🏷️ Basic Information

Make:

Suzuki

Model:

RM-Z250

Model Variant:

Motocross

Chassis Code 2009:

RM-Z250 K9

Chassis Code 2010:

RM-Z250 L0

👋 Introduction

Segment:

Professional Motocross Competition Bike

Target Audience:

Motocross racers, mechanics, and enthusiasts seeking in-depth repair and maintenance knowledge.

Key Competitors:

Yamaha YZ250F, Honda CRF250R, Kawasaki KX250F, KTM 250 SX-F.

Engine Technology:

Fuel injected, liquid-cooled, four-stroke engine known for strong mid-range power and throttle response.

Suspension Technology:

Features KYB SSS (Speed Sensitive System) front forks and KYB rear shock, a class-leading suspension package.

Chassis Design:

Lightweight aluminum frame for agility and a low center of gravity.

Comprehensive Coverage:

Provides the necessary information for owners to perform all levels of maintenance and repair, reducing reliance on dealerships or specialized shops.

Cost Savings:

Enables DIY maintenance and repairs, leading to significant cost savings over the ownership period.

📋 Manual Details

Manual Type:

Service Repair Manual

Language:

English

Format:

PDF

Estimated Page Count:

Hundreds (specific count not provided in product info, estimated based on scope)

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of all engine components.

Fuel System:

Fuel injection system (EFI), throttle body, fuel pump, injectors, fuel pressure regulator.

Cooling System:

Radiator, coolant hoses, water pump, thermostat, fan operation.

Ignition System:

Ignition coil, spark plug, CDI unit, timing.

Transmission Drivetrain:

Clutch operation and adjustment, gearbox disassembly and reassembly, shift mechanism, final drive.

Suspension Front:

Front fork (KYB SSS - Speed Sensitive System) disassembly, seal replacement, oil levels, valving, air pressure.

Suspension Rear:

Rear shock absorber (KYB), linkage system, spring preload, damping adjustments.

Brakes Front:

Brake caliper, master cylinder, brake lines, disc, pad replacement, bleeding procedures.

Brakes Rear:

Rear brake caliper, master cylinder, brake lines, disc, pad replacement, bleeding procedures.

Electrical System:

Wiring diagrams, battery, stator, starter motor (if applicable), lighting, switches, sensors.

Chassis Frame:

Frame inspection, steering head bearings, swingarm, pivot bearings.

Bodywork Plastics:

Fairing removal and installation, seat, fuel tank cover, fenders.

Wheels Tires:

Wheel bearing inspection and replacement, tire mounting and balancing, spoke tension.

Maintenance:

Routine checks, oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning.

Troubleshooting:

Diagnostic flowcharts, common problem identification and solutions for engine, electrical, and chassis issues.

Repair:

Detailed step-by-step instructions for component removal, repair, and installation.

Rebuild Refurbish:

Comprehensive engine rebuild procedures, transmission overhaul, suspension fork and shock rebuilding.

Adjustment:

Clutch, throttle cable, chain slack, suspension settings, carburetor adjustments (if applicable - though these are EFI).

Specifications Settings:

Torque values, clearances, fluid capacities, pressure specifications, diagnostic codes.

Depth Level:

Comprehensive - covers everything from basic maintenance to full engine and chassis rebuilds.

Diagnostic Capabilities:

Detailed troubleshooting guides and symptom-based diagnostics, likely including EFI system analysis.

Rebuild Scope:

Full engine, transmission, and suspension component rebuilds.

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing quick access to specific information.

Printability:

Designed to be printable for workshop use.

Image Resolution:

Expected to contain high-resolution diagrams and photographs.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

Four-stroke, DOHC, single-cylinder

Displacement:

249cc

Bore X Stroke:

76.0 mm x 55.0 mm

Compression Ratio:

12.5:1 (Typical for this generation)

Horsepower Estimated:

Approximately 39-40 HP at peak (specific dyno results vary).

Torque Estimated:

Approximately 19-20 lb-ft at peak (specific dyno results vary).

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual injectors

Throttle Body Size:

43mm Mikuni

Fuel Type Recommended:

Unleaded gasoline, octane rating 91 or higher

Oil Type:

SAE 10W-40 API SG, JASO MA certified motorcycle oil

Oil Capacity W Filter:

1.0 L (1.1 US qt)

Cooling Method:

Liquid-cooled

Ignition Type:

Digital CDI with variable ignition timing

Spark Plug Type:

NGK CR9E (or equivalent)

🔧 Transmission

Transmission Type:

Constant mesh, 5-speed

Clutch Type:

Wet multi-plate

Final Drive:

O-ring sealed chain, 13/49T sprockets (typical)

Gear Ratios:

1st: 2.500, 2nd: 1.875, 3rd: 1.500, 4th: 1.250, 5th: 1.045 (Typical, consult manual for exact ratios)

Transmission Oil Type:

SAE 10W-40 API SG, JASO MA certified motorcycle oil (Shared with engine oil)

Transmission Oil Capacity:

0.75 L (0.8 US qt) (Typical, consult manual for exact capacity)

📐 Dimensions

Overall Length:

2170 mm (85.4 in)

Overall Width:

810 mm (31.9 in)

Overall Height:

1270 mm (50.0 in)

Wheelbase:

1475 mm (58.1 in)

Ground Clearance:

335 mm (13.2 in)

Seat Height:

955 mm (37.6 in)

Dry Weight:

95 kg (209.4 lbs)

Curb Weight:

104 kg (229.3 lbs) (Estimated, including necessary fluids)

Front Tire Size:

80/100-21 51M

Rear Tire Size:

100/90-19 57M

Wheel Bolt Pattern:

N/A (Spoked wheels with axle nuts)

🛡️ Safety Features

Safety Ratings:

Not applicable (Competition off-road motorcycle, not designed for road use or standard safety ratings like NHTSA/Euro NCAP).

Braking System:

Hydraulic disc brakes front and rear for strong stopping power.

Frame Rigidity:

Tuned aluminum frame provides excellent rigidity and rider feedback.

Engine Braking:

Controlled engine braking through the 5-speed transmission.

Ergonomics:

Designed for rider control and stability during aggressive riding.

💡 Technology Features

Infotainment System:

None (Pure competition motocross bike, no infotainment features).

Electronic Aids:

No electronic rider aids such as ABS or traction control.

Connectivity Features:

None (Not applicable).

Efi Features:

Dual injector system for improved fuel atomization and throttle response across the RPM range. ECU mapping can be adjusted via specific tuning tools (not covered in a standard service manual but often mentioned in performance tuning).

Fork Technology:

KYB 48mm AOS (Air Oil Separate) Speed Sensitive System (SSS) forks with adjustable compression, rebound damping, and spring preload (often adjustable via air pressure).

Shock Technology:

KYB CUSCO rear shock absorber with adjustable compression (high and low speed), rebound damping, and spring preload.

🔧 Maintenance

Engine Oil Change:

Every 5-10 hours of riding or as per manual recommendation for competitive use.

Air Filter Cleaning:

Clean after every few rides or more frequently in dusty conditions.

Spark Plug Replacement:

Inspect every 10-20 hours, replace as needed based on condition.

Chain Lubrication Adjustment:

Lubricate every 3-5 rides, check and adjust slack every 5-10 rides.

Suspension Fork Oil Change:

Recommended every 20-30 hours of riding for optimal performance.

Engine Oil Spec:

SAE 10W-40, API SG, JASO MA

Coolant Type:

High-quality ethylene glycol-based coolant with demineralized water (50/50 mix)

Brake Fluid Type:

DOT 4 hydraulic brake fluid

Common Wear Items:

Clutch plates, piston rings, valve seats, wheel bearings, steering head bearings due to demanding use.

Efi Maintenance:

Requires periodic cleaning of throttle body and injectors to maintain optimal fuel delivery.

Suspension Care:

Regular maintenance of KYB SSS forks and shock is crucial for maintaining their performance and longevity.

📚 Vehicle History

Brand Focus:

Suzuki has a long and successful history in motorcycle racing, particularly in motocross and supercross.

Rmz Lineage:

The RM-Z line has evolved significantly, transitioning from carbureted to fuel-injected models, with continuous improvements in engine performance, chassis design, and suspension technology.

Key Changes 2009-2010:

Suzuki made significant updates for the 2009 model, including a new fuel injection system, revised chassis, and updated suspension settings, which carried over to the 2010 model with minor refinements.

Manufacturing Location:

Japan

🏆 Awards & Recognition

Motocross Reviews:

The RM-Z250 models from this era generally received positive reviews from motocross publications for their strong engines and premium suspension.

Suspension Ranking:

KYB SSS forks were widely considered the benchmark in the 250F class during this period.

Emissions Certification:

Not applicable (Competition off-road motorcycle).