2003 service data.pdf

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SERVICE DATA
2 STROKE
CYLINDER + PISTON + PISTON RING
ITEM
Piston to cylinder clearance
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.
1st &
2nd
1st &
2nd
1st &
2nd
R
STD/SPEC.
0.0452 – 0.0550
(0.0018 – 0.0022)
66.400 – 66.415
(2.6142 – 2.6148)
Measure 20 (0.79) from the top surface.
66.350 – 66.365
(2.6122 – 2.6128)
Measure 25.5 (1.00) from the skirt end.
—
—
8.4
Approx. (0.33)
0.40 – 0.60
(0.016 – 0.024)
0.020 – 0.060
(0.0008 – 0.0024)
18.002 – 18.008
(0.7087 – 0.7090)
17.995 – 18.000
(0.7085 – 0.7087)
Date: June 25, 2002
Model: RM250K3
Unit: mm (in)
LIMIT
0.120
(0.0047)
Nicks or
scratches
66.280
(2.6100)
0.05
(0.002)
0.05
(0.002)
6.7
(0.26)
0.80
(0.031)
—
18.030
(0.7098)
17.980
(0.7079)
Unit: mm (in)
STD/SPEC.
23.003 – 23.011
(0.9056 – 0.9059)
—
—
59.9 – 60.1
(2.358 – 2.366)
—
LIMIT
23.040
(0.9071)
3.0
(0.12)
1.0
(0.04)
—
0.05
(0.002)
Unit: mm (in)
STD/SPEC.
10 – 15
(0.40 – 0.60)
3.07 – 3.23
(0.121 – 0.127)
13.85 – 13.95
(0.545 – 0.549)
—
39.78
(1.57)
LIMIT
—
2.77
(0.109)
13.05
(0.514)
0.15
(0.006)
37.8
(1.49)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Crank web to web width
Crankshaft runout
CLUTCH
ITEM
Clutch lever play
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
Model: RM250K3
1/5
E-03, 28
RADIATOR + COOLANT
ITEM
Radiator cap valve release pres-
sure
Engine coolant type
Engine coolant capacity
STD/SPEC.
95 – 125 kPa
(0.95 – 1.25 kgf/cm
2
, 14 – 18 psi)
Use a anti-freeze & Summer coolant compatible
with aluminum radiator, mixed with distilled water
only, at the ratio of 50:50.
1 100 ml
(1.2/1.0 US/lmp qt)
LIMIT
—
—
—
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
STD/SPEC.
3.000 (63/21)
3.769 (49/13)
1.800 (27/15)
1.470 (25/17)
1.210 (23/19)
1.000 (21/21)
0.869 (20/23)
0.10 – 0.30
(0.004 – 0.012)
4.80 – 4.90
(0.189 – 0.193)
4.60 – 4.70
(0.181 – 0.185)
DAIDO: D.I.D 520DMAZ
112 links
—
40 – 50
(1.6 – 2.0)
0–5
(0 – 0.2)
Unit: mm (in) Except ratio
LIMIT
—
—
—
—
—
—
—
0.50
(0.020)
—
—
—
—
323.8
(12.75)
—
—
Low
2nd
3rd
4th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Drive chain
Type
Links
20-pitch
lenght
Drive chain slack
Gearshift lever height
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Float height
Main jet
Jet needle
Slow jet
Air screw
Power jet
Throttle cable play
STD/SPEC.
E-03
KEIHIN PWK38S
38 mm
37F4
6.5 mm (0.26 in)
#175
N8RH-3rd
#48
1·1/2 turns aut
#50
2 – 4 mm (0.08 – 0.16 in)
at the throttle grip
Others
←
←
37F5
←
#190
N8RH-4th
#50
2 turns out
#55
←
(M.J.)
(J.N.)
(S.J.)
(A.S.)
(PW.J.)
Model: RM250K3
2/5
E-03, 28
ELECTRICAL
ITEM
Spark plug
Type
Gap
Ignition coil resistance
Primary
Secondary
Magneto coil resistance
STD/SPEC.
NGK: BR8EG
0.5 – 0.6
(0.020 – 0.024)
W/Bl – B/W
0.17 – 0.46
Ω
Plug cap – B/W
13 – 20 kΩ
Ω
78 – 122
Ω
28 – 46
Ω
Unit: mm (in)
NOTE
R–G
R/W – B/R
Unit: mm (in)
BRAKE + WHEEL
ITEM
Rear brake pedal height
Brake disc thickness
Front
Rear
Brake disc runout
Master cylinder bore
Front &
Rear
Front
Rear
Master cylinder piston diam.
Front
Rear
Brake caliper cylinder bore
Front
Rear
Brake caliper pison diam.
Front
Rear
Brake fluid type
Wheel rim runout
STD/SPEC.
5 – 15
(0.2 – 0.6)
2.8 –
(0.11 –
3.8 –
(0.15 –
—
11.000 –
(0.4331 –
12.700 –
(0.5000 –
10.957 –
(0.4314 –
12.657 –
(0.4983 –
27.000 –
(1.0630 –
27.000 –
(1.0630 –
26.930 –
(1.0602 –
26.918 –
(1.0598 –
DOT 4
—
—
21 × 1.60
19 × 2.15
—
—
11.043
0.4348)
12.743
0.5017)
10.984
0.4324)
12.684
0.4994)
27.050
1.0650)
27.050
1.0650)
26.950
1.0610)
26.968
1.0617)
LIMIT
—
3.2
0.13)
4.2
0.17)
2.5
(0.10)
3.5
(0.14)
0.30
(0.012)
—
—
—
—
—
—
—
—
2.0
(0.08)
2.0
(0.08)
—
—
0.25
(0.010)
0.25
(0.010)
Axial
Radial
Wheel rim size
Wheel axle runout
Front
Rear
Front
Rear
Model: RM250K3
3/5
E-03, 28
TIRE
ITEM
Tire air pressure
Front
Rear
Tire size
Tire tread depth
{Recomend depth}
Front
Rear
STD/SPEC.
70 – 110 kPa
(0.7 – 1.1 kgf/cm
2
, 10 – 16 psi)
70 – 110 kPa
(0.7 – 1.1 kgf/cm
2
, 10 – 16 psi)
80/100-21 51M
110/90-19 62M
—
—
Unit: mm (in)
LIMIT
—
—
—
—
4.0
(0.16)
4.0
(0.16)
Unit: mm (in)
STD/SPEC.
E-03
300
(11.8)
—
4.2 N/mm
(0.43 kgf/mm)
SUZUKI FORK OIL
L01 or an equivalent
fork oil
130
(5.12)
Others
←
—
4.3 N/mm
(0.44 kgf/mm)
←
LIMIT
—
455
(17.9)
—
—
Cpmpress
outer tube
and
damper
rod fully.
NOTE
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork spring rate
Front fork oil type
Front fork oil level
125
(4.92)
—
Front fork oil capacity
(each leg)
Front fork damping
force adjuster
Front fork aire pressure
Rebound
Conpression
Rear shock absorber gas pressure
Rear shock absorber oil type
Rear shock absorber oil capacity
Rear shock absorber spring set
length
Rear shock absorber spring rate
Rear shock absorber
Rebound
damping force adjuster
Conpression
(High speed)
Conpression
(Low speed)
580 ml (19.60/20.42 585 ml (19.77/20.60
US/lmp oz)
US/Imp oz)
9 clicks turns back
←
10 clicks turns back 14 clicks turns back
0 kPa
←
(0 kgf/cm
2
, 0 psi)
980 kPa
(10 kgf/cm
2
, 142 psi)
SUZUKI REAR SUSPECNSION OIL K2C or
an equivalent rear suspension oil
331 ml (11.2/11.7 US/lmp oz)
253
(9.96)
47 N/mm
(4.8 kgf/mm)
10 – 12 clicks turns out
3/4 – 1·1/4 clicks turns out
8 – 10 clicks turns out
320
(12.6)
—
—
—
—
—
Rear wheel travel
Swingarm pivot shaft runout
0.3
(0.01)
Model: RM250K3
4/5
E-03, 28
FUEL + OIL
ITEM
Fuel type
STD/SPEC.
Use only unleaded gasoline of at least 90 pume
octane (
R + M
) method.
2
Use only unleaded gasoline of at least 95 octane.
(Research method)
8.0 L
(2.1/1.8 US/Imp gal)
SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRI-
CANT or equivalent Two Cycle Racing Lubricant
MOTUL 800 2T or equivalent Two Cycle Racing
Lubricant
30:1
SAE 10W-40
750 ml
Change
(0.8/0.7 US/Imp qt)
850 ml
Overhaul
(0.9/0.7 US/Imp qt)
NOTE
For USA and
Canada
Others
Fuel tank capacity
Engine oil type
For USA
Others
Fuel and engine oil mixture ratio
Transmission oil type
Transmission oil capacity
Model: RM250K3
5/5
E-03, 28

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