Enter a keyword to search over 12,000 manuals:

2003-2004 Suzuki RM250 service, repair manual

Price: 18.99 USD
Lifetime Guarantee
File specifications File size: 30.43 MB File ending in: pdf
To make it easier for you to choose the right manual, we have compiled various information for you below, such as model designations, types, and production years. The following models are included in this manual: RM250 / Suzuki Motor Corporation 2003 Suzuki RM250 2004 Suzuki RM250 Engine: 249 cc, two-stroke, single cylinder, liquid-cooled, AETC, crankcase reed, 2.6x2.8 in OR 66 mm, 8.8-10.6:1, 55/8000 KW(hp)/RPM, 37/7500 lb-ft/RPM OR 50/7500 Nm/RPM, Keihin PWK38S carburetor. Production year(s): 2003-2004 Number of pages: 229 Language: English (some of our manuals are multilanguage) # ³ "Download Your Motocross Motorcycle Manual Now: Fix Suzuki RM250 Issues Like a Pro!" A pinnacle of performance in its era, the 2003-2004 Suzuki RM250 is a motocross motorcycle that is still respected and adored by off-road enthusiasts today. Its unique blend of high-revving power, adept handling, and steadfast reliability made it a popular choice among both amateur and professional riders. This detailed guide provides comprehensive data, maintenance tips, and insightful reviews to help you get the most out of your RM250. Engine Specifications/Technical Data: • The Suzuki RM250 is powered by a liquid-cooled, single-cylinder, two-stroke engine. • This engine has a displacement of 249cc. • The bore and stroke measurements are 66.4 mm and 72 mm, respectively. • The compression ratio of the RM250 is 8.6:1. • The fuel system utilizes a Mikuni TMX38S carburetor. • A digital CDI ignition ensures reliable startups and smooth performance. • The engine transfers power through a manual, five-speed gearbox. • The transmission features a wet multi-disc, manual clutch. • Suzuki employed a unique exhaust valve system known as the Advanced Power Exhaust System (A-PEX). • The RM250 utilizes a liquid-cooled system with a high-capacity radiator. • The fuel tank capacity of the RM250 is approximately 2.11 gallons. • The bike uses a high-capacity air filter for optimum engine protection. • It utilizes a lubrication system called Fuel and oil mixed lubrication. • The RM250 comes equipped with a Suzuki Holeshot Assist Control (S-HAC) to enhance the launch. • Suzuki integrated a Progressive Linkage system for smooth power delivery. • The bike uses a Keihin PWK38S AG carburetor to fuel the engine. • The RM250 is designed with an aluminum, twin-spar frame for maximum strength and minimal weight. • The engine's power delivery is optimized by an expansion chamber shape exhaust. • The RM250 has a power output of approximately 46 horsepower. • It features a unique close-ratio transmission for maximum performance on the race track. • The bike uses a race-proven, large-diameter front forks for superior handling. • The rear suspension features a Showa piggyback-reservoir shock for improved damping performance. • Suzuki has installed a Renthal aluminum handlebar for a reduction in overall weight. • The RM250 has a ground clearance of approximately 14.6 inches. • The bike has a seat height of about 37.4 inches. • The dry weight of the RM250 is around 209 pounds. • The wheelbase measures approximately 58.1 inches. Facts and Details: - The RM250 was Suzuki's top-tier motocross bike for the 2003-2004 model years. - It was known for its exceptional handling, making it a favorite among motocross riders. - The bike came with an advanced suspension setup, featuring fully adjustable Showa components. - It was one of the first bikes to feature Suzuki's Progressive Linkage system, enhancing its off-road performance. - The bike's slim, lightweight design allowed for exceptional maneuverability. - The RM250 came with a gripper seat, providing excellent grip and rider control. - It was recognized for its powerful two-stroke engine and responsive power delivery. - The RM250 was also praised for its high-quality construction and reliability. - Suzuki offered the RM250 in a distinctive yellow and blue color scheme. - The bike featured aggressive styling that was modern and appealing. - The RM250 was an exceptional performer on the track, consistently earning top spots in motocross events. - The bike's A-PEX system optimized power output at high rpm, delivering an edge in competitive racing. - It featured Suzuki's Holeshot Assist Control (S-HAC), offering riders an advantage at the start of races. - Despite its powerful performance, the RM250 was known for its user-friendly nature, appealing to riders of various skill levels. - The 2003-2004 Suzuki RM250 remains a sought-after bike in the used motocross market due to its performance and durability. - This bike was the last of the RM two-stroke series to feature significant updates before the production of two-stroke motocross bikes was phased out by Suzuki. Maintenance Intervals and Tips: ► Regularly change the oil: Every 5 to 10 hours of ride time is a good interval for a two-stroke like the RM250. ► Air filter maintenance: Clean the air filter after every ride or more often in dusty conditions. ► Spark Plug Check: Check the spark plug regularly, ideally every 5-6 hours of use, to ensure it's not fouled. ► Piston and Ring Replacement: For motocross bikes, these components usually require replacement every 20-30 hours of competitive use. ► Check and Adjust Valves: Inspect and adjust as needed every 20 hours of ride time. ► Clutch Inspection: For a motocross bike like the RM250, inspect the clutch every 10 hours of ride time. Common Issues and Solutions: * Piston and ring wear: This is a common issue for two-stroke bikes. Regular inspection and replacement are required. * Clutch wear: Regular inspection and adjustment will help you catch and resolve this problem early. * Fouled spark plug: If the bike doesn't start or runs poorly, check the spark plug. Replace if necessary. * Carburetor issues: Keep the carburetor clean to ensure optimal performance. If the bike is hard to start or idles poorly, a dirty carburetor might be the cause. * Suspension wear: Regularly inspect and maintain the suspension. If the bike handles poorly or feels loose, suspension components may need replacement. Maintenance Tips: ■ Regularly clean your RM250, especially after riding in muddy or dusty conditions. This will help to prevent build-up and corrosion. ■ Regularly lubricate the chain and adjust its tension as necessary. ■ Keep an eye on tire wear, and ensure they are always correctly inflated. ■ Regularly check and adjust the brake pads and fluids to ensure optimal stopping power. ■ Keep the air filter clean and replace it regularly to ensure optimal engine performance. Popular Tuning Tips and Modifications: + Jetting the Carburetor: Fine-tuning the carburetor can optimize power output and fuel efficiency. + Suspension Upgrades: Upgrading the suspension components can improve handling and rider comfort. + Performance Exhaust: A performance exhaust system can increase horsepower and torque. + Reeds: Upgraded reed valves can improve throttle response and power. + Sprocket Change: Changing the sprocket sizes can fine-tune the bike's performance to better suit specific tracks or riding styles. Accessories and Attachments: ♦ Skid Plates: Provides protection for the underside of the bike. ♦ Performance Air Filter: Enhances airflow to the engine for improved performance. ♦ Aftermarket Exhaust Systems: Improve performance and sound. ♦ Hand Guards: Provide protection for the rider's hands and the bike's levers. ♦ Custom Graphics Kit: Personalize your bike's appearance. ♦ Aftermarket Seats or Seat Covers: Improve comfort and grip. ♦ Aftermarket Handlebars: Customize for rider comfort and control. ♦ Radiator Guards: Protect the radiator from damage during rides. ♦ High-Performance Tires: Improve grip and performance on various terrains. ♦ Performance Brake Pads and Rotors: Improve braking performance and feel. Owner Reviews and Opinions: Most owners appreciate the RM250 for its powerful two-stroke engine, exceptional handling, and overall reliability. The bike's lightweight design and advanced suspension system allow it to perform exceptionally well in off-road conditions. However, some owners mention the need for regular maintenance, particularly for the engine, as a point of contention. While this is common for two-stroke engines, new riders might find it overwhelming. Nevertheless, the consensus among RM250 owners is overwhelmingly positive. Common Repairs and Parts that Often Break: → Piston and ring replacement due to wear. → Clutch replacement or adjustment due to wear. → Spark plug replacement due to fouling. → Air filter replacement due to dirt accumulation. → Brake pad and rotor replacements due to wear. → Chain and sprocket replacements due to wear. → Suspension maintenance or replacement due to wear or damage. → Tire replacements due to wear. → Carburetor cleaning or replacement due to clogging. → Radiator maintenance or replacement due to leaks or clogs. The 2003-2004 Suzuki RM250 is a fantastic motocross motorcycle that shines in its performance, handling, and reliability. Despite its age, the RM250 remains a competitive machine in off-road environments and is praised for its top-tier construction and user-friendly nature. Regular maintenance, especially of the engine, is necessary to keep this two-stroke powerhouse running smoothly. With proper care, the RM250 can offer an unbeatable motocross experience that suits riders of various skill levels. Whether it's the thrill of the race or the passion for off-roading, the RM250 is a choice that won't disappoint. Make your PayPal purchase now and download the Suzuki RM250 manual in PDF format. After completing your payment, the download link for the OEM Suzuki parts list and shop manual will be available on the checkout page. Additionally, a confirmation of your payment will be promptly sent to your email. §
Price: 18.99 USD
Lifetime Guarantee
Manuals which could also interest you:
2003-2009 Suzuki RM250 service manual

you to choose the right manual, we have compiled various information for you below, such as model designations, types, and production years. The following

2000 Suzuki RM250 service manual

you to choose the right manual, we have compiled various information for you below, such as model designations, types, and production years. Service/Repair your

2003-2004 Suzuki RM250 repair, service manual

you to choose the right manual, we have compiled various information for you below, such as model designations, types, and production years. Repair/Service your

Add Comment

* Required information
Captcha Image
Powered by Commentics


No comments yet. Be the first!