SERVICE DATA Date: July 27, 2001 Model: RM250K2

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Randall George
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1 2 STROKE CYLINDER + PISTON + PISTON RING Piston to cylinder clearance mm mm ( in) ( in) Cylinder bore mm ( in) Nicks or Measure 20 mm (0.79 in) from the top surface scratches Piston diam mm ( in) mm Measure 23.5 mm (0.93 in) from the skirt end ( in) Cylinder distortion Cylinder head distortion Piston ring free 1st & 8.4 mm 6.7 mm R Approx. end gap 2nd (0.33 in) (0.26 in) Piston ring end gap 1st & mm 0.80 mm 2nd ( in) (0.031 in) Piston ring to 1st & mm groove clearance 2nd ( in) Piston pin bore mm mm ( in) ( in) Piston pin O.D mm mm ( in) ( in) CONROD + CRANKSHAFT Conrod small end I.D mm mm ( in) ( in) Conrod deflection Conrod big end side clearance Crank web to web width Crankshaft runout CLUTCH SERVICE DATA Date: July 27, 2001 Model: RM250K ± 0.1 mm (2.283 ± in) 3.0 mm (0.12 in) 1.0 mm (0.04 in) Clutch lever play mm ( in) Drive plate thickness mm 2.62 mm ( in) (0.103 in) Drive plate claw width mm mm ( in) (0.514 in) Driven plate distortion 0.15 mm (0.006 in) Clutch spring free length mm mm (1.59 in) (1.49 in) Model: RM250K2 1/5 E-02, 03, 04, 24, 28

2 RADIATOR + COOLANT Radiator cap valve release pressure 110 kpa (1.1 kgf/cm 2, 16 psi) Engine coolant type Use a anti-freeze & Summer coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50: 50. Engine coolant capacity ml (1.2/1.0 US/Imp qt) TRANSMISSION + DRIVE CHAIN Primary reduction ratio (63/21) Final reduction ratio (49/13) Gear ratios Low (27/15) 2nd (25/17) 3rd (23/19) 4th (21/21) Top (20/23) Shift fork to groove clearance mm 0.50 mm ( in) (0.020 in) Shift fork groove width mm ( in) Shift fork thickness mm ( in) Drive chain Type DAIDO: D.I.D 520DM Links 112 links 20-pitch length mm (12.75 in) Drive chain slack mm ( in) Gearshift lever height 0 5 mm (0 0.2 in) CARBURETOR ITEM STD/SPEC. E-03 The other countries Carburetor type KEIHIN PWK38S Bore size 38 mm I.D. No. 37F2 37F3 Float height 6.5 mm (0.26 in) Main jet (M.J.) #170 #175 Jet needle (J.N.) N8RH-3rd N8RH-4th Slow jet (S.J.) #48 #50 Air screw (A.S.) 1-½ turns out Power jet (PW.J.) #45 #55 Throttle cable play 2 4 mm ( in) at the throttle grip Model: RM250K2 2/5 E-02, 03, 04, 24, 28

3 ELECTRICAL ITEM STD/SPEC. NOTE Spark plug Type NGK: BR8EG Gap mm ( in) Ignition coil resistance Primary Terminal Ground Ω Secondary Plug cap Terminal kω Magneto coil resistance Ω R G Ω R/W B/R Ω Y Y BRAKE + WHEEL brake pedal height 0 10 mm (0 0.4 in) Brake disc thickness 3.0 mm (0.12 in) 2.5 mm (0.10 in) 4.0 mm (0.16 in) 3.5 mm (0.14 in) Brake disc runout & 0.30 mm (0.012 in) Master cylinder bore mm ( in) mm ( in) Master cylinder piston diam mm ( in) mm ( in) Brake caliper cylinder bore mm ( in) mm ( in) Brake caliper piston diam mm ( in) mm ( in) Brake fluid type DOT 4 Wheel rim runout Axial 2.0 mm (0.08 in) Radial 2.0 mm (0.08 in) Wheel rim size Wheel axle runout 0.25 mm (0.010 in) 0.25 mm (0.010 in) Model: RM250K2 3/5 E-02, 03, 04, 24, 28

4 TIRE Tire air pressure kpa ( kgf/cm 2, psi) kpa ( kgf/cm 2, psi) Tire size 80/ M 110/ M Tire type DUNLOP: SPORTS D756F...E-02 BRIDGESTON: MOTOCROSS-M77... E-03, 24, 28 BRIDGESTON: MOTOCROSS-M49... E-04 DUNLOP: SPORTS D E-02 BRIDGESTON: MOTOCROSS-M78... E-03, 24, 28 BRIDGESTON: MOTOCROSS-M60... E-04 Tire tread depth 4.0 mm {Recommend depth} (0.16 in) SUSPENSION NOTE fork stroke 310 mm (12.2 in) fork spring free length 465 mm (18.3 in) fork spring rate 4.2 N/mm (0.43 kgf/mm) fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil. fork oil level Compress outer 100 mm tube and damper (3.94 in) rod fully. fork oil capacity 454 ml (each leg) (15.3/16.0 US/Imp oz) fork damping force 9 clicks Rebound adjuster Compres- 9 clicks sion fork air pressure 0 kpa (0 kgf/cm 2, 0 psi) Model: RM250K2 4/5 E-02, 03, 04, 24, 28

5 NOTE shock absorber gas 980 kpa pressure (10 kgf/cm 2, 142 psi) shock absorber oil type shock absorber oil 331 ml (11.2/11.7 capacity US/Imp oz) shock absorber spring pre-load 7 mm (0.28 in) shock absorber spring 47 N/mm rate (4.8 kgf/mm) shock absorber damping 10 clicks force adjuster Rebound wheel travel Swingarm pivot shaft runout FUEL + OIL Fuel type SUZUKI REAR SUSPENSION OIL K2C or an equivalant rear suspension oil Compression (High speed) 1 and ½ Compression 9 clicks (Low speed) 320 mm (12.6 in) 0.3 mm (0.01 in) ITEM STD/SPEC. NOTE Use only unleaded gasoline of at least 90 pump octane ( method). E-03, 28 The other countries Fuel tank capacity 8.0 L (2.1/1.8 US/Imp gal) Engine oil type SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRICANT or equivalent Two Cycle Racing E-03 Lubricant MOTUL 800 2T The other or equivalent Two Cycle Racing Lubricant countries Fuel and engine oil mixture ratio 32 : 1 Transmission oil type SAE 10W/40 Transmission oil capacity 750 ml Change (0.8/0.7 US/Imp qt) Overhaul R + M 2 Use only unleaded gasoline of at least 95 octane. (Research method) 850 ml (0.9/0.7 US/Imp qt) Model: RM250K2 5/5 E-02, 03, 04, 24, 28

SERVICE DATA ITEM STD/SPEC. LIMIT. ( in) 1st & 2nd R Approx. 8.2 mm (0.32 in)

SERVICE DATA ITEM STD/SPEC. LIMIT. ( in) 1st & 2nd R Approx. 8.2 mm (0.32 in) 2 STROKE CYLINDER + PISTON + PISTON RING CONROD + CRANKSHAFT CLUTCH SERVICE DATA Piston to cylinder clearance 0.045 0.055 mm (0.0018 0.0022 in) 0.120 mm (0.0047 in) Cylinder bore Piston diam. Cylinder