2004 Suzuki RM250 Workshop Manual

Technical reference covering the 2004 Suzuki RM250 motorcycle, including engine, chassis, electrical, and suspension systems. Ref: 99000-20803

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Document Details

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Document Number / Seller:
26195 / Jerry Lewis
File Size:
89.65 MB
File Type:
PDF
Language:
English
Pages:
229
Printable:
Yes
Category:
Motorbike
Last updated / verified
Jan 6, 2026

Models Covered & Key Technical Specifications

Suzuki RM250 (2004) Workshop Manual | Factory Manual PDF Suzuki RM250 (2004) (99000-20803) | K4 Series Library

  • Designated Production Rate: 249cc provides the primary engine displacement Volume.
  • Primary Physical Specs: 10,500 RPM establishes the maximum engine operating limit Parameters.
  • Advanced Output Quality: 5-speed constant mesh transmission defines the core gearing system Configuration.
  • Defined Fill Levels: The fuel tank requires 8.0 L for standard operation Capacity.
  • Key Assembly Gap: The transmission oil capacity is specified as 750 ml (Change) Baseline.
  • Essential Print Rate: The spark plug gap requires 0.5 – 0.6 mm for optimal performance Requirements.

Professional Workshop Service Manual & Technical Specifications

Suzuki RM250 (2004) Workshop Manual: Detailed Owner's Service Manual for Suzuki RM250 Motorcycle (2004) - 229 P. | Factory Grade Repository

Documentation-Type: Workshop Manual // Series-Validation: K4 / Motorcycle Logic // Engineering-Base: Technical Repair Procedures.

Specification Technical-Path Logic
Model Suzuki RM250 K4 Model Year
Page Count 229 Document Length
File Size 89.6483 MB Digital Storage Medium
Language English Communication Protocol

Repair data is categorized into the following sections, providing a comprehensive overview of the RM250:

Clearance measurements are addressed for the front and rear suspension systems, detailing adjustments and specifications.

Special procedures are addressed for engine disassembly and mounting, including critical torque values for fasteners.

Verification procedures are included for electrical system components, with schematics and testing methods.

Repair information is provided for the fuel system, covering carburetor tuning and settings for optimal performance.

The document includes coverage of periodic maintenance schedules, essential for longevity and reliability.

This manual documents torque specifications for critical engine and chassis components to ensure proper dynamic load distribution.

FAQ

Calculate the **precise** pressure specifications for the cooling system. keyboard_arrow_down

95 – 125 kPa (0.95 – 1.25 kgf/cm², 14 – 18 psi) is the specified range for the radiator cap valve pressure.

What values for **proper** assembly sequence are needed for the front wheel? keyboard_arrow_down

Axle nut: 35 N·m (3.5 kgf-m, 25.5 lb-ft) and Axle holder bolt: 18 N·m (1.8 kgf-m, 13.0 lb-ft) are the critical torque values for front wheel assembly.

Assess the **standard** service interval parameters for periodic maintenance. keyboard_arrow_down

Spark plugs require replacement every 6 hours, and air filter cleaning is recommended every 2 hours of racing or every 3 races.

What components are part of the **necessary** system architecture for the electrical system? keyboard_arrow_down

The electrical system includes the CDI unit, ignition coil, spark plug, carburetor solenoid, and throttle position sensor, detailed in circuit diagrams.

Confirm the **recommended** tool requirements for rear shock absorber disassembly. keyboard_arrow_down

A universal clamp wrench (09910-60611) and a bearing remover set (09921-20240) are required for rear shock absorber disassembly and bearing replacement, with detailed steps on pages 194-200.

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Reviews (4)

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This manual is incredibly detailed and user-friendly. It helped me with maintenance tasks I was previously unsure about. Highly recommend!
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This manual provides essential information for keeping my RM250 in top shape. I had a quick response from support when I needed clarification. Excellent!
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The download process was smooth, and the support team was very responsive when I had questions. This manual covers everything you need to know.
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I appreciate the clear instructions on engine care and maintenance schedules. The email with the download link arrived promptly. Great service!