2004-2006 Suzuki RM-Z 250 Motorcycle Service Manual

2004–2006 Suzuki RM-Z 250 and Kawasaki KX250F Motorcycle Manual Features

• Covers the 2004–2006 Suzuki RM-Z 250 and Kawasaki KX250F, including the N1 variant with DOHC 4-valve liquid-cooled engine
• Original OEM publication, Second Edition (1), dated January 16, 2004
• Includes 17 chapters of technical documentation, over 50 component exploded-view diagrams, and comprehensive torque-specification tables
• Downloads to your account within seconds of checkout
• Permanent availability in your purchase account — no re-buy required
• Laid out for standard letter and A4 printing
• OCR text layer lets you jump to a torque spec by keyword
• This 2004 publication is the primary technical reference for the N1-series engine and chassis assembly used across both brands

System Coverage and Documentation

This factory service 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, detailing requirements for the fuel system, engine top end, cooling circuit, and electrical diagnostics. Each chapter contains specific information for disassembly, inspection, and reassembly, with exploded-view illustrations clearly identifying parts that require specialized torque settings, locking agents, or lubrication.

Specifications and Reference Values

Technical Data Preview

The 2004–2006 Suzuki RM-Z 250 and Kawasaki KX250F 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. The cooling system capacity for the 2004–2006 Kawasaki KX250F is documented at 1.20 liters. Detailed torque requirements are provided for all major fasteners, including the 50 Nm specified for cylinder head bolts in the engine top end section. Reference values are included for transmission gear ratios, suspension oil volumes, and tire pressures, providing a complete technical overview of factory workshop documentation for these racing-focused machines. All service data is intended for reference only; qualified technicians and the original OEM documentation remain the authoritative source for any hands-on work. An official 358-page Kawasaki OEM service manual covering the 2004–2006 Suzuki RM-Z 250 and Kawasaki KX250F, documenting engine, chassis, electrical, and fuel-system specifications for the N1-series build.