2004 Suzuki RM250 Workshop Manual

2004 Suzuki RM250 Factory Service Manual

• This factory-authorized publication covers the 2004 Suzuki RM250, documenting precise service specifications and maintenance data for this 249cc motocross machine.
• Official Suzuki Motor Corporation publication 99000-20803, copyright 2003, detailing the K4 production series specifications.
• Documents hundreds of critical engine and chassis clearances including crankshaft runout, cylinder bore measurements, and clutch plate thickness service limits.
• Includes over 75 exploded-view diagrams showing torque values, fluid-application points, and component assembly order for the engine, transmission, and suspension systems.
• Downloads to your account within seconds of checkout.
• Your order stays downloadable from your account for life.
• Laid out for standard letter and A4 printing.
• Full-text search finds any part number in seconds.
• This 229-page technical reference is the original workshop documentation used for the 2004 RM250 model, providing the definitive baseline for engine, cooling, and fuel system maintenance.

Component and System Documentation

The 2004 Suzuki RM250 service manual provides a structured overview of the motorcycle, beginning with general information, serial number locations, and operating instructions. Periodic maintenance sections outline the necessary intervals for inspecting the fuel system, drive chain, and engine cooling components. Comprehensive chapters then detail the dismounting and mounting of the 249cc engine, followed by internal specifications for the piston, cylinder head, and clutch assembly. The transmission and crankshaft section provides clear visual mapping of gear clusters and bearing locations alongside documented service limits for wear and runout.

Engine and Fuel System Specifications

Technical Reference and Fluid Data

The manual documents precise setup parameters for the Keihin carburetor, listing standard jetting configurations for various operational conditions. Carburetor float height is documented at 6.5 mm ± 1.0 mm for proper fuel delivery. Cylinder head nut torque values are specified in a multi-stage sequence, with a final tightening value of 25 Nm. Clutch spring bolt torque is specified at 5 Nm. Crankcase bolt torque is listed at 11 Nm in the assembly data. Transmission oil capacity is specified at 750 ml for routine changes, while the cooling system capacity is 1100 ml. This official Suzuki workshop manual serves as the primary technical resource for owners and technicians performing precision maintenance on the 2004 Suzuki RM250, including detailed specifications for engine, chassis, fuel, and transmission systems.