2004-2006 Suzuki RM-Z 250 Factory Service Manual (PN 99000-10910)

• Covers the 2004–2006 Suzuki RM-Z 250 and Kawasaki KX250F, including the N1 variant with the DOHC 4-valve liquid-cooled engine.
• Official 358-page OEM publication (PN 99000-10910, Second Edition, January 2004).
• Contains 17 chapters of technical documentation and descriptive repair data, featuring over 50 component exploded-view diagrams.
• Primary technical reference for the N1-series engine and chassis assembly used across both brands.

System Coverage and Documentation

This factory publication provides complete maintenance, adjustment, and assembly data for the 2004–2006 Suzuki RM-Z 250 and Kawasaki KX250F. The document is organized by major motorcycle system. It details baseline requirements for the fuel system, engine top end, cooling circuit, and electrical diagnostics. Each chapter outlines component sequences for disassembly, inspection, and reassembly. Exploded-view illustrations clearly identify parts requiring specialized torque settings, locking agents, or lubrication. This documentation streamlines complex repair work by eliminating guesswork during critical assembly stages.

Specifications and Reference Values

The engine is specified with a 249 mL displacement and a 12.6:1 compression ratio. Standard valve clearance for the intake is listed at 0.10–0.15 mm in the cylinder head specification table. Cooling system capacity is documented at 1.20 liters. Detailed torque requirements are provided for all major fasteners. For instance, the cylinder head bolts in the engine top end section require exactly 50 Nm. Additional reference values cover transmission gear ratios, suspension oil volumes, and precise tire pressures. Working on high-performance motorcycles involves inherent physical risks and the potential for property damage. Always utilize standard workshop safety protocols when handling heavy components or combustible fluids. Ensure all service data and torque specifications are cross-checked against this authoritative OEM publication before executing any mechanical procedures.