CHANGE 2 10 ENGINE COOLANT 2 11 ENGINE COOLANT LEVEL CHECK 2 11 ENGINE COOLANT REPLENISHMENT 2 12 ENGINE COOLING SYSTEM INSPECTION 2 12 CLUTCH 2 13 MAJOR ADJUSTMENT 2 13 MINOR ADJUSTMEN...

Page 18: ...IDE BUFFER 2 18 DRIVE CHAIN CONTROL ROLLER 2 18 BRAKES 2 18 BRAKE FLUID LEVEL 2 18 BRAKE PAD 2 19 FRONT BRAKE LEVER ADJUSTMENT 2 19 BRAKE PEDAL HEIGHT ADJUSTMENT 2 20 FRONT FORK 2 20 AIR PRESSURE ADJU...

Page 19: ...rhaul or storage Clutch I Replace clutch plates as necessary Throttle and clutch cable I L Carburetor I Fuel hose I Replace every 4 years Piston R Piston ring R Cylinder head cylinder C Exhaust valve...

Page 20: ...eplace if necessary L Lubricate Interval races Every race Every 3 races Every 5 races Remarks Service Item hours Every 2 hours Every 6 hours Every 10 hours Tire I Spoke nipple I Inspect every 20 min u...

Page 21: ...ive chain Slack lubrication chain joint clip condition Drive chain guide buffer Wear damage Suspension Smooth operation Front fork air pressure Wheels Spoke tension Rim lock tightness Tires Tire press...

Page 22: ...plug gap 0 5 0 6 mm 0 020 0 024 in 09900 20803 Thickness gauge Tighten the spark plug to the specified torque after tightening the spark plug temporarily by hand Spark plug 20 N m 2 0 kgf m 14 5 lb f...

Page 23: ...ag pour in some foam filter oil B and work the oil into the element Squeeze the element to remove excess oil INSTALLATION Apply grease to the element base where contacts the air cleaner box Fit the el...

Page 24: ...keep the air cleaner element dry when cleaning the motorcycle Cover the element with a plastic bag Install the seat Cover the inlet holes on the frame covers to prevent water from coming into the air...

Page 25: ...n the filler cap firmly and tighten the oil level check bolt to the specified torque Oil level check bolt 5 5 N m 0 55 kgf m 4 0 lb ft WARNING Transmission oil and exhaust pipe can be hot enough to bu...

Page 26: ...y Remove filler cap and drain plug 3 Drain oil thoroughly Tighten the drain plug firmly Oil drain plug 21 N m 2 1 kgf m 15 0 lb ft Pour specified amount of oil Oil change 750 ml 0 8 0 7 US Imp qt Over...

Page 27: ...ding only water will dilute engine coolant and it may decrease cool ing performance If the motorcycle is to be exposed to temperatures below 31 C 24 F the percentage of antifreeze should be increased...

Page 28: ...alloy Using non recommended coolant may corrode aluminum alloy and may clog the coolant passageways Bleed air from the cooling circuit ENGINE COOLING SYSTEM INSPECTION Inspect the following items befo...

Page 29: ...felt Clutch lever play 10 15 mm 0 4 0 6 in THROTTLE CABLE Adjust the throttle cable play as follows Loosen the locknut 1 Turn the adjuster 2 so that the throttle grip obtains 2 4 mm 0 08 0 16 in play...

Page 30: ...ge and fuel leakage If any defects are found the fuel hose must be replaced Replace fuel hose every four years FUEL VALVE Drain fuel from the fuel tank Remove the fuel valve If the fuel filter is dirt...

Page 31: ...4 Remove carbon deposits from the top surface of the piston Check for scratches cracks and wear around the piston bosses Remove minor scuffs with 1 000 1 200 sand paper Check piston ring wear Remove...

Page 32: ...cle on the side stand Inspect the drive chain slack at the middle point between the drive chain guide buffer and rear sprocket Drive chain slack 40 50 mm 1 6 2 0 in DRIVE CHAIN ADJUSTMENT Loosen axle...

Page 33: ...ve chain with non flammable cleaning solvent Do not use gasoline to clean the drive chain Dry the drive chain Apply Suzuki Chain Lube or an equivalent to the link plates and rollers Reassemble the dri...

Page 34: ...chain control roller bolts for tightness Drive chain control roller bolt 31 N m 3 1 kgf m 22 5 lb ft BRAKES BRAKE FLUID LEVEL Inspect the brake fluid level in both front and rear reservoirs If the br...

Page 35: ...r A Pre race and between every race Run oil through cables until it exits the lower end Lube the cable ends where they pivot 2 Throttle grip throttle housing cable A Pre race Lightly oil the inside of...

Page 36: ...3 ENGINE DISMOUNTING AND MOUNTING 3 1 CONTENTS ENGINE DISMOUNTING AND MOUNTING ENGINE DISMOUNTING 3 2 ENGINE MOUNTING 3 5 INSPECTION AFTER ENGINE MOUNTING 3 6...

Page 37: ...G Drain transmission oil 2 9 Drain engine coolant 2 12 Remove the seat Remove the fuel tank with the radiator cover Remove the carburetor 9 10 Remove the exhaust pipe fitting springs with the special...

Page 38: ...G 3 3 Remove the exhaust pipe gasket Disconnect the radiator hoses 1 Disconnect the spark plug cap 2 Disconnect the magneto lead wire coupler 3 and clamp 4 Remove the clip and open the chain Remove th...

Page 39: ...when disconnecting 2 13 Remove the engine mounting bolts and brackets Remove the swingarm pivot shaft nut 5 and washer Extract three quarters of the swingarm pivot shaft so as to keep the swingarm in...

Page 40: ...g bolts nuts to the specified torque NOTE Replace the self locking nuts with new ones N m kgf m lb ft 1 2 43 4 3 31 0 3 4 5 45 4 5 32 5 6 70 7 0 50 5 Bolt Diameter Bolt Length A 8 mm 0 3 in 45 mm 1 8...

Page 41: ...exhaust pipe gasket Apply a small quantity of transmission oil to the O ring before installing the exhaust pipe Fit the projection of the carburetor to the depression of the intake pipe INSPECTION AFT...

Page 42: ...2 REMOVAL 4 3 CYLINDER HEAD 4 3 CYLINDER 4 3 PISTON AND PISTON RING 4 4 INSPECTION 4 5 CYLINDER HEAD 4 5 CYLINDER 4 5 PISTON TO CYLINDER CLEARANCE 4 5 CONROD 4 6 PISTON AND PISTON RING 4 6 INSTALLATIO...

Page 43: ...AND PISTON CONSTRUCTION 20 N m 2 0 kgf m 14 5 lb ft 45 N m 4 5 kgf m 33 0 lb ft 4 5 N m 0 45 kgf m 3 3 lb ft 4 5 N m 0 45 kgf m 3 3 lb ft 4 5 N m 0 45 kgf m 3 3 lb ft 38 N m 3 8 kgf m 27 5 lb ft 25 N...

Page 44: ...1 Disconnect the spark plug cap 2 and remove the spark plug 3 Remove the engine mounting brackets 4 Remove the cylinder head NOTE Loosen the cylinder head nuts diagonally to prevent cylinder head dist...

Page 45: ...t and move the radiator forward Remove the cylinder NOTE Take care not to drop the exhaust side valve spacer 5 Remove the gasket 6 and dowel pins PISTON AND PISTON RING Remove the piston pin circlip 1...

Page 46: ...ect the cylinder bore for wear and scratches NOTE Chrome plated cylinder bore can not be modified such as boring and honing Inspect for cylinder distortion with the thickness gauge Cylinder distortion...

Page 47: ...n pin bore Service limit 18 030 mm 0 7098 in Piston pin O D Service limit 17 980 mm 0 7079 in 09900 20605 Dial caliper 09900 20205 Micrometer Remove carbon deposits from piston ring and piston ring gr...

Page 48: ...gine oil to the piston rings and piston ring grooves Fit the piston rings into the piston ring grooves so that the each piston ring end comes to the piston ring locating pin Apply engine oil to the pi...

Page 49: ...val Pay attention to the following points Fit a new gasket 1 and dowel pins Apply engine oil to the cylinder bore Tighten the cylinder nuts to the specified torque according to the specified tightenin...

Page 50: ...7B CYLINDER HEAD Tighten the cylinder head nuts to the specified torque accord ing to the specified tightening order as shown Cylinder head nut Initial 15 N m 1 5 kgf m 11 0 lb ft Final 25 N m 2 5 kgf...

Page 51: ...PECTION 5 5 DRIVE PLATE 5 5 DRIVEN PLATE 5 5 CLUTCH SPRING 5 5 CLUTCH PUSH ROD 5 6 PRIMARY DRIVEN GEAR ANDCLUTCH SLEEVE HUB 5 6 BEARING AND SPACER 5 6 CLUTCH RELEASE CAMSHAFT 5 6 OIL SEAL AND BEARING...

Page 52: ...5 2 CLUTCH CONSTRUCTION 1 No 1 drive plate 2 No 2 drive plate 10 N m 1 0 kgf m 0 7 lb ft 5 N m 0 5 kgf m 3 5 lb ft 90 N m 9 0 kgf m 65 0 lb f...

Page 53: ...oil 2 9 Remove the rear brake pedal 3 3 Remove the clutch cover 1 Loosen and remove the bolts diagonally Remove the clutch springs Remove the pressure plate 2 Remove the bearing 3 push piece 4 and pu...

Page 54: ...th the special tool and remove the nut 3 09920 53740 Clutch sleeve hub holder Remove the clutch sleeve hub Remove the washer 4 and primary driven gear assembly 5 Remove the bearing 6 and spacer 7 CLUT...

Page 55: ...Service limit 13 05 mm 0 514 in 09900 20101 Vernier calipers DRIVEN PLATE Inspect the driven plates for wear and discoloration Measure the driven plate distortion Driven plate distortion Service limi...

Page 56: ...lutch sleeve hub and primary driven gear assem bly for wear and cracks BEARING AND SPACER Inspect the needle bearing and spacer for abnormal noise and damage CLUTCH RELEASE CAMSHAFT Inspect the clutch...

Page 57: ...o the spacer 1 and needle bearing 2 Fit the clutch sleeve hub 3 new lock washer 4 and clutch sleeve hub nut 5 NOTE The flat side of the nut must face outside Tighten the clutch sleeve hub nut with the...

Page 58: ...the clutch push piece and bearing The roller side A of the bearing should face to the clutch push piece Fit the pressure plate 1 Insert the springs and tighten the bolts diagonally to the spec ified...

Page 59: ...ETO COVER Install the clutch release camshaft Install the magneto rotor and stator 7 4 Install a new gasket Tighten the bolts to the specified torque Magneto cover bolt 11 N m 1 1 kgf m 8 0 lb ft INSP...

Page 60: ...6 KICK STARTER 6 1 CONTENTS KICK STARTER CONSTRUCTION 6 2 REMOVAL 6 3 INSPECTION 6 3 REASSEMBLY 6 4 INSPECTION AFTER REASSEMBLY 6 5...

Page 61: ...6 2 KICK STARTER CONSTRUCTION 10 N m 1 0 kgf m 7 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft...

Page 62: ...tarter idle gear 1 and washer 09900 06107 Snap ring pliers Unhook the kick return spring and remove the kick starter assembly Remove the kick starter guide 2 Disassemble the following parts from the k...

Page 63: ...eth for wear and damage Inspect the kick starter idle gear and driveshaft contact sur face for wear and damage REASSEMBLY Reassemble the kick starter assembly in the reverse order of disassembly Pay a...

Page 64: ...e kick starter lever with the punched mark on the lever aligned with the punched mark on the kick starter shaft Kick starter lever bolt 23 N m 2 3 kgf m 16 5 lb ft Install the rear brake pedal 3 6 INS...

Page 65: ...7 MAGNETO ROTOR AND STATOR 7 1 CONTENTS MAGNETO ROTOR AND STATOR CONSTRUCTION 7 2 REMOVAL 7 3 INSTALLATION 7 4 INSPECTION AFTER INSTALLATION 7 5...

Page 66: ...7 2 MAGNETO ROTOR AND STATOR CONSTRUCTION 55 N m 5 5 kgf m 40 0 lb ft 11 N m 1 1 kgf m 8 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft...

Page 67: ...magneto lead wire coupler 1 and clamp 2 Remove the magneto cover Remove the magneto rotor nut with the special tool 09930 40113 Rotor holder Remove the magneto rotor with the special tool 09930 30113...

Page 68: ...apered portion of the crankshaft and magneto rotor Align the line on the stator and line on the crankcase to set the ignition timing correctly Tighten the stator mounting bolts to the specified torque...

Page 69: ...w gasket Tighten the magneto cover bolts to the specified torque Magneto cover bolt 11 N m 1 1 kgf m 8 0 lb ft INSPECTION AFTER INSTALLATION After installing the stator and magneto rotor inspect the f...

Page 70: ...SE 8 5 TRANSMISSION 8 5 CRANKSHAFT 8 6 INSPECTION 8 6 GEARSHIFT SHAFT 8 6 GEARSHIFT CAM DRIVEN GEAR 8 6 TRANSMISSION 8 6 CRANKSHAFT 8 8 CONROD 8 8 CRANK CASE 8 9 OIL SEAL INSPECTION AND REMOVAL 8 9 OI...

Page 71: ...8 2 TRANSMISSION AND CRANKSHAFT CONSTRUCTION CRANKSHAFT AND CRANKCASE 70 N m 7 0 kgf m 50 5 lb ft 5 5 N m 0 55 kgf m 4 0 lb ft 21 N m 2 1 kgf m 15 0 lb ft...

Page 72: ...TRANSMISSION AND CRANKSHAFT 8 3 TRANSMISSION 23 5 N m 2 35 kgf m 17 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft...

Page 73: ...ers Remove the gearshift shaft 2 and washer Remove the retainer 3 and gearshift cam driven gear 4 NOTE Be careful not to drop the pins and springs when removing the gearshift cam driven gear Remove th...

Page 74: ...he crankcase Keep all the tool arms parallel to the crankcase surface Separate the crankcase gradually while tapping the crankcase boss and countershaft softly with a plastic hammer Remove the dowel p...

Page 75: ...e crankcase surface INSPECTION GEARSHIFT SHAFT Inspect the gearshift shaft for bends and damage Inspect the return spring for damage GEARSHIFT CAM DRIVEN GEAR Inspect the pawls springs and pins for da...

Page 76: ...earshift fork thickness Standard 4 60 4 70 mm 0 181 0 185 in 09900 20101 Vernier calipers Measure the gearshift fork groove width with the vernier cali pers Gearshift fork groove width Standard 4 80 4...

Page 77: ...20101 Vernier calipers CONROD Measure the conrod small end inside diameter with the small bore gauge Conrod small end I D Service Limit 23 040 mm 0 907 in 09900 20605 Dial calipers 10 34 mm 09900 224...

Page 78: ...e the oil seal with the special tool 09913 50121 Oil seal remover OIL SEAL INSTALLATION Fit a new oil seal with the special tool Apply grease to the oil seal lip 09913 70210 Bearing installer set NOTE...

Page 79: ...finger and inspect for smooth move ment Remove the bearing retainers Remove and install the bearings with the special tool Bearing remover installer Tighten the bearing retainer screws to the specifi...

Page 80: ...09910 32812 Crankshaft installer 09911 11310 Attachment NOTE Do not hit the crankshaft with a hammer for installation TRANSMISSION NOTE Seat the snap ring in the groove and locate its end as shown in...

Page 81: ...ins 3 CRANKCASE Fit the left crankcase half on the right crankcase half Tighten the crankcase bolts Crankcase bolt 11 N m 1 1 kgf m 8 0 lb ft NOTE Tighten the bolts gradually and diagonally to guide t...

Page 82: ...the specified torque Primary drive gear bolt 70 N m 7 0 kgf m 50 5 lb ft GEARSHIFT LINKAGE Fit the gearshift cam plate NOTE Align the gearshift cam plate hole with the pin Tighten the gearshift cam bo...

Page 83: ...7 0 lb ft Install the gearshift shaft 4 Match the center teeth of the gear on the gearshift shaft with the center teeth on the cam driven gear as shown INSPECTION AFTER INSTALLATION After mounting th...

Page 84: ...OR TUNING IN PRACTICE 9 7 CARBURETOR 9 10 REMOVAL AND DISASSEMBLY 9 10 INSPECTION 9 12 REASSEMBLY AND REMOUNTING 9 12 CARBURETOR SOLENOID 9 13 REMOVAL AND INSPECTION 9 13 REASSEMBLY 9 13 THROTTLE POSI...

Page 85: ...9 2 FUEL SYSTEM CONSTRUCTION 4 5 N m 0 45 kgf m 3 25 lb ft...

Page 86: ...uretor Specifications PRINCIPLES OF CARBURETOR TUNING CARBURETOR COMPONENTS AND FUNC TIONS The carburetor consists of a number of parts as shown below The asterisk marked parts are pre cisely machined...

Page 87: ...w Jet The slow jet meters the fuel supplied to the slow system Each jet size is indicated by a number Larger number means a larger bore diameter and fitting a larger numbered slow jet enriches the air...

Page 88: ...tself controls air fuel mixture ratio particulary on lower mid throttle opening The smaller the O D the richer the air fuel mixture becomes Main Jet The main jet like the slow jet meters fuel flow Eac...

Page 89: ...he engine to continue idling Throttle valve opening Standard After touching the throttle stop screw to the throttle valve turn in the stop screw five to six turns to raise the throttle valve CAUTION T...

Page 90: ...o 100 humidity difference As for humidity its nor mal range is from 20 to 95 Therefore the possible effect of humidity on the oxygen concentration is so lit tle that it can be disregarded Consequently...

Page 91: ...he spark plug is burned white 5 The speed of the engine fluctuates and lack of power is noticed 6 Detonation and pinging are experienced Tuning Procedure The following indicates the correct tuning pro...

Page 92: ...through 5 fine tune the carbu retor according to the actual race conditions 1 Adjust the air fuel mixture by turning the air screw within 1 2 2 turns out 2 If the mixture can not be adjusted by the a...

Page 93: ...solenoid couplers Loosen the carburetor clamp screws and remove the carbure tor 1 Remove the carburetor top cap 2 and throttle valve Holding the spring 3 remove the throttle cable 4 from the throttle...

Page 94: ...eedle 9 Throttle valve 0 Remove the screws and carburetor float chamber A Remove the float pin B and floats C Remove the needle valve ass y D Remove the main jet E and slow jet F Remove the power jet...

Page 95: ...ure the float height tilt the carburetor until the float tip just con tacts the float valve Standard float height 6 5 1 0 mm 0 26 0 04 in REASSEMBLY AND REMOUNTING Reassemble the carburetor in the rev...

Page 96: ...position Others If the valve operation is not correct inspect the solenoid valve by following procedure Connect 12 V battery and solenoid as shown Check the valve movement when the circuit is opened a...

Page 97: ...value replace the CDI unit Measure the throttle position sensor coil resistance with the Multi circuit tester 09900 25008 Multi circuit tester set Tester knob indication Resistance Blue probe Black pr...

Page 98: ...nt the throttle position sensor assembly REED VALVE REMOVAL Remove the carburetor 9 10 Remove the intake pipe and reed valve INSPECTION Inspect the reeds for damage Inspect the reed valve stoppers for...

Page 99: ...2 COOLING CIRCUIT INSPECTION 10 3 COOLING CIRCUIT 10 3 RADIATOR CAP 10 3 REMOVAL 10 3 RADIATOR 10 3 WATER PUMP 10 4 INSPECTION 10 4 RADIATOR 10 4 IMPELLER AND GEAR SHAFT 10 5 WATER PUMP BEARING 10 5...

Page 100: ...10 2 COOLING SYSTEM CONSTRUCTION 5 5 N m 0 55 kgf m 4 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft...

Page 101: ...g com ponent or part RADIATOR CAP Inspect the radiator cap for function with a radiator cap pres sure gauge Radiator cap valve release pressure 95 125 kPa 0 95 1 25 kgf cm2 14 18 psi NOTE Apply water...

Page 102: ...ired by straightening them with the blade of a small screwdriver WARNING Do not open the radiator cap when the engine is hot as you may be injured by escaping hot liquid or vapor The engine must be co...

Page 103: ...he water pump bearing with a new one BEARING REPLACEMENT Remove the water pump bearing with the special tool 09921 20220 Bearing remover set Install a new bearing with the special tool 09913 70210 Bea...

Page 104: ...on to the following points Tighten the impeller to the specified torque Impeller 10 N m 1 0 kgf m 7 0 lb ft 1 Washer 2 Water pump shaft 3 Water pump driven gear 4 Water pump case 5 Bearing 6 Oil seal...

Page 105: ...e cover bolts to the specified torque Crankcase cover bolt 11 N m 1 1 kgf m 8 0 lb ft INSPECTION AFTER REASSEMBLY After reinstalling the water pump inspect the followings Transmission oil level 2 9 En...

Page 106: ...TS EXHAUST VALVE CONSTRUCTION 11 2 EXHAUST VALVE 11 3 DISASSEMBLY 11 3 INSPECTION 11 5 REASSEMBLY 11 5 EXHAUST VALVE GOVERNER AND ACTUATOR 11 8 DISASSEMBLY 11 8 INSPECTION 11 9 REASSEMBLY 11 9 INSPECT...

Page 107: ...11 2 EXHAUST VALVE CONSTRUCTION 10 N m 1 0 kgf m 7 0 lb ft 4 5 N m 0 45 kgf m 3 3 lb ft 4 0 N m 0 4 kgf m 3 0 lb ft 4 5 N m 0 45 kgf m 3 3 lb ft...

Page 108: ...linder 4 3 EXHAUST SIDE VALVE RH Remove the exhaust side valve spacer 1 Remove the exhaust side valve cam 2 and shaft 3 Remove the exhaust side valve bolt 4 stopper pin 5 and gasket 6 Remove the exhau...

Page 109: ...he side valve cap 1 Remove the exhaust side valve in the same manner as the right side Remove the spring cap 2 Remove the gasket 3 and spring 4 EXHAUST MAIN VALVE Remove the exhaust valve cover 1 and...

Page 110: ...nt parts Inspect the exhaust valves for wear and scratches Inspect the return spring for spring tension and damage REASSEMBLY Reassemble the exhaust valve in the reverse order of disassem bly Pay atte...

Page 111: ...ite mark A on the exhaust valve must face to the left side valve Make sure to pinch the pin of the main valve with the spring ends Install the retainer 8 Tighten the bolts to the specified torque of e...

Page 112: ...be installed on left side Install the exhaust side valve cam Install the pin Install the spacer I with the hollow faced outside Install the left exhaust side valve in the same manner as the right exha...

Page 113: ...smoothness by rotating the exhaust valve shaft NOTE Temporarily install the bolt to the exhaust valve shaft for above inspection Hold the exhaust side valve in fear of dropping off EXHAUST VALVE GOVE...

Page 114: ...INSPECTION Inspect the disassembled parts for wear and damage Inspect the exhaust valve rod for smooth movement REASSEMBLY Reassemble the exhaust valve governer and actuator in the reverse order of d...

Page 115: ...governer Connect the exhaust valve rod to the exhaust valve shaft using the pin 1 as a stopper NOTE The pin 1 is one of the included parts Exhaust valve rod bolt 10 N m 1 0 kgf m 7 0 lb ft INSPECTION...

Page 116: ...12 CONSTRUCTIONS 12 1 CONTENTS CONSTRUCTIONS EXTERIOR PARTS 12 2 HANDLEBAR CONTROLS 12 3 REMOVAL 12 3 REMOUNTING 12 4 SEAT RAIL DRIVE CHAIN CONTROL ROLLER 12 6...

Page 117: ...12 2 CONSTRUCTIONS EXTERIOR PARTS Seat Bolt Washer Frame Frame cover Seat rail 5 N m 0 5 kgf m 3 5 lb ft...

Page 118: ...e the clutch lever Remove the engine stop switch 1 Remove the clamps Remove the throttle assembly 2 Remove the front brake master cylinder 3 25 N m 2 5 kgf m 18 0 lb ft 6 N m 0 6 kgf m 4 5 lb ft 6 N m...

Page 119: ...dlebar clamp forward Tighten the handlebar clamp bolts to the specified torque Handlebar clamp bolt 25 N m 2 5 kgf m 18 0 lb ft NOTE When tightening the handlebar clamp bolts first tighten the bolts 1...

Page 120: ...ark D on the handlebars with the throttle holder matching surface Install the front brake master cylinder 14 13 Inspect the throttle cable play 2 13 Align the punched mark E on the handlebars with the...

Page 121: ...12 6 CONSTRUCTIONS SEAT RAIL DRIVE CHAIN CONTROL ROLLER 23 N m 2 3 kgf m 16 5 lb ft 23 N m 2 3 kgf m 16 5 lb ft 31 N m 3 1 kgf m 22 5 lb ft 31 N m 3 1 kgf m 22 5 lb ft 43 N m 4 3 kgf m 31 0 lb ft...

Page 122: ...L 13 3 REAR WHEEL REASSEMBLY 13 4 FRONT AND REAR WHEEL INSPECTION 13 4 SPACER AND DUST SEAL INSPECTION 13 4 AXLE SHAFT INSPECTION 13 4 WHEEL RIM INSPECTION 13 4 WHEEL BEARING INSPECTION 13 5 WHEEL BEA...

Page 123: ...13 2 FRONT AND REAR WHEELS CONSTRUCTION 110 N m 11 0 kgf m 79 5 lb ft 35 N m 3 5 kgf m 25 5 lb ft 10 N m 1 0 kgf m 7 0 lb ft 32 N m 3 2 kgf m 23 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft FWD...

Page 124: ...cified torque with the special tool 09940 34581 Attachment F Axle nut 35 N m 3 5 kgf m 25 5 lb ft Fit the axle holder and tighten the bolts temporarily Remove the block from under the chassis tube and...

Page 125: ...s Replace the spacer together with the dust seal if you find excessive wear on the spacer NOTE Apply grease on the spacer and dust seal before reassembling AXLE SHAFT INSPECTION Support the axle shaft...

Page 126: ...seal 09913 50121 Oil seal remover Insert the adaptor 1 into the wheel bearing After inserting the wedge bar from the opposite side lock the wedge bar 2 in the slit of the adaptor Drive out both wheel...

Page 127: ...ted side of the dust seal outside REAR WHEEL BEARING REASSEMBLY Apply grease to the bearings Reassemble the spacer and bearings with the special tools 09941 34513 Steering race installer 09913 70210 B...

Page 128: ...R WHEELS 13 7 REAR SPROCKET REPLACEMENT Tighten the nuts to the specified torque Rear sprocket nut 32 N m 3 2 kgf m 23 0 lb ft NOTE Reassemble the rear sprocket as the letter on the sprocket sur face...

Page 129: ...SASSEMBLY 14 7 REAR CALIPER REMOVAL AND DISASSEMBLY 14 8 CALIPER INSPECTION 14 8 CALIPER CLEANING 14 9 FRONT CALIPER REASSEMBLY 14 9 REAR CALIPER REASSEMBLY 14 10 MASTER CYLINDER 14 11 FRONT MASTER CY...

Page 130: ...m 1 8 kgf m 13 0 lb ft 10 N m 1 0 kgf m 7 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft 18 N m 1 8 kgf m 13 0 lb ft 6 0 N m 0 6 kgf m 4 5 lb ft 13 N m 1 3 kgf m 9 5 lb ft 13 N m 1 3 kgf m 9 5 lb ft 6 0 N m 0 6...

Page 131: ...nd induce vomiting Flush eyes or skin with water if brake fluid gets in eyes or comes in contact with skin WARNING The use of any fluid except DOT4 brake fluid from a sealed container can damage the b...

Page 132: ...TE Do not release the brake lever pedal while the bleeder valve is opened Replenish brake fluid to the UPPER line when the brake fluid level drops below LOWER line Tighten the air bleeder valve Air bl...

Page 133: ...ke pad mounting pin 18 N m 1 8 kgf m 13 0 lb ft NOTE Pump the brake lever several times to seat the brake pads after reassembling REAR BRAKE PADS Remove the cap 1 and pad mounting pin 2 Remove the bra...

Page 134: ...DOT4 brake fluid from a sealed container Never use or mix different types of brake fluid WARNING Brake fluid can be hazardous to humans and pets Brake fluid is harmful or fatal if swallowed and harm f...

Page 135: ...emove the caliper bracket from the caliper Remove the boots from the caliper bracket Wrap the caliper with a rag to prevent brake fluid scatter and piston pop out Apply low pressure air into the calip...

Page 136: ...nting pin Remove the brake pad 14 5 Remove the caliper axle bolt Remove the boots Remove the pad spring Wrap the caliper with a rag to prevent brake fluid scatter and piston pop out Apply low pressure...

Page 137: ...t the piston seals dust seals and pistons Fit the caliper brackets and pad springs Apply SUZUKI SILICONE GREASE to the caliper axles 99000 25100 SUZUKI SILICONE GREASE Fit the brake pads Tighten the b...

Page 138: ...y SUZUKI SILICONE GREASE to the caliper axles 99000 25100 SUZUKI SILICONE GREASE Tighten the caliper axle bolt 1 to the specified torque Caliper axle bolt 28 N m 2 8 kgf m 20 0 lb ft Tighten the brake...

Page 139: ...m ful if it comes in contact with your skin or eyes Keep brake fluid away from children Call your doctor immediately if brake fluid is swallowed and induce vomiting Flush eyes or skin with water if br...

Page 140: ...4 Place a rag under the hose to catch spilled brake fluid Remove the brake hose union bolt Remove the master cylinder mounting bolts Remove the master cylinder cap Remove the diaphragm Remove the dust...

Page 141: ...llowing points Temporary tighten the master cylinder mounting bolts NOTE When remounting the master cylinder onto the handlebar align the master cylinder holder s mating surface A with the punch mark...

Page 142: ...RAKE PEDAL REMOVAL Remove the cotter pin 1 and brake pedal pivot bolt Remove the return spring Remove the cotter pin 2 washer and pin REASSEMBLY Fit the return spring properly Apply SUZUKI SUPER GREAS...

Page 143: ...IL QUANTITY MINOR ADJUSTMENT 15 4 OIL CHANGE Only for outer tube oil chamber 15 5 SPRING CHANGE 15 7 FRONT FORK TUNING PROCEDURE 15 9 SUSPENSION BALANCE 15 10 FRONT FORK 15 11 REMOVAL 15 11 DISASSEMBL...

Page 144: ...2 5 lb ft 25 N m 2 5 kgf m 18 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft 30 N m 3 0 kgf m 21 5 lb ft 35 N m 3 5 kgf m 25 5 lb ft 22 N m 2 2 kgf m 16 0 lb ft 23 N m 2 3 kgf m 16 5 lb ft 18 N m 1 8 kgf m 13 0...

Page 145: ...ster you must gently turn the adjuster screw clockwise until it stops then back it out the recommended num ber of turns Do not force the adjuster screw past the stopped position or you may damage the...

Page 146: ...2 in Measure the fork oil quantity added reduced and record it to know the oil quantity after adjustment Front fork oil quantity With standard fork spring used Standard 362 ml 12 24 12 75 US lmp oz O...

Page 147: ...ube 15 12 09941 53630 Front fork top cap wrench Hold the front fork inverted position for move than 20 minutes to allow the fork oil to fully drain Force out the remaining oil using compressed air com...

Page 148: ...rk cap wrench Iinstall the front fork 15 23 Iinstall the handlebars 12 4 Parts No Spring rate Identification Slit mark on the spring end STD Oil quantity Oil quantity adjustable range Soft 51171 37FD0...

Page 149: ...ont fork inverted position for more than 20 minutes the allow the fork oil to fully drain 15 5 Force out the remaining oil using compressed air completely 15 5 Replace the spring Install the damper ro...

Page 150: ...lt 22 N m 2 2 kgf m 16 0 lb ft Tighten the center bolt to the specified torque Center bolt 70 N m 7 0 kgf m 51 0 lb ft Pour the specified amount fork oil into the outer tube in accor dance with the fo...

Page 151: ...s 1 Adjust both the compression and rebound damping to a softer setting 2 Decrease fork oil capacity 3 Replace the spring with an optional softer one Feels too soft overall and bottoms Jump Large bump...

Page 152: ...on to bottom where as it felt fine before the front fork adjustment was made BALANCE TEST Stand next to the motorcycle on level ground Place one foot on the footrest closest to you Sharply push down T...

Page 153: ...3 Remove the fork protectors brake hose guide and brake hose clamp Remove the front brake caliper 14 7 Loosen the front fork cap bolt 1 2 turns to facilitate later dis assembly 09941 53630 Front fork...

Page 154: ...ap bolt sub tank from the outer tube and slowly slide down the outer tube 09941 53630 Front fork top cap wrench Place a drain pan under the front fork and drain fork oil NOTE Face the oil hole A on th...

Page 155: ...cket wrench Compress the outer tube by hands and install the conrod holder special tool between the axle holder bottom 2 and locknut 4 09910 20115 Conrod holder Hold the locknut with a wrench and remo...

Page 156: ...st seal 9 and the stopper ring 0 CAUTION Removing the locknut 4 and pushing the inner rod thread into the damper rod will damage the inner rod oil seal Do not remove the locknut 4 from the inner rod C...

Page 157: ...ve the slide bushing from the inner tube Remove the following parts from the inner tube Guide bushing 1 Seal retainer 2 Oil seal 3 Stopper ring 4 Dust seal 5 Clamp the bottom flat part of the sub tank...

Page 158: ...the inner rod several strokes INSPECTION CENTER BOLT Inspect the adjuster rod of the center bolt for damage If it is damaged replace it with a new one Replace the O ring with a new one COMPRESSION DAM...

Page 159: ...unout using the V blocks and dial gauge Inner tube runout Service Limit 0 4 mm 0 02 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block DAMPER ROD Inspect the damper rod...

Page 160: ...st seal Cover the inner tube with a plastic film Install the following parts to the inner tube New dust seal 1 Stopper ring 2 New oil seal 3 NOTE The side of the oil seal that has a mark should face t...

Page 161: ...could allow water mud and the like to enter and cause an oil leak COMPRESSION DAMPER UNIT NOTE Clean each threaded part before installing With the damper rod in fully extended position pour the spec i...

Page 162: ...er unit to the specified torque Compression damper unit 30 N m 3 0 kgf m 21 5 lb ft With the damper rod held in vertical position slowly move the inner rod several strokes Tighten the locknut by hand...

Page 163: ...eat the COMPRESSION DAMPER UNIT procedures Pour the specified amount fork oil and discharge an excess of oil 15 19 Make sure approx 10 mm 0 39 in of inner rod thread is exposed on the end Completely w...

Page 164: ...ter bolt clockwise until resistance is felt and check the clearance between the locknut and center bolt to provide more than 1 mm 0 04 in Turn the locknut counterclockwise until it contacts with the c...

Page 165: ...sed 362 ml 12 24 12 75 US lmp oz 99000 99001 SS5 SUZUKI FORK OIL SS 05 Raise the outer tube and temporarily tighten the fork cap bolt sub tank 09941 53630 Front fork top cap wrench INSTALLATION Reinst...

Page 166: ...5 lb ft Tighten the fork cap bolt sub tank to the specified torque 09941 53630 Front fork top cap wrench Fork cap bolt 35 N m 3 5 kgf m 25 5 lb ft Install the handlebars 12 4 Install the front wheel 1...

Page 167: ...t wheel 13 3 Remove the front number plate Remove the handlebar holder bolts and remove the handle bars Remove the brake caliper Remove the brake hose guide Remove the front forks Remove the front fen...

Page 168: ...for wear Inspect the needle bearings for wear Inspect the steering stem for distortion BEARING REPLACEMENT NOTE Replace the outer race and bearing as a set Remove the upper and lower outer races with...

Page 169: ...teering nut socket wrench 09940 14960 Attachment Steering stem nut 45 N m 4 5 kgf m 32 5 lb ft Move the steering stem right and left several times to seat the bearings Turn back the steering stem nut...

Page 170: ...BER 16 7 REAR SHOCK ABSORBER REMOVAL 16 7 SPRING REMOVAL 16 8 REAR SHOCK ABSORBER INSPECTION 16 8 BEARING REPLACEMENT 16 9 SPRING INSTALLATION 16 10 REAR SHOCK ABSORBER INSTALLATION 16 10 OIL REPLACEM...

Page 171: ...16 2 REAR SUSPENSION CONSTRUCTION 60 N m 6 0 kgf m 43 5 lb ft 60 N m 6 0 kgf m 43 5 lb ft 80 N m 8 0 kgf m 58 0 lb ft 80 N m 8 0 kgf m 58 0 lb ft 70 N m 7 0 kgf m 50 5 lb ft...

Page 172: ...juster screw 1 clockwise until it stops full hard position NOTE Do not force the adjuster screw past the stopped position or you may damage the adjuster Turn the adjuster screw 1 counterclockwise the...

Page 173: ...at and right frame cover 3 2 12 2 Remove the silencer Loosen the air cleaner clamp screw Remove the bolts and nut right and left and remove the rear frame assembly Loosen the lock nut 1 with the speci...

Page 174: ...le normally in full riding gear Find the sag by subtracting L2 from L1 Standard sag range is 101 mm 3 97 in Spring Part No Spring rate Marking paint Set length adjustable range Soft 62211 37FA0 48 N m...

Page 175: ...ng See note below Bottom feeling or feels too soft and unstable Jump Large bump Series of bumps 1 Adjust the low speed compression damping to a harder setting See note below 2 Adjust the rebound dampi...

Page 176: ...rest closest to you Sharply push down The front and rear suspensions should both collapse equally BALANCING TIPS Check for air pressure build up in front forks Heat and altitude will increase air pres...

Page 177: ...2 with the special tool Turn the locknut 1 and adjuster 2 fully to the end of the thread 09910 60611 Universal clamp wrench Depress the spring seat 3 and remove the stopper ring 4 Remove the spring se...

Page 178: ...eedle roller bearings 1 Remove the dust seals 2 Remove the needle roller bearing cage 3 with the special tool 09921 20240 Bearing remover set Press the bearing cage with the special tool and suitable...

Page 179: ...ameter side is bot tom Adjust the spring set length and tighten the locknut Standard spring set length 6 3 mm 0 24 in compressed from the free length Spring set length adjustable range 2 12 mm 0 08 0...

Page 180: ...ools and equipment are required to perform oil replacement 1 Screwdriver or small punch 7 Rags 2 Vise 8 Nitrogen tank 3 Drain Pan 9 Filler Hose and Nozzle 4 Oilcan 0 Regulator Assembly 5 Beaker A Owne...

Page 181: ...the compression adjuster assembly 1 from the rear shock absorber Place a drain pan under the rear shock absorber unit Move the rod and drain the oil completely Push the valve core again to equalize t...

Page 182: ...fresh rear suspension oil fully into the reservoir tank 99000 99001 S25 SUZUKI REAR SUSPENSION OIL SS 25 Oil capacity Approx 380 ml 12 84 13 38 US Imp oz Cover the compression adjuster hole by the roo...

Page 183: ...wdriver to bleed out nitrogen gas 16 12 Remove the compression adjuster assembly Drain the oil 16 12 WARNING Use of flammable gas for pressuring the rear shock absorber unit can be hazardous Flammable...

Page 184: ...l the circlip 3 is fully exposed Remove the circlip 3 NOTE Avoid scratching the inner surface of the shock absorber body to avoid oil leaks Extract the damper rod assembly from the shock absorber body...

Page 185: ...Pressure the rear shock absorber unit with nitrogen gas to 981 kPa 9 8 kgf cm2 139 5 psi 16 14 Reassemble the spring and adjust the spring set length 16 10 Tighten the valve cap Remount the rear shoc...

Page 186: ...es Remove the rear wheel 13 3 Remove the chain guide 1 Remove the brake hose guide 2 Remove the rear caliper assembly 3 from the swingarm Remove the rear cushion lever bolt and nut 4 Remove the brake...

Page 187: ...s Dust seal Washer Thrust bearing INSPECTION Inspect the chain buffer for damage and excessive wear Measure the pivot shaft runout with a dial gauge and V blocks Swingarm pivot shaft rounout Service l...

Page 188: ...A USA 99000 25010 SUZUKI SUPER GREASE A Others Press the new bearings with the special tools 09924 84521 Bearing installer set 09941 34513 Steering race installer set REASSEMBLY Reassemble and remount...

Page 189: ...e the rear wheel 13 4 REAR SUSPENSION LINKAGE DISASSEMBLY Place a block under chassis tubes Remove the lower drive chain control roller 1 Remove the rear cushion rod bolt and nut Remove the cushion le...

Page 190: ...00 25010 SUZUKI SUPER GREASE A Others Press the bearings with the special tool and suitable size socket wrench 09924 84521 Bearing installer set NOTE Position the bearings by refering to the illustrat...

Page 191: ...wingarm nuts to the specified torque Tightening torque A 60 N m 6 0 kgf m 43 5 lb ft B 60 N m 6 0 kgf m 43 5 lb ft C 80 N m 8 0 kgf m 58 0 lb ft D 80 N m 8 0 kgf m 58 0 lb ft E 80 N m 8 0 kgf m 58 0 l...

Page 192: ...ion move ment and damage the rear suspension linkage Make sure that the rear shock absorber rebound damping adjuster on the bottom bracket of the rear shock absorber is located to the right side Inser...

Page 193: ...17 ELECTRICAL SYSTEM 17 1 CONTENTS ELECTRICAL SYSTEM ELECTRICAL CIRCUIT 17 2 INSPECTION 17 2 IGNITION SYSTEM PEAK VOLTAGE 17 2 IGNITION COIL 17 4 CDI UNIT 17 4 STATOR COIL 17 5...

Page 194: ...Y Yellow R W Red with White tracer INSPECTION IGNITION SYSTEM PEAK VOLTAGE Remove the seat and fuel tank 3 2 Remove the spark plug Disconnect the magneto lead wire coupler 1 Magneto Engine stop switch...

Page 195: ...er Connect the magneto lead wire coupler and disconnect the ignition coil lead wire coupler 2 Connect the multi circuit tester with the peak volt adaptor between Black White lead wire and White Blue l...

Page 196: ...e 09900 25008 Multi circuit tester CDI UNIT Remove the CDI unit from the steering head pipe Measure voltage between the lead wires with the multi circuit tester Tester knob indication Diode 09900 2500...

Page 197: ...3 0 757 1 357 0 382 0 982 0 576 1 176 5 0 173 0 773 1 137 1 523 0 967 1 523 0 578 1 178 0 832 1 432 1 174 1 523 0 778 1 378 0 616 1 216 0 173 0 773 0 072 0 672 6 0 443 1 043 1 181 1 523 1 032 1 523 0...

Page 198: ...18 TROUBLESHOOTING 18 1 CONTENTS TROUBLESHOOTING TROUBLESHOOTING 18 2 ENGINE 18 2 CHASSIS 18 5...

Page 199: ...ine stalls Fuel deterioration Fouled spark plug Fuel hose clogged Air cleaner clogged Carburetor jets clogged Low compression Piston ring worn or stuck Cylinder worn Air leak from cylinder gasket Air...

Page 200: ...valve malfunction Piston ring stuck Adjust or replace Adjust Adjust Replace Adjust Replace Replace Clean or replace Replace Replace Clean adjust or replace Replace Engine speed does not return smooth...

Page 201: ...ylinder or cylinder head cracked Cylinder or cylinder head O rings damage Replace Repair Repair or replace Replace Replace Replace Replace Replace Replace Replace Replace Clutch does not disen gage Cl...

Page 202: ...amping force maladjustment Damping valve malfunction Standard spring too soft Replace Replenish Replace Adjust Replace Use optional spring Hard front suspension High fork oil level High fork oil visco...

Page 203: ...7 CHASSIS 19 7 TIGHTENING TORQUE CHART 19 8 SPECIAL TOOLS 19 9 WIRING DIAGRAM 19 11 WIRE CABLE AND HOSE ROUTING 19 12 WIRE HARNES ROUTING 19 12 CABLE ROUTING 19 13 CARBURETOR HOSE AND WATER HOSE ROUTI...

Page 204: ...012 0 018 in 0 50 mm 0 02 in Piston ring to groove clearance 1st 2nd 0 020 0 060 mm 0 0008 0 0024 in Piston pin bore 18 002 18 008 mm 0 7087 0 7090 in 18 030 mm 0 7098 in Piston pin O D 17 995 18 000...

Page 205: ...1 210 23 19 4th 1 000 21 21 Top 0 869 20 23 Shift fork to groove clearance 0 10 0 30 mm 0 004 0 012 in 0 50 mm 0 020 in Shift fork groove width 4 80 4 90 mm 0 189 0 193 in Shift fork thickness 4 60 4...

Page 206: ...nout Front Rear 0 30 mm 0 012 in Master cylinder bore Front 11 000 11 043 mm 0 4331 0 4348 in Rear 12 700 12 743 mm 0 5000 0 5017 in Master cylinder piston diam Front 10 957 10 984 mm 0 4314 0 4324 in...

Page 207: ...75 US Imp oz INNER 180 ml 6 08 6 34 US Imp oz Front fork damping force adjuster Compression 6 clicks turns back Rebound 13 clicks tuns back Front fork air pressure 0 kPa 0 kgf cm2 0 psi Rear shock ab...

Page 208: ...e of at least 95 octane Research method For other coun tries Fuel tank capacity 8 0 L 2 1 1 8 US Imp gal Engine oil type MOTUL 800 2T FACTORY LINE OFF ROAD or equivalent Two Cycle Racing Lubricant Fue...

Page 209: ...23 2 3 16 5 Steering stem head nut 100 10 0 72 5 Front fork cap bolts 35 3 5 25 5 Front fork center bolt 70 7 0 50 5 Compression damper unit 30 3 0 21 5 Master cylinder set bolt front rear 10 1 0 7 0...

Page 210: ...own headed bolt N m kgf m lb ft N m kgf m lb ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 0 3 2 0 4 5 0 45 3 5 6 5 5 0 55 4 0 10 0 1 0 7 0 8 13 0 1 3 9 5 23 0 2 3 16 5 10 29 0 2 9 21 0 50 0 5 0 36 0 12 45 0 4...

Page 211: ...9900 20701 Magnetic stand 09900 20803 Thickness gauge 09900 21304 V block set 100 mm 09900 25008 Multi circuit tester set 09910 20115 Conrod holder 09910 32812 Crankshaft installer 09911 11310 Attachm...

Page 212: ...40 14911 Steering nut wrench 09940 14960 Steering nut socket wrench 09940 34581 Attachment F 09940 52861 Front fork oil seal installer set 09941 34513 Steering race installer 09941 50111 Bearing remov...

Page 213: ...tracer W Bl White with Blue tracer RUN OFF ENGINE STOP SWITCH CDI UNIT THROTTLE POSITION SENSOR MAGNETO IGNITION COIL CARBURETOR SOLENOID O R Y R O B R W L O W O B P B Y B Br W Bl B W O R O B R R W O...

Page 214: ...Engine stop switch lead wire Ignition coil coupler Frame CDI unit Clamp Engine stop switch Wiring harness Clamp Exhaust valve breather hose Cylinder breather hose Magneto lead wire Clamp Carburetor so...

Page 215: ...CABLE ROUTING Throttle cable Throttle cable Clutch cable Clutch cable Clamp Pass the clutch cable between the engine mounting brackets Throttle cable Clutch cable Pass the clutch cable under the radi...

Page 216: ...d the frame Face the clamp upward Face the clamp backward Face the clamp backward Face the white marking paint left Face the clamp left side Face the white marking paint right Cylinder breather hose E...

Page 217: ...ose Radiator outlet hose Radiator overflow hose Upward Left side Face the white marking paint to the left side Face the white marking paint to the right side Backward Right side Backward Radiator Spac...

Page 218: ...er touching the brake hose union to the stopper tighten the union bolt to the specified torque Front brake hose Clamp Front fork protector Clamp the upper difference portion in brake hose diameter Was...

Page 219: ...rake hose union to the stopper tighten the union bolt to the specified torque After touching the brake hose union to the stopper tighten the union bolt to the specified torque Guide Rear brake fluid r...

Page 220: ...e mark on the throttle grip with the hole on the throttle rotor Apply adhesive agent onto the handlebars then install the handle grip Align the master cylinder holder s mating surface with the punched...

Page 221: ...Rear fender Seat rail Seat rail Silencer Spacer Cushion Seat rail Nut Silencer Silencer E 28 000 Clearance Install the springs as their movable ends face to the muffler side 1st muffler 1st muffler Fr...

Page 222: ...ke 72 0 mm 2 834 in Piston displacement 249 cm3 15 2 cu in Corrected compression ratio 8 8 1 EX VALVE OPEN and 10 6 1 EX VALVE CLOSE Carburetor KEIHIN PWK38PWJ TPS single Air cleaner Polyurethane foam...

Page 223: ...Rear brake Disc brake Front tire size 80 100 21 51M Rear tire size 110 90 19 62M Front fork stroke 310 mm 12 2 in Rear wheel travel 310 mm 12 2 in ELECTRICAL Ignition type Electronic Ignition CDI Ign...

Page 224: ...CASE 11481 37F20 1 8 GASKET CLUTCH COVER 11482 37F01 1 9 GASKET MAGNETO COVER 11483 37E02 1 10 O RING CLUTCH COVER OUTER 11484 37E00 1 11 PISTON COMP 12110 37F20 0F0 1 12 RING PISTON 12141 37F00 4 13...

Page 225: ...ARNING Failure to follow these safety precautions may increase your risk of injury Wear a helmet eye protection and bright protective clothing Don t ride after consuming alcohol or other drugs This ow...

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Suzuki RM 250 2003, Owner'S Service Manual

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Summary of Contents for RM 250 2003

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