2007 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.
0.045 – 0.055 mm
(0.0018 – 0.0022 in)
66.400 – 66.415 mm
(2.6142 – 2.6148 in)
Measure 20 mm (0.79 in) from the top surface.
66.350 – 66.365 mm
(2.6122 – 2.6128 in)
Measure 19 mm (0.75 in) from the skirt end.
—
—
Approx. 8.2 mm (0.32 in)
0.30 – 0.45 mm
(0.012 – 0.018 in)
0.02 – 0.06 mm
(0.0008 – 0.0024 in)
18.002 – 18.008 mm
(0.7087 – 0.7090 in)
17.995 – 18.000 mm
(0.7085 – 0.7087 in)
Date: May 23, 2006
Model: RM250K7
LIMIT
0.120 mm
(0.0047 in)
Nicks or
scratches
66.280 mm
(2.6100 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)
—
18.030 mm
(0.7098 in)
17.980 mm
(0.7079 in)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Crank web to web width
Crankshaft runout
STD/SPEC.
23.003 – 23.011 mm
(0.9056 – 0.9059 in)
—
0.1 – 0.8 mm
(0.0039 – 0.0315 in)
59.9 – 60.1 mm
(2.358 – 2.366 in)
—
LIMIT
23.040 mm
(0.9071 in)
3.0 mm
(0.12 in)
1.0 mm
(0.04 in)
—
0.05 mm
(0.002 in)
CLUTCH
ITEM
Clutch lever play
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
STD/SPEC.
10 – 15 mm
(0.4 – 0.6 in)
3.07 – 3.23 mm
(0.121 – 0.127 in)
13.85 – 13.95 mm
(0.545 – 0.549 in)
—
51.94 mm
(2.04 in)
1/6
LIMIT
—
2.77 mm
(0.109 in)
13.35 mm
(0.514 in)
0.10 mm
(0.004 in)
49.4 mm
(1.94 in)
E-03, 28
Model: RM250K7
RADIATOR + COOLANT
ITEM
Radiator cap valve release
pressure
Engine coolant type
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/Imp qt)
LIMIT
—
—
—
Engine coolant capacity
TRANSMISSION + DRIVE CHAIN
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
STD/SPEC.
3.000 (63/21)
3.846 (50/13)
1.800 (27/15)
1.470 (25/17)
1.210 (23/19)
1.000 (21/21)
0.869 (20/23)
0.1 – 0.3 mm
(0.004 – 0.012 in)
4.8 – 4.9 mm
(0.189 – 0.193 in)
4.6 – 4.7 mm
(0.181 – 0.185 in)
DID 520DMA2
114 links
—
40 – 50 mm
(1.6 – 2.0 in)
0 – 5 mm below
(0 – 0.2 in)
LIMIT
—
—
—
—
—
—
—
0.5 mm
(0.020 in)
—
—
—
—
323.8 mm
(12.75 in)
—
—
Low
2nd
3rd
4th
Top
Shift fork to groove
No.1, 2 & 3
clearance
Shift fork groove width No.1, 2 & 3
Shift fork thickness
Drive chain
No.1, 2 & 3
Type
Links
20-pitch length
Drive chain slack
Gearshift lever height
CARBURETOR
ITEM
Carburetor type
Bore size
I.D. No.
Float height
Main jet
Jet needle
Cut-away
Slow jet
Air screw
Power jet
Throttle cable play
STD/SPEC.
KEIHIN PWK38S
39 mm (1.54 in)
37FB
6.5 mm (0.26 in)
#172
NEDH-4th
#7
#50
1 turn out
#55
2.0 – 4.0 mm (0.08 – 0.16 in) at the throttle grip
(M.J.)
(J.N.)
(C.A.)
(S.J.)
(A.S.)
(PW.J.)
Model: RM250K7
2/6
E-03, 28
ELECTRICAL
ITEM
Ignition timing
Spark plug
Type
Gap
Pick-up coil resistance
(Reference data)
Pick-up coil peak voltage
Exciter coil resistance
(Reference data)
Exciter coil peak voltage
Charge coil resistance
(Reference data)
Charge coil peak voltage
Ignition coil resistance
Ignition coil primary peak voltage
STD/SPEC.
BTDC 4.5° at 1 000 r/min
NGK: BR8EG
0.5 – 0.6 mm
(0.020 – 0.024 in)
72 – 127
Ω
at 20 °C (68 °F)
2 V and more
24 – 40
Ω
at 20 °C (68 °F)
25 V and more
1.6 – 2.6
Ω
at 20 °C (68 °F)
Primary
Secondary
8 V and more
0.17 – 0.70
Ω
13 – 20 kΩ
200 V and more
NOTE
R–G
+
R–
-
G
B/R – R/W
+
B/R –
-
R/W
Y – B/W
+
Y –
-
B/W
W/Bl – B/W
Plug cap – W/Bl
+
B/W –
-
W/Bl
BRAKE
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 piston diam.
Front
Rear
Brake fluid type
STD/SPEC.
0 – 10 mm below
(0 – 0.39 in)
2.8 – 3.2 mm
(0.11 – 0.13 in)
3.8 – 4.2 mm
(0.15 – 0.17 in)
—
11.000 – 11.043 mm
(0.4331 – 0.4348 in)
12.700 – 12.743 mm
(0.5000 – 0.5017 in)
10.957 – 10.984 mm
(0.4314 – 0.4324 in)
12.657 – 12.684 mm
(0.4983 – 0.4994 in)
27.000 – 27.050 mm
(1.0630 – 1.0650 in)
27.000 – 27.050 mm
(1.0630 – 1.0650 in)
26.930 – 26.950 mm
(1.0602 – 1.0610 in)
26.918 – 26.968 mm
(1.0598 – 1.0617 in)
DOT 4
LIMIT
—
2.5 mm
(0.10 in)
3.5 mm
(0.14 in)
0.3 mm
(0.012 in)
—
—
—
—
—
—
—
—
Model: RM250K7
3/6
E-03, 28
WHEEL
ITEM
Wheel rim runout
STD/SPEC.
Axial
Radial
Wheel rim size
Wheel axle runout
Front
Rear
Front
Rear
—
—
21 × 1.60
19 × 2.15
—
—
LIMIT
2.0 mm
(0.08 in)
2.0 mm
(0.08 in)
—
—
0.25 mm
(0.010 in)
0.25 mm
(0.010 in)
TIRE
ITEM
Cold inflation tire pressure
Front
Rear
Tire size
Tire type
Tire tread depth
(Recommend depth)
Front
Rear
Front
Rear
Front
Rear
STD/SPEC.
LIMIT
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
—
BRIDGESTONE MOTOCROSS-M59
—
BRIDGESTONE MOTOCROSS-M70
—
—
4.0 mm (0.16 in)
—
4.0 mm (0.16 in)
Model: RM250K7
4/6
E-03, 28
SUSPENSION
ITEM
Front fork stroke
Inner tube outside diam.
Front fork spring free length
Front fork spring rate
Front fork oil type
Front fork oil capacity (each leg)
Front fork damping force adjuster
Front fork air pressure
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 damping
force adjuster
STD/SPEC.
310 mm
(12.2 in)
47 mm
(1.85 in)
494 mm
(19.45 in)
4.4 N/mm
(0.44 kgf/mm)
SUZUKI FORK OIL SS-05 or equivalent fork oil
OUTER: 350 ml (11.83/12.32 US/Imp oz)
INNER: 193 ml (6.52/6.80 US/Imp oz)
Compression
8 clicks turn back
Rebound
11 clicks turn back
0 kPa (0 kgf/cm
2
,
0 psi)
981 kPa
(9.8 kgf/cm
2
,
139.5 psi)
SUZUKI REAR SUSPENSION OIL SS-25
or equivalent rear suspension oil
380 ml (12.84/13.38 US/Imp oz)
4.1 mm (0.161 in) compressed from the free length
53 N/mm
(5.3 kgf/mm)
Rebound
11 clicks turn back
Compression
2 turns back
(High speed)
Compression
9 clicks turn back
(Low speed)
310 mm
(12.2 in)
—
LIMIT
—
—
487 mm
(19.17 in)
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
0.3 mm
(0.01 in)
Rear wheel travel
Swingarm pivot shaft runout
Model: RM250K7
5/6
E-03, 28

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