Suzuki RM250 1996-2002 Clymer Motorcycle Repair Manual

Description

This Clymer Suzuki RM250 1996 1997 1998 1999 2000 2001 2002 Repair Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1996-2002 Suzuki RM250 two-stroke motocross motorcycles.

Includes everything you need to know to perform tune-up and routine maintenance on the engine top and lower-end, clutch, drive gear, transmission, fuel system, exhaust system, electrical system, suspension, steering, rear axle, final drive, brakes, frame and body. Features complete wiring diagrams and 344 illustrated pages.

QUICK REFERENCE DATA

CHAPTER ONE, GENERAL INFORMATION
Manual organization, Warnings, cautions and notes, Safety, Basic service methods, Serial numbers, Fasteners, Shop supplies, Basic tools, Precision measuring tools, Storage

CHAPTER TWO, TROUBLESHOOTING
Operating requirements, Starting the engine, Engine spark test, Engine performance, Engine noise, Engine leakdown test, Clutch, External shift mechanism and transmission, Kickstarter, Brakes, Steering, Electrical test, Electrical component replacement

CHAPTER THREE, LUBRICATION, MAINTENANCE AND TUNE-UP
Service precautions and practices, Pre-ride inspection, Engine break-in, Maintenance intervals, Fuel and lubricants, Transmission and component lubrication, Maintenance and inspection, Engine tune-up, Spark plugs

CHAPTER FOUR, ENGINE TOP END
Shop cleanliness, Exhaust system, Cylinder head, Cylinder, Exhaust valve system, Exhaust valves and shaft assembly, Exhaust valve solenoid, Exhaust valve governor and actuator, Piston and piston rings, Reed valves

CHAPTER FIVE, ENGINE LOWER END
Shop cleanliness, Engine, Crankcase, Crankcase seal replacement, Crankcase bearing replacement, Crankshaft

CHAPTER SIX, CLUTCH AND GEARSHIFT LINKAGE
Clutch cover, Clutch, Right crankcase cover, Gearshift linkage, Kickstarter and idle gear, Primary drive gear, Clutch cable

CHAPTER SEVEN, TRANSMISSION AND INTERNAL SHIFT MECHANISM
Transmission operation, Service notes, Mainshaft, Countershaft, Transmission inspection, Shift drum and forks

CHAPTER EIGHT, FUEL SYSTEM
Service precautions and practices, Carburetor, Carburetor cleaning and inspection, Float adjustment, Carburetor jetting, Fuel tank, Fuel valve and filter, Throttle cable replacement, Air filter housing

CHAPTER NINE, IGNITION SYSTEM
Basic ignition system operation, Alternator cover, Flywheel, Stator, Ignition system testing, CDI unit, Ignition coil, Stator, Engine stop switch, Ignition timing

CHAPTER TEN, COOLING SYSTEM
Safety precautions, Radiators, Water pump

CHAPTER ELEVEN, WHEELS, TIRES AND DRIVE CHAIN
Front wheel, Rear wheel, Front and rear hubs, Rim and spoke service, Drive chain, Sprockets, Tire changing

CHAPTER TWELVE, FRONT SUSPENSION AND STEERING
Handlebar, Steering stem and head, Fork oil change, Fork removal and installation, Fork service, Fork adjustment (all models)

CHAPTER THIRTEEN, REAR SUSPENSION
Link-type suspension system, Shock absorber, Shock absorber linkage, Swing arm, Rear suspension adjustment

CHAPTER FOURTEEN, BRAKES
Brake system fundamentals, Front brake pads, Front brake caliper, Front master cylinder, Rear brake pads, Rear brake caliper, Rear master cylinder, Rear brake pedal, Brake system draining, Brake system bleeding, Brake disc

CHAPTER FIFTEEN, BODY
Seat, Frame covers, Radiator covers, Subframe

INDEX

WIRING DIAGRAMS