SUZUKI RM250 REPAIR SHOP & SERVICE MANUAL 1996 1997 1998 1999 2000 2001 2002

THE COMPLETE, LARGEST & EASY-TO-USE REPAIR & RESTORER MANUAL FOR

SUZUKI RM250 OFF-ROAD MOTORCYCLES

1996 ~ 2002

This repair manual covers Suzuki RM250 1996-2002, including RM250T, RM250V, RM250W, RM250X, RM250Y, RM250K1 and RM250K2.

THIS ESSENTIAL 344 PAGE REPAIR MANUAL IS A MUST FOR OWNERS & MECHANICS

Table of Contents

QUICK REFERENCE DATA

CHAPTER ONE: GENERAL INFORMATION

Manual organization | Warnings, cautions and notes | Safety | Serial numbers | Fasteners | Shop supplies | Basic tools /Special tools | Precision measuring tools | Electrical system fundamentals | Basic service methods | Storage | Specifications

CHAPTER TWO: TROUBLESHOOTING

Operating requirements | Starting the engine | Engine performance | Starting system | Charging system | Ignition system | Engine management system diagnostic codes | Fuel system | Engine noises | Engine lubrication | Clutch | Transmission | Lighting system | Excessive vibration | Front suspension and steering | Brake problems | Specifications

CHAPTER THREE: LUBRICATION, MAINTENANCE and TUNE-UP

Routine safety checks | Tires and wheels | Periodic lubrication | Periodic maintenance | Tune-up | Idle speed adjustment | Specifications

CHAPTER FOUR: ENGINE

Service precautions | Special tools | Servicing engine in frame | Engine | Rocker arms and pushrods | Cylinder head | Valves and valve components | Cylinder | Pistons and piston rings | Pushrods | Valve lifters | Oil pump | Oil tank and oil lines | Camshaft support plate | Crankcase and crankshaft | Counter balancer assembly | Engine break-in | Specifications

CHAPTER FIVE: CLUTCH and PRIMARY DRIVE

Primary chaincase cover | Clutch assembly | Clutch shell, compensating sprocket and primary drive chain | Clutch shell, clutch hub and sprocket | Primary chain and guide inspection | Primary chain alignment | Compensating sprocket inspection | Primary chaincase housing | Starter jackshaft | Clutch cable replacement | Specifications CHAPTER SIX: TRANSMISSION

Shifter assembly | External shift mechanism | Transmission top cover | Shift cam | Shift arm assembly | Shift forks | Transmission side door and transmission shaft assemblies | Transmission shafts | Main drive gear | Transmission clutch release mechanism cover | Transmission drive sprocket | Transmission case | Specifications

CHAPTER SEVEN: FUEL, EXHAUST and EMISSION CONTROL SYSTEMS

Air filter backplate | Carburetor | Intake manifold | Electronic fuel injection | Depressurizing the fuel system | Induction module | Throttle and idle cables | Starting enrichment valve (choke) cable replacement | Throttle and idle cables | Fuel tank console | Fuel hose and clamps | Fuel tank | Fuel tank inspection | Fuel pump and fuel filter | Fuel shutoff valve | Fuel tank gauge | Exhaust system | Evaporative emission control system | Specifications

CHAPTER EIGHT: ELECTRICAL SYSTEM

Electrical connectors | Battery | Charging system | Alternator | Voltage regulator | Ignition system | Starting system | Lighting system | Switches | Horn | Electrical panel | Turn signal module | Turn signal module and turn signal/security module | Speedometer speed sensor | Starter relay switch replacement | Speedometer and indicator lights | Fuses | Circuit breaker | Electrical connector service | Wiring diagrams | Specifications

CHAPTER NINE: WHEELS, HUBS and TIRES

Motorcycle stands | Front wheel | Rear wheel | Front and rear hubs | Driven sprocket assembly | Drive sprocket | Drive belt | Wheel runout | Rim and laced wheel service | Disc and cast wheels | Wheel balance | Tires | Tire changing | Tire repairs | Tire runout | Specifications

CHAPTER TEN: FRONT SUSPENSION and STEERING (TELESCOPIC FORK)

Handlebar | Front fork | Steering head and stem | Steering head bearing race replacement | Steering play adjustment | Specifications

CHAPTER ELEVEN: FRONT SUSPENSION and STEERING (SPRINGER FORK)

Springer service precautions | Handlebar and risers | Shock absorber | Fork rockers | Springer fork | Rigid fork | Steering stem | Steering play adjustment | Specifications

CHAPTER TWELVE: REAR SUSPENSION

Spring preload adjustment | Shock absorbers | Rear swing arm | Specifications

CHAPTER THIRTEEN: BRAKES

Brake service | Front brake pad replacement | Front brake caliper | Brake reaction link | Front brake caliper | Front master cylinder | Rear brake pad replacement | Rear brake caliper | Rear master cylinder | Brake hose and line replacement | Brake disc | Bleeding the system | Rear brake pedal | Specifications

CHAPTER FOURTEEN: BODY

Seat | Front fender | Rear fender inner panel | Rear fender | Footboards and footrests

INDEX | COLOR WIRING DIAGRAMS

Clymer motorcycle repair manuals can save you money on maintenance and repair bills. Step-by-step procedures and detailed illustrations guide you through every job, from maintenance and troubleshooting, all the way to complete teardown and rebuild.

CONDITION: NEW

SIZE: 7 1/2 x 11

FORMAT: GLOSSY HEAVY PAPER STOCK COVER

NUMBER OF PAGES: 344

PROFUSELY ILLUSTRATED WITH HUNDREDS OF ORIGINAL PHOTOS & DRAWINGS