Motorcycle 2012 Model: RM-Z250 Date: August 2011

Transcription

1 RM-Z250L2 Motorcycle 2012 Model: RM-Z250 Date: August 2011 New Features New graphics Key Features cm3, 4-stroke, fuel-injected, DOHC engine, designed compact and lightweight, powers the RM-Z250's Championship-winning performance. 2. Advanced, battery-less fuel-injection (FI) system, featuring a 44mm throttle body with progressive throttle linkage and a 16-bit computer. 3. The FI system uses a unique capacitor-assisted starting system, and is powered by a durable, lightweight magneto-generator after starting. 4. Aluminum cylinder with Suzuki Composite Electrochemical Material (SCEM) coating, built for durability, light weight and efficient heat transfer. 5. A sturdy connecting rod and mirror finishing permits a stunning 13,500 rpm maximum engine speed. 1

2 RM-Z250L2 6. Updated Engine Control Unit (ECU) settings make for a more linear acceleration and smoother over-rev character. Revised cam profiles upgrade the overall power feel. 7. Engine and exhaust pipe updates allow the RM-Z250 to meet the latest noise regulations while delivering a further refined power feel. 8. Inverted twin chamber Showa forks and Showa piggyback shock designed with emphasis on smooth shock absorption and ample bottoming resistance. 9. Tuned to offer superb handling for a wide range of riders, the suspension delivers excellent traction without sacrificing quick-turning ability. 10. Twin-spar aluminum frame and swingarm developed and refined for a highly optimized rigidity balance and superb high-speed traction. 11. Smart chassis design details include footpeg brackets shaped to help prevent mud clogging. 12. Radiator louvers (for the twin side-mounted aluminum-alloy radiators) are joined to the outer bodywork to add strength without adding weight. 13. Race-inspired disc rotors offer enhanced cooling performance and efficient mud slinging. 14. High-quality Renthal handlebars featuring a tapered design and fixed to the triple clamp on a rubber mount. 15. Gripper seat, with projected cross-shaped patterns on top surface to provide additional grip. 16. The number plates have a black background to conform to rules for competition numbers. 2

3 RM-Z250L2 SPECIFICATIONS: MODEL: 2012 RM-Z250 DIMENSIONS AND CURB MASS Overall length mm (85.4 in) Overall width mm (32.7 in) Overall height mm (50.0 in) Wheelbase mm (58.1 in) Ground clearance mm (13.6 in) Seat height mm (37.6 in) Curb mass kg (230 lbs) ENGINE Type stroke, liquid-cooled, DOHC Number of cylinders... 1 Bore mm (3.03 in) Stroke mm (2.11 in) Displacement cm3 (15.2 cu. in) Compression ratio : 1 Fuel system... Fuel injection Air cleaner... Polyurethane foam element Starter system... Primary kick Lubrication system... Semi-dry sump Idle speed ± 50 r/min DRIVE TRAIN Clutch... Wet multi disc Transmission... 5-speed constant mesh Gearshift pattern... 1-down, 4-up Primary reduction ratio (63/19) Gear ratios, Low (28/13) 2nd (30/17) 3rd (25/17) 4th (26/21) Top (24/22) Final reduction ratio (49/13) Drive chain... DID520DMA2, 114 links CHASSIS Front suspension... Upside-down telescopic fork suspension... Swingarm type Front suspension stroke mm (12.2 in) wheel travel mm (12.2 in) Caster Trail mm ( 5.5 in) Steering angle (right & left) Front brake... Disc brake brake... Disc brake Front tire size... 80/ M, tube type tire size / M, tube type ELECTRICAL Ignition type... Electronic ignition (CDI) Ignition timing... 8 B.T.D.C. at 2100 r/min Spark plug... NGK CR8EIA -10 CAPACITIES Fuel tank, including reserve L (1.7/1.4 US/Imp gal) Engine oil, oil change ml (1.0/0.8 US/Imp qt) with filter change ml (1.1/0.9 US/Imp qt) overhaul ml (1.2/1.0 US/Imp qt) Coolant ml (1.0/0.8 US/Imp qt) 3

4 Model: RM-Z250L2 E-03, 19, 28 Date: July 5, 2011 SERVICE DATA VALVE + GUIDE Valve diam. IN. 31 (1.22) EX. 25 (0.98) Tappet clearance (when cold) IN ( ) EX ( ) Valve guide to valve stem clearance Valve stem deflection Valve guide I.D. Valve stem O.D. Valve stem runout Valve seat width Valve head radial runout Valve spring free length Valve spring tension IN. EX ( ) ( ) IN. & EX. IN. & EX. IN. EX ( ) ( ) ( ) IN. & EX. IN. & EX ( ) IN. & EX. IN. EX. IN. EX N ( kgf, lbs) at length mm (1.321 in) N ( kgf, lbs) at length mm (1.321 in) 0.25 (0.010) 0.05 (0.002) 0.03 (0.001) 37.1 (1.46) 37.5 (1.48) 1/12

5 CAMSHAFT + CYLINDER HEAD Cam height CYLINDER + PISTON + PISTON RING Camshaft journal oil clearance Camshaft journal holder I.D. Camshaft journal O.D. IN. EX. IN. & EX. IN. & EX. IN. & EX ( ) ( ) ( ) ( ) ( ) (1.357) (1.324) (0.0059) Camshaft runout 0.10 (0.004) Cam chain pin 13th pin Cylinder head distortion 0.05 (0.002) Compression pressure (Automatic decomp. actuated) kpa ( kgf/cm 2, psi) Piston to cylinder clearance ( ) Cylinder bore ( ) Piston diam ( ) Measure at 8.0 mm (0.31 in) from the skirt end. Cylinder distortion Piston ring free end gap Piston ring end gap Piston ring to groove clearance 1st IR Approx. 7.1 (0.28) 1st ( ) 1st Piston ring groove width 1st ( ) Oil ( ) Piston ring thickness 1st ( ) Piston pin bore ( ) Piston pin O.D ( ) (0.0047) Nicks or scratches (3.0268) 0.05 (0.002) 5.7 (0.22) 0.50 (0.020) (0.0071) (0.6311) (0.6291) 2/12

6 CONROD + CRANKSHAFT OIL PUMP CLUTCH RADIATOR + ENGINE COOLANT Conrod small end I.D ( ) Conrod deflection Conrod big end side clearance ( ) Conrod big end width ( ) Crank web to web width ( ) Crankshaft runout (0.6315) 3.0 (0.12) 1.0 (0.04) 0.08 (0.003) Oil pressure (at 50 C, 122 F) 25 kpa (0.25 kgf/cm 2, 3.6 psi) at r/min Clutch cable play 2 3 ( ) Drive plate thickness ( ) Drive plate claw width ( ) Driven plate distortion Clutch spring free length (1.998) Radiator cap valve opening pressure Engine coolant type Engine coolant capacity 2.42 (0.095) (0.514) 0.10 (0.004) 48.2 (1.90) ITEM STANDARD/SPECIFICATION LIMIT kpa ( kgf/cm 2, psi) Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50: ml (1.0/0.8 US/lmp qt) 3/12

7 TRANSMISSION + DRIVE CHAIN INJECTOR + FUEL PUMP + FUEL PRESSURE REGULATOR FI SENSORS Except ratio Primary reduction ratio (63/19) Final reduction ratio (49/13) Gear ratios Low (28/13) 2nd (30/17) 3rd (25/17) 4th (26/21) Top (24/22) Shift fork to groove clearance Shift fork groove width Shift fork thickness No.1, 2 & 3 No.1, 2 & 3 No.1, 2 & ( ) ( ) ( ) 0.50 (0.020) Drive chain Type DID 520 DMA4 Links 114 links 20-pitch length Drive chain slack ( ) Gearshift lever height ( ) (Above the top face of the foot rest) (12.75) ITEM SPECIFICATION NOTE Injector resistance at 24 C (75 F) Fuel pump discharge amount 89 ml (3.0/3.1 US/Imp oz) and more /10 sec. Fuel pressure regulator operating set pressure Approx. 294 kpa (2.94 kgf/cm 2, psi) ITEM STANDARD/SPECIFICATION NOTE CKP sensor resistance CKP sensor peak voltage 2.8 V and more Crankshaft rotation signal sensor resistance Crankshaft rotation signal sensor peak voltage 3.5 V and more IAP sensor input voltage V IAP sensor output voltage V at idle speed TP sensor input voltage V TP sensor output voltage Closed Approx. 0.6 V Opened Approx. 3.8 V ECT sensor input voltage V ECT sensor resistance Approx k at 20 C (68 F) IAT sensor input voltage V 4/12

8 ITEM STANDARD/SPECIFICATION NOTE IAT sensor resistance Approx k at 20 C (68 F) TO sensor resistance k TO sensor voltage Normal V Leaning V When leaning 65 GP switch voltage 0.89 V and more From 1st to Top Injector voltage Battery voltage THROTTLE BODY ITEM Bore size I.D. No. Idle r/min Throttle cable play Hot starter lever clearance SPECIFICATION 44 mm (1.73 in) 49H ± 50 r/min 2 4 mm ( in) 2 3 mm ( in) ELECTRICAL ITEM STANDARD/SPECIFICATION NOTE Ignition timing 8 B.T.D.C. at r/min. Spark plug Type NGK: CR8EIA10 Gap ( ) Spark performance Over 8 (0.3) at 1 atm. CKP sensor resistance R G Crankshaft rotation signal sensor resistance B/R R/W Charge coil resistance Y Y CKP sensor peak voltage 2.8 V and more + R - G Crankshaft rotation signal sensor peak voltage Ignition coil resistance Ignition coil primary peak voltage Primary Secondary 3.5 V and more at 20 C (68 F) k at 20 C (68 F) 175 V and more + B/R - R/W Terminal Terminal Plug cap + Terminal + Ground - W/Bl Magneto no-load voltage (When engine is cold) 95 V (AC) and more at r/min Regulated voltage V at r/min Engine stop switch resistance Under 1 B/Y B/W 5/12

9 BRAKE + WHEEL TIRE Brake lever adjuster length ( ) brake pedal height 0 10 (0 0.4) (Below the top face of the foot rest) Brake disc thickness Front ( ) 2.5 (0.10) Brake disc distortion Front & ( ) 3.5 (0.14) 0.3 (0.012) Master cylinder bore Front ( ) ( ) Master cylinder piston diam. Front ( ) ( ) Brake caliper cylinder bore Front ( ) ( ) Brake caliper piston diam. Front ( ) ( ) Brake fluid type DOT 4 Wheel rim runout Axial 2.0 (0.08) Radial 2.0 (0.08) Wheel rim size Front Wheel axle runout Front 0.25 (0.010) 0.25 (0.010) ITEM STD/SPEC. LIMIT Cold inflation tire pressure Front & kpa ( kgf/cm 2, psi) Tire size Front 80/ M 100/ M Tire type Front D742FA D756 Tire tread depth (Recommend depth) Front & 4.0 mm (0.16 in) 6/12

10 SUSPENSION NOTE Front fork stroke 310 (12.2) Front fork inner tube O.D. Front fork spring free length Front fork damping force adjuster Front fork air pressure Front fork spring rate Rebound Compression shock absorber gas pressure shock absorber spring set length shock absorber spring rate shock absorber damping force adjuster Rebound Compression (High speed) Compression (Low speed) 47 (18.5) 495 (19.49) MAX 11 clicks turn back MAX 10 clicks turn back 0 kpa (0 kgf/cm 2, 0 psi) 4.7 N/mm (0.47 kgf/mm) 784 kpa (8.0 kgf/cm 2, 113.8psi) 4.2 (0.17) 57 N/mm (5.7 kgf/mm) MAX 14 clicks turn back 485 (19.09) MAX 2 turn back MAX 12 clicks turn back wheel travel 310 (12.2) Swingarm pivot shaft runout 0.3 (0.01) 4.2 mm (0.17 in) compressed from spring free length 7/12

11 FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 90 pump octane (R/2 + M/2 method). E-03, 28 Use only unleaded gasoline of at least 95 octane. (Research method) The others Fuel tank capacity 6.5 L (1.7/1.4 US/Imp gal) Engine oil type SAE 10W-40, API SG/SH/SJ/SL with JASO MA/MA1/MA2 E-03 MOTUL 300V 10W-40 (Recommendation oil) or SAE 10W-40, API SG/SH/SJ/SL with The others JASO MA/MA1/MA2 Engine oil capacity Change 950 ml (1.0/0.8 US/Imp qt) Air cleaner element oil type Front fork oil type Front fork oil capacity (each leg) shock absorber oil type shock absorber oil capacity Filter change Overhaul ml (1.1/0.9 US/Imp qt) ml (1.2/1.0 US/Imp qt) MOTUL AIR FILTER OIL or equivalent filter oil SUZUKI FORK OIL SS-19 or an equivalent fork oil 388 ml (13.12/13.66 US/Imp oz) 193 ml (6.52/6.80 US/lmp oz) REAR SUSPENSION OIL SS-25 or an equivalent suspension oil 383 ml (12.95 /13.49 US/Imp oz) Outer tube oil quantity Damper rod oil quantity 8/12

12 TIGHTENING TORQUE ENGINE PART N m kgf-m lbf-ft Cylinder head cover bolt Spark plug Cylinder head bolt (Initial) (Final) Cylinder head base nut Cylinder base bolt Camshaft journal holder bolt Primary drive gear nut Magneto rotor nut Clutch sleeve hub nut Clutch spring set bolt Gearshift arm stopper bolt Gearshift cam driven gear pin Gearshift cam stopper bolt Pawl lifter screw Kick starter guide bolt Cam chain tension adjuster mounting bolt Cam chain tension adjuster cap bolt Cam chain tensioner bolt Cam chain guide retainer mounting bolt Right crankcase cover bolt Bearing retainer screw Reed valve guide bolt Engine oil drain plug Engine oil drain No.2 plug Engine oil check bolt Engine oil strainer cap Oil filter cap bolt Oil gallery plug Oil pump No.1 bolt Oil pump No.2 bolt Oil strainer No.2 bolt Crankcase bolt Clutch cover bolt TDC plug Magneto cover bolt Magneto stator bolt Crankshaft hole plug Regulator/rectifier mounting bolt Condenser bracket bolt /12

13 PART N m kgf-m lbf-ft Engine mounting bolt (upper) Engine mounting nut (lower) Engine mounting nut (front) Engine mounting bracket nut (upper) Engine mounting bracket nut (front) Engine sprocket cover bolt Kick starter lever bolt Kick starter lever screw Intake pipe bolt Exhaust pipe nut Muffler connector clamp bolt Muffler mounting bolt (front & rear) Exhaust pipe cover bolt FI SYSTEM AND INTAKE AIR SYSTEM ITEM N m kgf-m lbf-ft CKP sensor bolt IAT sensor mounting screw GP switch mounting bolt Fuel delivery pipe mounting screw Fuel pipe mounting screw Fuel pump mounting bolt TP sensor mounting screw ECT sensor TO sensor bracket bolt COOLING SYSTEM ITEM N m kgf-m lbf-ft Water pump impeller Water pump case bolt Engine coolant drain bolt Radiator air bleeder bolt Water hose clamp screw /12

14 CHASSIS PART N m kgf-m lbf-ft Handlebar clamp bolt Handlebar holder set nut Front fork upper clamp bolt (right and left) Front fork lower clamp bolt (right and left) Steering stem head nut Front fork cap bolt Lock-nut/center bolt Front fork center bolt Fork cylinder compression damper unit Fork air bleeder valve Fork protector bolt Front brake master cylinder holder bolt (upper) Front brake master cylinder holder bolt (lower) brake master cylinder mounting bolt brake master cylinder rod lock-nut Brake lever pivot bolt Brake lever pivot bolt lock-nut Brake pedal pivot bolt Brake hose union bolt (front and rear) Front brake hose guide bolt Front brake caliper mounting bolt Brake pad mounting pin (front and rear) Front brake caliper axle bolt (caliper) Front brake caliper axle bolt (bracket) brake caliper axle bolt (caliper) brake caliper axle bolt (bracket) Brake air bleeder valve (front and rear) Disc plate bolt (front) Disc plate bolt (rear) Front axle nut Front axle holder bolt axle nut sprocket nut Chain roller bolt/nut Spoke nipple Front wheel rim lock wheel rim lock Swingarm pivot nut (engine mounting) shock absorber mounting nut (upper and lower) Compression adjuster assembly Cushion lever nut Cushion rod nut (front and rear) Spring adjuster lock-nut /12

15 PART N m kgf-m lbf-ft Seat rail bolt and nut (upper and lower) Footrest bolt Cable adjuster lock-nut (throttle, clutch and hot starter) Clutch cable bracket bolt Radiator cover upper bolt Radiator cover bolt /12