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2004 Suzuki RM-Z250 service manual

Models covered in this manual:

RM-Z250 / Suzuki Motor Corporation

Production year(s): 2004

File specifications

File size: 56.30 MB
File type: PDF
Language: _Language:_ English (some of our manuals are multi-language)

Printable: Yes
Estimated download time: 1.15 Minutes
$18.99 Instant Download

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Product Information

Table of Contents

1. General Information

  • Foreword
  • General precautions
  • Specifications
  • Technical data

2. Periodic Maintenance

  • Maintenance schedule
  • Maintenance procedures
  • Lubrication points
  • Tightening torques
  • Special tools

3. Fuel System

  • Fuel tank
  • Fuel pump
  • Fuel filter
  • Carburetor
  • Throttle body

4. Cooling System

  • Radiator
  • Water pump
  • Thermostat
  • Cooling fan
  • Coolant replacement

5. Engine Top End

  • Cylinder head
  • Valve mechanism
  • Cylinder and piston

6. Engine Right Side

  • Clutch
  • Crankshaft

7. Engine Lubrication System

  • Oil pump
  • Oil filter
  • Lubrication routes

8. Engine Removal/Installation

  • Engine removal procedure
  • Engine installation procedure

9. Crankshaft/Transmission

  • Crankshaft removal and installation
  • Transmission removal and installation
  • Gear shifting mechanism

10. Wheels/Tires

  • Wheel removal and installation
  • Tire inspection
  • Tire replacement

11. Final Drive

  • Drive chain
  • Sprockets
  • Final drive inspection

12. Brakes

  • Brake system overview
  • Brake pad replacement
  • Brake disc inspection
  • Brake fluid replacement

13. Suspension

  • Front suspension
  • Rear suspension
  • Suspension adjustment

14. Steering

  • Steering head
  • Handlebar

15. Frame

  • Frame inspection
  • Frame repair

16. Electrical System

  • Wiring diagram
  • Battery
  • Charging system
  • Ignition system
  • Lighting system
  • Indicators
  • Sensors
  • Switches

17. Appendix

  • Troubleshooting
  • Service data
  • Diagnostic procedures
  • Special tools

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