Segment:
2-stroke Motocross Performance
Target Audience:
Motocross racers, performance enthusiasts, DIY mechanics
Key Competitors:
Yamaha YZ250, Honda CR250R, Kawasaki KX250
Vehicle Focus:
Lightweight, powerful 2-stroke engine, agile handling, competitive motocross platform.
Manual Value Proposition:
Essential resource for maintaining peak performance and executing repairs on the 2004 RM250, saving time and money on professional labor.
Primary Coverage:
Complete Service and Repair
Included Sections:
Engine, Transmission, Fuel System, Ignition System, Cooling System, Frame, Suspension, Brakes, Electrical System, Troubleshooting, Maintenance
Estimated Pages:
Approx. 300-400
Type:
Service Repair Manual
Engine:
Complete overhaul, top-end rebuild, bottom-end assembly, carburetor tuning and cleaning, cooling system (liquid-cooled), lubrication, ignition timing, performance modifications (within stock parameters).
Transmission:
Clutch operation and adjustment, gear shift mechanism, transmission overhaul, lubrication, gear inspection.
Fuel System:
Carburetor model (Mikuni TMX38), jetting specifications, float adjustment, fuel line maintenance, fuel tank inspection.
Ignition System:
CDI ignition, spark plug selection and gap, ignition coil testing, stator and rotor inspection.
Frame And Suspension:
Frame inspection and straightening procedures (minor), front fork (Showa 47mm USD) disassembly, assembly, oil change, and damping adjustment, rear shock absorber (Pro-Link) service and adjustment, swingarm pivot and linkage maintenance.
Brakes:
Front and rear hydraulic disc brake system, caliper maintenance, master cylinder service, brake pad replacement, fluid bleeding procedures, rotor inspection.
Electrical System:
Wiring diagrams, lighting systems (if applicable for street legality, though typically race-focused), battery maintenance, charging system (alternator) testing.
Maintenance:
Regular service checks, oil changes, filter cleaning/replacement, chain adjustment and lubrication, spark plug maintenance, air filter cleaning, coolant flush and replacement.
Troubleshooting:
Systematic diagnosis of common problems, including engine starting issues, performance degradation, transmission shifting problems, brake fade, and suspension inconsistencies.
Repair:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and adjustment for all major systems.
Technical Data:
Torque specifications for all fasteners, critical clearances, fluid capacities, wear limits, and diagnostic values.
Depth:
Comprehensive, covering from basic owner maintenance to full engine and chassis rebuilds. Includes detailed diagrams and exploded views.
Displacement:
249 cc (15.2 cu. in.)
Bore X Stroke:
66.4 x 72.0 mm (2.61 x 2.83 in.)
Cooling System:
Liquid-cooled
Carburetor:
Mikuni TMX38, flat slide
Compression Ratio:
9.7:1 (stock)
Horsepower Estimated:
Approx. 50-55 HP (crankshaft, stock tune)
Torque Estimated:
Approx. 30-33 lb-ft (crankshaft, stock tune)
Fuel Type:
Unleaded gasoline (91 octane or higher recommended)
Oil Mixture:
2-stroke engine oil, typically mixed at 32:1 or 40:1 ratio (refer to manual for exact specification and oil type)
Oil Change Transmission:
Every 10-15 hours of riding or annually (refer to manual for specifics)
Air Filter Cleaning:
Every 5-10 hours of riding, or as needed depending on conditions
Spark Plug Inspection:
Every 10-15 hours of riding
Chain Lubrication:
Every 5-10 hours of riding or after washing/wet conditions
Engine Oil Premix:
High-quality 2-stroke motorcycle oil (e.g., Motul 800, Yamalube 2R) at recommended ratio (32:1 or 40:1)
Transmission Oil:
SAE 80W API GL-4 gear oil
Coolant:
Mixture of distilled water and permanent antifreeze (ethylene glycol based) in a 50:50 ratio.
Common Wear Items:
Piston rings, clutch plates, wheel bearings, steering head bearings, swingarm pivot bearings, brake pads.
Potential Performance Degradation:
Carburetor jetting issues, clogged power valve, worn reeds, inefficient cooling can lead to loss of power.
Pre Ride Check:
Thorough pre-ride inspection of tires, brakes, chain tension, and controls is crucial for safety and reliability.
Manufacturer:
Suzuki Motor Corporation
Moto Cross Legacy:
Suzuki has a long and successful history in professional motocross racing with the RM and RM-Z lines.
Rm250 Development:
The RM250 was a dominant force in the 250cc class for decades, continuously evolving with chassis and engine technology.
Production Period:
The RM250 model has been in production for many years, with the 2004 model representing a refined iteration.
