1996–2002 Suzuki RM250 Owner´s Service Manual (P/N C4085-91017)

• Covers 1996–2002 Suzuki RM250 motorcycles, focusing on 2-stroke engine maintenance, drivetrain, and chassis tuning for competition-grade performance
• Official Suzuki owner's service publication, first edition covering the 1996–2002 RM250 series, P/N C4085-91017
• Contains 51 exploded-view diagrams, 39 troubleshooting charts, and 45 technical specification tables covering torque, tolerances, and fluid capacities
• This 185-page manual is the primary reference for the 1996–2002 Suzuki RM250, including essential specifications for Keihin carburetor tuning and suspension setup

Component and Systems Coverage

The 1996–2002 Suzuki RM250 service manual provides a comprehensive look at the machine's primary assemblies. Chapters are dedicated to general service instructions, periodic maintenance schedules, and systematic troubleshooting for engine and chassis performance. The engine section details dismounting, cylinder head and piston maintenance, clutch assembly, kick starter systems, and transmission rebuilds. Fuel and cooling systems are documented with specific diagrams for hose routing, jetting, and radiator inspection.

The chassis and suspension sections cover front fork adjustment—including compression and rebound damping—and rear suspension sag measurement. Electrical component location and connection points are included to assist in maintenance. Every section is supported by detailed exploded-view illustrations identifying all major fasteners and components for precise reassembly.

Specification Highlights and Technical Data

This publication includes critical service values for tuning the 2-stroke engine and suspension geometry. Cylinder head nut torque is listed at 25 Nm (18.0 ft-lb) for standard assembly. Engine coolant capacity is managed via a 50:50 ratio of anti-freeze to distilled water. Drive chain slack is specified at 40–50 mm (1.6–2.0 in) to maintain performance during competition.

Cylinder head distortion is documented at a service limit of 0.05 mm. Piston pin bore service limit is specified at 18.030 mm. Brake pedal play is defined as 5–15 mm at the pedal end for optimal braking response. An official 185-page Suzuki OEM owner's service manual covering the 1996–2002 RM250, documenting engine, chassis, electrical, and carburetor specifications for the high-performance 2-stroke race-ready build.