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

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1 2 STROKE CYLINDER + PISTON + PISTON RING CONROD + CRANKSHAFT CLUTCH SERVICE DATA Piston to cylinder clearance mm ( in) mm ( in) 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 Piston pin O.D mm ( in) Measure 20 mm (0.79 in) from the top surface mm ( in) Measure 19 mm (0.75 in) from the skirt end 1st & 2nd R Approx. 8.2 mm (0.32 in) 1st & 2nd 1st & 2nd mm ( in) mm ( in) mm ( in) mm ( in) Nicks or scratches mm ( in) 0.05 mm (0.002 in) 0.05 mm (0.002 in) 6.6 mm (0.26 in) 0.80 mm (0.031 in) mm ( in) mm ( in) Conrod small end I.D mm ( in) mm ( in) Conrod deflection Conrod big end side clearance Crank web to web width Crankshaft runout mm ( in) mm ( in) 3.0 mm (0.12 in) 1.0 mm ( in) 0.05 mm (0.002 in) Clutch lever play mm ( in) Drive plate thickness mm ( in) 2.77 mm (0.109 in) Drive plate claw width Driven plate distortion Clutch spring free length mm ( in) mm (2.04 in) Date: May 23, 2005 Model: RM250K mm (0.514 in) 0.10 mm (0.004 in) 49.4 mm (1.94 in) Model: RM250K6 1/6 E-03, 28

2 RADIATOR + COOLANT Radiator cap valve release pressure Engine coolant type Engine coolant capacity kpa ( kgf/cm 2, psi) Use a anti-freeze & Summer coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50: ml (1.2/1.0 US/Imp qt) TRANSMISSION + DRIVE CHAIN Primary reduction ratio (63/21) Final reduction ratio (50/13) Gear ratios Low (27/15) 2nd (25/17) 3rd (23/19) 4th (21/21) Top (20/23) Shift fork to groove clearance CARBURETOR No.1, 2 & mm ( in) Shift fork groove width No.1, 2 & mm ( in) 0.5 mm (0.020 in) Shift fork thickness No.1, 2 & mm ( in) Drive chain Type DID520DMA2 Links 114 links Drive chain slack Gearshift lever height 20-pitch length mm ( in) 0 5 mm below (0 0.2 in) ITEM STD/SPEC. Carburetor type KEIHIN PWK38S Bore size 39 mm (1.54 in) I.D. No. 37FB Float height 6.5 mm (0.26 in) Main jet (M.J.) #172 Jet needle (J.N.) NEDH-4th Cut-away (C.A.) #7 Slow jet (S.J.) #50 Air screw (A.S.) 1 turn out Power jet (PW.J.) #55 Throttle cable play mm ( in) at the throttle grip mm (12.75 in) Model: RM250K6 2/6 E-03, 28

3 ELECTRICAL ITEM STD/SPEC. NOTE Ignition timing BTDC 4.5 at r/min Spark plug Type NGK: BR8EG Gap mm ( in) Pick-up coil resistance (Reference data) Ω at 20 C (68 F) R G Pick-up coil peak voltage 2 V and more + R - G Exciter coil resistance (Reference data) Ω at 20 C (68 F) B/R R/W Exciter coil peak voltage 25 V and more + B/R - R/W Charge coil resistance (Reference data) Ω at 20 C (68 F) Y B/W Charge coil peak voltage 8 V and more + Y - B/W Ignition coil resistance Primary Ω W/Bl B/W Secondary kω Plug cap W/Bl Ignition coil prinary peak voltage 200 V and more + B/W - W/Bl BRAKE brake pedal height 0 10 mm below ( in) Brake disc thickness mm ( in) 2.5 mm (0.10 in) Brake disc runout Master cylinder bore Master cylinder piston diam. & mm ( in) mm ( in) mm ( in) mm ( in) mm ( in) Brake caliper cylinder bore mm ( in) mm ( in) Brake caliper piston diam mm ( in) mm ( in) Brake fluid type DOT mm (0.14 in) 0.3 mm (0.012 in) Model: RM250K6 3/6 E-03, 28

4 WHEEL Wheel rim runout Axial 2.0 mm (0.08 in) Radial 2.0 mm (0.08 in) Wheel rim size Wheel axle runout TIRE 0.25 mm (0.010 in) 0.25 mm (0.010 in) Cold inflation tire pressure kpa ( kgf/cm 2, psi) kpa ( kgf/cm 2, psi) Tire size 80/ M 110/ M Tire type BRIDGESTONE MOTOCROSS-M59 BRIDGESTONE MOTOCROSS-M70 Tire tread depth (Recomend depth) 4.0 mm (0.16 in) 4.0 mm (0.16 in) Model: RM250K6 4/6 E-03, 28

5 SUSPENSION fork stroke 310 mm (12.2 in) Inner tube outside diam. 47 mm (1.85 in) fork spring free length 494 mm (19.45 in) 487 mm (19.17 in) fork spring rate 4.4 N/mm (0.44 kgf/mm) fork oil type SUZUKI FORK OIL SS-05 or equivalent fork oil fork oil capacity (each leg) OUTER: 350 ml (11.830/ US/Imp oz) INNER: 193 ml (6.523/6.769 US/Imp oz) fork damping force adjuster Compression 8 clicks turn back Rebound 11 clicks turn back fork air pressure 0 kpa (0 kgf/cm 2, 0 psi) shock absorber gas pressure 981 kpa (9.8 kgf/cm 2, psi) shock absorber oil type SUZUKI REAR SUSPENSION OIL SS-25 or equivalent rear suspension oil shock absorber oil capacity 380 ml (12.844/ US/Imp oz) shock absorber spring set length 4.1 mm (0.161 in) compressed from the free length shock absorber spring rate 5.3 N/mm (0.53 kgf/mm) shock absorber damping force adjuster wheel travel Swingarm pivot shaft runout Rebound 11 clicks turn back Compression (High speed) 2 turns back Compression (Low speed) 9 clicks turn back 310 mm (12.2 in) 0.3 mm (0.01 in) Model: RM250K6 5/6 E-03, 28

6 FUEL + OIL Fuel type ITEM STD/SPEC. NOTE Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2 method). For Canada Use only unleaded gasoline of at least 95 octane. (Research method) Fuel tank capacity 8.0 L (2.1/1.8 US/Imp gal) Engine oil type MOTUL 800 2T FACTORY LINE OFF ROAD or equivalent Two Cycle Racing Lubricant Air cleaner element oil type MOTUL AIR FILTER OIL or equivalent filter oil Fuel and engine oil mixture ratio 30:1 Transmission oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA Transmission oil capacity Change Overhaul 750 ml (0.8/0.7 US/Imp qt) 850 ml (0.9/0.7 US/Imp qt) For other countries Model: RM250K6 6/6 E-03, 28

SERVICE DATA Date: July 27, 2001 Model: RM250K2

SERVICE DATA Date: July 27, 2001 Model: RM250K2 2 STROKE CYLINDER + PISTON + PISTON RING Piston to cylinder clearance 0.050 0.060 mm 0.120 mm (0.0020 0.0024 in) (0.0047 in) Cylinder bore 66.400 66.415 mm (2.6142 2.6148 in) Nicks or Measure 20 mm (0.79

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