Segment:
High-performance Motocross Competition Motorcycle
Competitors:
Honda CRF250R, Yamaha YZ250F, Kawasaki KX250F, KTM 250 SX-F
Engine Type:
Liquid-cooled, four-stroke, DOHC, single-cylinder
Suspension Type:
High-performance adjustable Showa suspension (front and rear)
Carburetor:
Keihin FCR MX40 flat-slide carburetor
Frame Material:
Aluminum alloy frame
Engine:
Complete engine disassembly, inspection, assembly, tuning, lubrication system, cooling system.
Transmission:
Gearbox, clutch, shift mechanism, lubrication, inspection, and repair.
Fuel System:
Carburetor (Keihin FCRMX), fuel pump, fuel lines, fuel tank, jetting specifications.
Ignition System:
CDI unit, spark plug specifications, wiring diagrams.
Electrical System:
Wiring diagrams, lighting, battery, charging system, troubleshooting.
Suspension:
Front forks (Showa USD, adjustable), rear shock absorber (Showa, adjustable), linkage, seal replacement, oil levels, pressure adjustments.
Brakes:
Front and rear disc brake systems, caliper maintenance, fluid replacement, bleeding procedures, master cylinder.
Chassis Frame:
Frame inspection, steering head bearings, swingarm, pivot bearings.
Wheels Tires:
Wheel bearing inspection, spoke tension, tire pressure specifications.
Bodywork Plastics:
Fairing removal and installation, seat, fenders.
Maintenance:
Regular servicing, oil changes, filter replacements, chain maintenance, valve clearance checks.
Troubleshooting:
Diagnostic guides for common issues, electrical system diagnostics, engine performance problems.
Rebuilds:
Complete engine rebuild procedures, transmission overhaul, suspension component rebuilds.
Adjustments:
Carburetor tuning, suspension adjustments, chain slack adjustment, idle speed adjustment.
Disassembly Assembly:
Step-by-step instructions for component removal and reinstallation.
Depth:
Comprehensive, from basic maintenance to complete engine and chassis overhaul.
Factory Specs:
Includes all factory specifications, torque values, clearances, and measurements.
Diagnostic Codes:
N/A (Primarily mechanical, limited electronic diagnostics for this era).
Engine Type:
Liquid-cooled, four-stroke, DOHC, single-cylinder
Bore X Stroke:
76.0 mm x 54.9 mm
Compression Ratio:
12.9:1
Valve Train:
DOHC, 4 valves, titanium intake valves
Horsepower Estimated:
Approx. 38-40 HP (at crank, factory spec varies)
Torque Estimated:
Approx. 20-21 lb-ft (at crank, factory spec varies)
Carburetor:
Keihin FCR MX40 with hot start
Fuel Type:
Unleaded gasoline, minimum octane rating 91
Fuel Tank Capacity:
7.0 L (1.8 US gal)
Oil Type:
SAE 10W-40, API SG or higher (specific Suzuki recommendations may vary, check manual)
Oil Capacity:
Approximately 1.0 L (1.1 US qt) with filter change
Oil Change Interval:
Every 10-15 hours of riding or annually, whichever comes first (refer to manual for precise recommendations).
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions.
Spark Plug Replacement:
As needed based on inspection, typically every 25-50 hours of use.
Valve Clearance Check:
Every 20-30 hours of riding.
Brake Fluid Type:
DOT 4 brake fluid.
Coolant Type:
High-quality ethylene glycol-based coolant (50/50 mix with distilled water recommended).
Common Wear Items:
Clutch plates, piston rings, valve guides, wheel bearings, steering head bearings are common wear items on high-performance dirt bikes.
Performance Tuning Considerations:
Carburetor jetting is critical for optimal performance and can require adjustments based on altitude, temperature, and rider preference. Exhaust and airbox modifications will necessitate re-jetting.
Suspension Setup:
Proper sag and clicker adjustments are crucial for handling and are model-specific to rider weight and track conditions.
Heritage Focus:
Suzuki has a long and successful history in motocross and off-road racing, known for performance-oriented machinery.
Generation Context:
The 2004 RM-Z250 marked Suzuki's significant entry into the competitive 250cc four-stroke motocross class, challenging established models with its performance and handling.
Key Updates 04-06:
Minor updates and refinements were made across these early years, focusing on engine tuning, suspension improvements, and chassis tweaks based on racing feedback.
Manufacturing Location:
Japan
