Suzuki RM-Z250L9 Easy Set-Up Manual Download Page 34

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CABLE ROUTING

Throttle cable (Pulling)

Throttle cable (Returning)

Clutch cable

Pass the throttle cables and clutch cable between the number plate mounting bolts.

Pass the clutch cable in front of the throttle cables.

Clamp

Cable guide

Throttle cable (Pulling)

Throttle cable (Returning)

Clutch cable

Clamp

(White tape position)

Pass the throttle cables and clutch cable under the
radiator joint upper hose and radiator overflow hose.

Throttle cable (Returning)

Throttle cable (Pulling)

Throttle cable (Returning)

0 – 1.5 mm

Pass the throttle cables between the radiator and frame.

Radiator

Throttle cable (Pulling)

Throttle cable (Returning)

Cable guide

Summary of Contents for RM-Z250L9

Page 1: ...ully To emphasize special information the symbol and the words WARNING CAUTION NOTICE and NOTE have special meanings Pay particular attention to messages highlighted by these signal words Indicates a...

Page 2: ...or where it is clean and spacious This photograph is not for this model This photograph is not for this model CAUTION Assembling the vehicle without proper clothes and protective gear can be hazardous...

Page 3: ...acket Remove the bolts to take off the rear wheel holding bracket A Bolt B Rear wheel holding bracket Remove the bolts from the crate A Bolt This photograph is not for this model This photograph is no...

Page 4: ...out the various component parts and spare parts packaged from the crate A Component parts B Spare parts LEFT CAUTION Careless steel frame separation can injure a person Lift the steel frame with two...

Page 5: ...uter gasket 1 3 Water pump case O ring 1 4 Sprocket spacer D ring 1 5 Engine oil filter comp 1 6 Exhaust pipe gasket 1 7 Muffler joint connector 1 8 Clutch lever 1 9 Brake lever 1 NOTE Please hand ove...

Page 6: ...w with lock washer 1 3 14 mm S HAC switch holder 2 Front and Rear Screw with lock washer 1 4 14 mm Clutch lever cover 1 Clutch adjuster cover 1 Item Part Name Q ty Remarks C Handlebar pad set 1 D Hold...

Page 7: ...the parts dismounted from the motorcycle in addition to the items shown in the preceding page A Front brake master cylinder B Throttle assembly Engine stop switch Clutch cable S HAC switch D D C C A...

Page 8: ...the bolt to take off the front brake master cyl inder from the bracket A Front brake master cylinder B Bolt C Bracket Remove the bolts to take off the bracket from the han dlebar holder A Bracket B B...

Page 9: ...clamp bolts to the specified torque Handlebar clamp bolt 25 N m 2 5 kgf m A 8 35 mm flange bolt B 8 35 mm flange bolt NOTE Check the spacer is onto the handlebars NOTE The dot mark on the clamp shows...

Page 10: ...D Engine stop switch wiring harness E S HAC switch wiring harness F Cable guide NOTE The line drawings on page 32 33 and 34 show the proper routing of the control cables hose and wirings Refer to them...

Page 11: ...0 mm of clearance between the grip end and the end of the handlebars Throttle case screw 3 8 N m 0 39 kgf m A Throttle assembly B Matching mark C 5 20 mm screw Fit the rubber cover onto the throttle...

Page 12: ...bolt 10 N m 1 0 kgf m A 6 22 mm flange bolt B 6 22 mm flange bolt C Holder D Front brake master cylinder E Handlebars NOTE Install the holder in position according to the mark UP Align the matching ma...

Page 13: ...arm Turn the clutch lever adjuster in as far as possible and align the slots Insert the inner cable end into the recess in the clutch lever then pull on the outer cable housing and insert it into the...

Page 14: ...C Holder Lower D Thread cutting Install the engine stop switch to the left of handlebars Engine stop switch screw 1 3 N m 0 13 kgf m A Engine stop switch B 3 14 mm screw with lock washer C Protrusion...

Page 15: ...will remove the rust preventive coating and dirt TAKING OUT THE MOTORCYCLE Bind a hoist band around the handlebar clamps as shown in the photograph A Hoist band 1 Lift the front of motorcycle by using...

Page 16: ...e the motorcycle on the stand then remove the hoist hook HANDLEBAR PAD Set the handlebar pad to the handlebar A Handlebar pad B Handlebars Install the handlebar pad cover as shown in the illus tration...

Page 17: ...B 6 12 mm flange bolt with washer C Front brake hose D Throttle cable E Clutch cable F S HAC switch wiring harness G Engine stop switch wiring harness Pass the strap of the number plate around the han...

Page 18: ...tank cap C Hole Steering shaft REMOVING THE WRAP FILM Remove the wrap film from the muffler A Muffler B Wrap film OWNER S MANUAL Remove the bolts to take off the seat A Seat B 6 16 mm flange bolt Spac...

Page 19: ...ll the seat Insert the seat hook into the seat hook retainer A Seat assembly B Seat hook C Seat hook retainer Tighten the bolts Seat mounting bolt 10 N m 1 0 kgf m A Front seat B 6 16 mm flange bolt S...

Page 20: ...l add the correct type of brake fluid Refer to the chart below for the proper selection Front reservoir cap screw A 1 5 N m 0 15 kgf m Rear reservoir cap screw B 1 5 N m 0 15 kgf m Specification and C...

Page 21: ...nd squeeze the lever Open the valve while squeezing brake lever 4 Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles 5 After bleeding the brake circuit tigh...

Page 22: ...nd cable B is for return ing Check the throttle cable play at the throttle grip Throttle cable play 2 0 4 0 mm If adjustment is necessary carry out the following pro cedure 1 Shift the rubber boot F 2...

Page 23: ...ace the rubber boot G 8 Fit the strap of the number plate C into the guide 9 Minor adjustments can now be made by using the clutch lever adjuster B provided with the adjuster cover A Clutch cable adju...

Page 24: ...SPENSION Move the front forks up and down several times Inspect for smooth movement and oil leakage REAR SUSPENSION Move the rear suspension up and down several times Inspect for smooth movement and o...

Page 25: ...rive chain slack is up and down at a point midway between the two sprockets 5 After adjusting tighten the axle nut to the specified torque 6 Tighten the lock nuts securely 7 Recheck the drive chain sl...

Page 26: ...tion of travel A Chain joint clip TIRE PRESSURE Check the air pressure of the front and rear tires by using an accurate air gauge The pressure should be as indicated in the table below COLD INFLATION...

Page 27: ...il from the oil filler hole 8 Remove the oil level bolt again and check that oil comes out from the oil level hole 9 After engine oil stops coming out reinstall the oil level bolt and the oil filler c...

Page 28: ...te clutch and transmission gears with engine oil JASO T903 specifies performance requirements for motorcycle and ATV clutches and transmission There are two classes MA and MB The oil container shows t...

Page 29: ...ct level IDLE SPEED ADJUSTMENT After completing all of the servicing procedures adjust the engine idle speed by turning the throttle stop screw knob Engine idle speed 2 150 2 250 r min A Throttle stop...

Page 30: ...ecs Confirm that all cables and wiring harnesses are con nected and routed correctly NOTE Use only premium unleaded gasoline with an octane rating of 95 or higher Research method or use only premium u...

Page 31: ...1 BRAKE G Front brake master cylinder mounting bolt 10 1 0 H Front brake caliper mounting bolt 26 2 7 I Rear brake master cylinder mounting bolt 10 1 0 Item Part Name N m kgf m BRAKE J Rear brake pus...

Page 32: ...32 3 2 23 0 12 50 5 0 36 0 14 72 7 2 52 0 16 116 11 6 84 0 A equivalent of 4T strength bolt with flange 18 176 17 6 127 5 Bolt type Thread diameter Nominal diameter A mm Unit N m kgf m lbf ft 4 2 3 0...

Page 33: ...SS ROUTING Clamp Engine stop switch lead wire S HAC switch lead wire Clamp Engine stop switch lead wire S HAC switch lead wire Clamp Engine stop switch lead wire Clutch cable Throttle cable Blue tape...

Page 34: ...Throttle cable Pulling Throttle cable Returning Clutch cable Clamp White tape position Pass the throttle cables and clutch cable under the radiator joint upper hose and radiator overflow hose Throttl...

Page 35: ...t upper hose and radiator overflow hose Pass the clutch cable behind the right radiator cushion Do not contact the clutch cable to the exhaust pipe Clutch cable bracket Fix the clutch cable aligning t...

Page 36: ...brake lever Check Adjust Adjuster length 11 15 mm Rear brake pedal Check Adjust Height 0 10 mm Clutch cable Check Adjust Play 2 0 3 0 mm Drive chain Check Adjust Lubricate Slack 35 45 mm Oiling point...

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Suzuki RM-Z250L9, Easy Set-Up Manual

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