SERVICE DATA
SERVICE DATA
Date: June 25, 2002
Model: RM250K3
2 STROKE
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
Unit: mm (in)
STD/SPEC.
0.0452 – 0.0550
(0.0018 – 0.0022)
66.400 – 66.415
(2.6142 – 2.6148)
Measure 20 (0.79) from the top surface.
66.350 – 66.365
(2.6122 – 2.6128)
Measure 25.5 (1.00) from the skirt end.
Cylinder bore
Piston diam.
Cylinder distortion
—
Cylinder head distortion
—
Piston ring free end gap
Piston ring end gap
Piston ring to groove
clearance
Piston pin bore
1st &
2nd
1st &
2nd
1st &
2nd
Piston pin O.D.
R
8.4
Approx. (0.33)
0.40 – 0.60
(0.016 – 0.024)
0.020 – 0.060
(0.0008 – 0.0024)
18.002 – 18.008
(0.7087 – 0.7090)
17.995 – 18.000
(0.7085 – 0.7087)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
LIMIT
0.120
(0.0047)
Nicks or
scratches
66.280
(2.6100)
0.05
(0.002)
0.05
(0.002)
6.7
(0.26)
0.80
(0.031)
—
18.030
(0.7098)
17.980
(0.7079)
Unit: mm (in)
STD/SPEC.
23.003 – 23.011
(0.9056 – 0.9059)
Conrod deflection
—
Conrod big end side clearance
—
LIMIT
23.040
(0.9071)
3.0
(0.12)
1.0
(0.04)
59.9 – 60.1
(2.358 – 2.366)
—
—
0.05
(0.002)
Crank web to web width
Crankshaft runout
CLUTCH
Unit: mm (in)
ITEM
Clutch lever play
STD/SPEC.
10 – 15
(0.40 – 0.60)
3.07 – 3.23
(0.121 – 0.127)
13.85 – 13.95
(0.545 – 0.549)
Drive plate thickness
Drive plate claw width
Driven plate distortion
—
Clutch spring free length
Model: RM250K3
39.78
(1.57)
1/5
LIMIT
—
2.77
(0.109)
13.05
(0.514)
0.15
(0.006)
37.8
(1.49)
E-03, 28
RADIATOR + COOLANT
ITEM
Radiator cap valve release pressure
Engine coolant type
Engine coolant capacity
STD/SPEC.
95 – 125 kPa
(0.95 – 1.25 kgf/cm2, 14 – 18 psi)
Use a anti-freeze & Summer coolant compatible
with aluminum radiator, mixed with distilled water
only, at the ratio of 50:50.
1 100 ml
(1.2/1.0 US/lmp qt)
TRANSMISSION + DRIVE CHAIN
—
—
—
Unit: mm (in) Except ratio
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
STD/SPEC.
3.000 (63/21)
3.769 (49/13)
1.800 (27/15)
1.470 (25/17)
1.210 (23/19)
1.000 (21/21)
0.869 (20/23)
0.10 – 0.30
(0.004 – 0.012)
4.80 – 4.90
(0.189 – 0.193)
4.60 – 4.70
(0.181 – 0.185)
DAIDO: D.I.D 520DMAZ
112 links
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
LIMIT
Type
Links
20-pitch
lenght
LIMIT
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
323.8
(12.75)
—
Drive chain slack
40 – 50
(1.6 – 2.0)
0–5
(0 – 0.2)
Gearshift lever height
—
—
CARBURETOR
STD/SPEC.
ITEM
Carburetor type
Bore size
I.D. No.
Float height
Main jet
Jet needle
Slow jet
Air screw
Power jet
Throttle cable play
Model: RM250K3
(M.J.)
(J.N.)
(S.J.)
(A.S.)
(PW.J.)
E-03
KEIHIN PWK38S
38 mm
37F4
6.5 mm (0.26 in)
#175
N8RH-3rd
#48
1·1/2 turns aut
#50
2 – 4 mm (0.08 – 0.16 in)
at the throttle grip
2/5
Others
←
←
37F5
←
#190
N8RH-4th
#50
2 turns out
#55
←
E-03, 28
ELECTRICAL
Unit: mm (in)
ITEM
Spark plug
STD/SPEC.
NGK: BR8EG
0.5 – 0.6
(0.020 – 0.024)
W/Bl – B/W
0.17 – 0.46 Ω
Plug cap – B/W
13 – 20 kΩ
Ω
78 – 122 Ω
28 – 46 Ω
Type
Gap
Ignition coil resistance
Primary
Secondary
Magneto coil resistance
BRAKE + WHEEL
STD/SPEC.
5 – 15
(0.2 – 0.6)
2.8 –
(0.11 –
3.8 –
(0.15 –
Front
Rear
Brake disc runout
Master cylinder bore
Front &
Rear
11.000 –
(0.4331 –
12.700 –
(0.5000 –
10.957 –
(0.4314 –
12.657 –
(0.4983 –
27.000 –
(1.0630 –
27.000 –
(1.0630 –
26.930 –
(1.0602 –
26.918 –
(1.0598 –
DOT 4
Front
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper pison diam.
Front
Rear
Brake fluid type
Wheel rim runout
LIMIT
—
3.2
0.13)
4.2
0.17)
—
Rear
Master cylinder piston diam.
11.043
0.4348)
12.743
0.5017)
10.984
0.4324)
12.684
0.4994)
27.050
1.0650)
27.050
1.0650)
26.950
1.0610)
26.968
1.0617)
Axial
—
Radial
—
Wheel rim size
Front
Rear
21 × 1.60
19 × 2.15
Wheel axle runout
Front
—
Rear
—
Model: RM250K3
R–G
R/W – B/R
Unit: mm (in)
ITEM
Rear brake pedal height
Brake disc thickness
NOTE
3/5
2.5
(0.10)
3.5
(0.14)
0.30
(0.012)
—
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
—
—
0.25
(0.010)
0.25
(0.010)
E-03, 28
TIRE
Unit: mm (in)
ITEM
Tire air pressure
STD/SPEC.
70 – 110 kPa
(0.7 – 1.1 kgf/cm2, 10 – 16 psi)
70 – 110 kPa
(0.7 – 1.1 kgf/cm2, 10 – 16 psi)
80/100-21 51M
110/90-19 62M
Front
Rear
Tire size
Front
Rear
Tire tread depth
{Recomend depth}
LIMIT
—
—
—
—
4.0
(0.16)
4.0
(0.16)
—
—
SUSPENSION
Unit: mm (in)
STD/SPEC.
ITEM
Front fork stroke
Front fork spring free length
Front fork spring rate
Front fork oil type
LIMIT
E-03
300
(11.8)
Others
←
—
—
—
455
(17.9)
4.2 N/mm
(0.43 kgf/mm)
SUZUKI FORK OIL
L01 or an equivalent
fork oil
4.3 N/mm
(0.44 kgf/mm)
—
←
—
Front fork oil level
130
(5.12)
Front fork oil capacity
(each leg)
Front fork damping
force adjuster
Rebound
Conpression
Front fork aire pressure
Rear shock absorber gas pressure
Rear shock absorber oil type
Rear shock absorber oil capacity
Rear shock absorber spring set
length
Rear shock absorber spring rate
Rear shock absorber
Rebound
damping force adjuster Conpression
125
(4.92)
580 ml (19.60/20.42 585 ml (19.77/20.60
US/lmp oz)
US/Imp oz)
9 clicks turns back
←
10 clicks turns back 14 clicks turns back
0 kPa
←
(0 kgf/cm2, 0 psi)
980 kPa
(10 kgf/cm2, 142 psi)
SUZUKI REAR SUSPECNSION OIL K2C or
an equivalent rear suspension oil
331 ml (11.2/11.7 US/lmp oz)
253
(9.96)
47 N/mm
(4.8 kgf/mm)
10 – 12 clicks turns out
(High speed)
3/4 – 1·1/4 clicks turns out
Conpression
(Low speed)
8 – 10 clicks turns out
Rear wheel travel
Cpmpress
outer tube
and
damper
rod fully.
—
—
—
—
320
(12.6)
Swingarm pivot shaft runout
Model: RM250K3
—
NOTE
—
4/5
0.3
(0.01)
E-03, 28
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity
Engine oil type
Fuel and engine oil mixture ratio
Transmission oil type
Transmission oil capacity
Model: RM250K3
STD/SPEC.
Use only unleaded gasoline of at least 90 pume
octane ( R +2 M ) method.
Use only unleaded gasoline of at least 95 octane.
(Research method)
8.0 L
(2.1/1.8 US/Imp gal)
SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRICANT or equivalent Two Cycle Racing Lubricant
MOTUL 800 2T or equivalent Two Cycle Racing
Lubricant
30:1
SAE 10W-40
750 ml
Change
(0.8/0.7 US/Imp qt)
850 ml
Overhaul
(0.9/0.7 US/Imp qt)
5/5
NOTE
For USA and
Canada
Others
For USA
Others
E-03, 28
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