2004–2007 Suzuki RM-Z250 K4/K5/K6 Service & Repair Manual (P/N 99500-42182-01E)

This Suzuki factory service manual covers the RM-Z250 K4, K5, and K6 variants for the U.S., Canada, Europe, and Australia. Publication 99500-42182-01E is the third edition, issued in July 2005.

• Engine repair: Engine removal, cylinder-head overhaul, valve-seat repair, camshaft installation, piston inspection, and crankcase separation.

• Clutch and transmission: Wet multi-disc clutch service, plate inspection, external shift-mechanism repair, and internal transmission disassembly and assembly.

• Fuel and intake: Keihin FCR-MX37 carburetor overhaul, fuel-level inspection, accelerator-pump adjustment, air-cleaner service, and throttle and hot-start cable checks.

• Cooling and lubrication: Cooling-system pressure testing, water-pump repair, oil-pressure measurement, and feed and scavenging oil-pump inspection.

• Brakes and wheels: Caliper seal replacement, master-cylinder service, hydraulic bleeding, brake-disc inspection, and wheel-bearing replacement.

• Suspension: Upside-down fork disassembly, seal and bushing replacement, rear-shock oil changes, and Uni-Trak linkage inspection.

• Electrical diagnosis: Digital AC-CDI tests, magneto and ignition-coil checks, throttle-sensor adjustment, wiring diagrams, and an ignition troubleshooting flowchart.

Written primarily for trained mechanics with a properly equipped shop, the manual also supports basic owner maintenance where the necessary mechanical knowledge and tools are available.

Engine, Valve Train, and Transmission

Valve-clearance checks include shim-selection calculations and a shim parts table. The top-end chapter covers valve-guide replacement, valve-seat cutting, cylinder inspection, and piston-ring wear checks.

The camshaft caps are machined with the cylinder head; the manual warns that incorrect cap placement can cause camshaft seizure.

Bottom-end work: Crankshaft inspection includes runout and connecting-rod clearance measurements. Crankshaft rebuilding requires a shop with the necessary precision equipment. The crankcase section provides a separate bolt-tightening diagram from engine No. KX250NE014233.

Transmission coverage extends to shaft assembly, shift-fork identification, gear-dog inspection, and shift-drum wear checks. Clutch documentation includes release-lever position checks and adjusting-washer selection.

Carburetor and Intake Service

The FCR-MX37 section distinguishes service fuel level from float height and covers accelerator-pump timing, jet inspection, and throttle-sensor positioning. Carburetor exploded views identify the hot-start plunger, leak jet, and pump diaphragm.

Cooling and Semi-Dry Sump Lubrication

Radiator-cap inspection, system pressure testing, water-pump seal replacement, and air bleeding are documented. Separate K4 and K5/K6 oil-filter and water-pump-cover instructions help you choose the procedure that matches the installed covers before disassembly.

The Lubrication System Chart traces the feed and scavenging circuits. The oil-filter instructions warn that reversed installation blocks oil flow and can cause engine seizure.

Ignition Tests and Fault Tracing

Magneto-output and stator-resistance tables distinguish the relevant lead connections, including K5-onward changes. Peak-voltage checks cover the ignition coil, crankshaft sensor, exciter coil, and charge coil.

The Wiring Diagram, throttle-sensor test connections, and ignition troubleshooting flowchart help narrow down weak-spark faults before replacing the CDI unit. The appendix adds common-symptom troubleshooting and Cable, Wire, and Hose Routing views.

Suspension, Brakes, and Chassis

Fork settings distinguish EU and other-market applications, with K5-onward changes identified. Rear suspension coverage includes spring preload, damping adjustment, and swingarm, tie-rod, and rocker-arm bearing service.

Rear-shock gas charging requires a qualified mechanic because the reservoir contains high-pressure nitrogen. Improper assembly can cause mechanical failure or injury.

Brake inspection includes master-cylinder bores and cups, caliper-holder wear, and pad condition. Steering-bearing service, wheel alignment, drive-chain and sprocket checks, and inspection of the tubular semi-double cradle frame are also covered.

Workshop references: The Periodic Maintenance Chart, torque and locking-agent tables, unit-conversion table, and special-tool cross-reference support the procedures. The latter pairs base-manual crankcase splitting tool 57001-1362 with Suzuki tool 09920-13120.

A Preview of Fluid Capacities and Wear Limits

These figures are a small selection of the manual's fluid-capacity and inspection specifications.

Fluid capacities: Engine oil capacity is 1.5 L with the engine completely dry; routine oil-change quantities are listed separately. Total coolant capacity is 1.2 L.

Wear checks: Connecting-rod big-end side clearance is 0.25–0.35 mm standard, with a 0.55 mm service limit. Front brake-pad lining thickness is 3.8 mm standard, with a 1 mm service limit.

Searchable Text, Chapter Bookmarks, and PDF Contents

Search and diagram detail: Body text is searchable, and bookmarks open the main chapters. Wiring-diagram and ignition-flowchart labels are not text-searchable. Small wiring labels and sensor-connection details are legible when enlarged.

Supplied as one printable, English-language 364-page PDF. The total includes 347 chapter and appendix pages, 15 opening pages with the cover and tool-reference material, and two closing publication/back-cover pages.