Suzuki RM-Z 250 . K6 2002-2005r. Service Manual (ID=1053).pdf

RM-Z250

99500-42182-01E

FOREWORD

This manual contains an introductory description on the SUZUKI RM-Z250 and procedures for its

inspection/service and overhaul of its main components.

Other information considered as generally known is not included.

Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance.

Use this section as well as other sections as a guide for proper inspection and service.

This manual will help you know the motorcycle better so that you can assure your customers of fast and

reliable service.

* This manual has been prepared on the basis of the latest specifications at the time of publication. If

modifications have been made since then, differences may exist between the content of this manual

andthe actual motorcycle.

*Illustrations in this manual are used to show the basic principles of operation and work procedures.They

may not represent the actual motorcycle exactly in detail.

*This manual is written for persons who have enough knowledge, skills and tools, including special tools,

for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your

authorized SUZUKI motorcycle dealer to help you.

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able

to properly perform the services described in this manual. Improper repair may result in injury to

the mechanic and may render the motorcycle unsafe for the rider.

COUNTRY AND AREA CODES

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

MODEL

CODE

COUNTRY or AREA

EFFECTIVE FRAME NO.

E-03

E-28

E-19

E-24

E-03

E-28

E-19

E-24

E-03

E-28

E-19

E-24

U.S.A.

Canada

Australia

U.S.A.

Canada

Australia

U.S.A.

Canada

Australia

JKSKXCPC 4A000001 –

JKSKX250NPA000001 –

JKSKXCPC 4A000001 –

JKSKXCPC 5A009001 –

JKSKX250NPA009001 –

JKSKXCPC 5A009001 –

JKSKXCPC 6A015001 –

JKSKX250NPA015001 –

JKSKXCPC 6A015001 –

List of corresponding materials and tools

Select applicable model, lubricant, adhesive, sealing agent, oil or special tools referring to this list when

reading this manual.

Lubricant Bond, Sealant and Oil

Symbol mark or defi-

nition in this manual

Suzuki

recomended lubrcant,

bond sealant

G: Apply grease

99000-25010

Suzuki Super grease

“A” or equivalent

L: Apply a non-perma-

nent locking agent

99000-32110

Suzuki Thread Lock

Super “1322” or

equivalent

56019-1063

Kawasaki Bond

(Liquid Gasket-Gray)

99000-31230

Suzuki Bond “1216B”

Front fork oil

KAYABA 01 or SAE

99000-99044-L01

Suzuki fork oil

L01 or an equivalent

fork oil

Rear shock absorber

oil

KYB K2-C or an equiv-

alent Rear shock

absorber oil

Rear shock absorber

oil

KYB K2-C or an equiv-

alent Rear shock

absorber oil

SPECIAL TOOLS

Base Manual Tools

SUZUKI Recommend

tools

Base Manual Tools

SUZUKI Recommend

tools

57001-122

Fuel level gauge,

M18 × 1.0

KK570-01122

Fuel level gauge,

M18 × 1.0

57001-137

Steering stem bea-

ring driver

09941-74910

Steering bearing

installer

09915-74511

Oil pressure gauge

57001-143

Inside circlip pliers

09900-06108

Snap ring pliers

57001-125

Oil pressure gauge

5 kgf/cm 2

09915-74550

Oil pressure gauge

adapter

57001-144

Outside circlip pliers

09900-06107

Snap ring pliers

57001-135

Bearing puller

KK570-01135

Bearing puller

57001-221

Compression gauge

20 kgf/cm 2

09915-64512

Compression gauge

Base Manual Tools

SUZUKI Recommend

tools

Base Manual Tools

SUZUKI Recommend

tools

57001-241

Valve spring

compressor assembly

09916-14510

Valve lifter

09923-74511

Bearing remover

57001-1063

Rim protector

09941-94510

Rim protector

09930-30104

Slide shaft

57001-1072

Bead breaker

assembly

KK570-11072

Bead breaker

assembly

57001-1058

Oil seal & Bearing

remover

09941-64511

Bearing & Oil seal

remover

57001-1095

Piston ring

compressor grip

09916-74512

Piston ring

compressor

57001-1097

Piston ring

compressor belt

É 67 – É 79

09916-74550

Piston ring holder

band

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