Top 20 2004 Suzuki RM 250 Questions & Answers

Sounds like fuel restriction causing lean mixture. Look for debris in carb float bowl and jets .

if its running good it may need a clutch

the only thing that is ajustable on the rear brake is the pedal eight ajustement closed to the master cylinder itself...if there is problem braking you may have inside cup done or air in the circuit due to low level or brake line done.....hope this help!

Take out the rear brake master cylinder and take it apart and clean it inside. It probably need new O-Rings set inside.Take out the rear brake hose and blow some compressed air into it to make sure it is not cloged.Push the rear caliper's piston all the way in.Assemble everything back on and poor fresh fluid in the system and pump it to take out the excess air from the small bleeder bolt on the rear caliper (unscrew it, press pedal and hold, tight it, let go of pedal).

32:1 is the recommended mix ratio. Use a good quality oil and keep your air filter clean!

does it want to start?

if so try these things

1. make sure that the connections between the plug and the coil is good
2. make sure that all the wires are plugged in securly
3. check to see if the spark plug is in good shape
4. replace coil if needed

good luck.

I believe you mean the clips that keep the brake pads from rattling.
The smaller one of the two, fits into the caliper where the front of the pads slide into the caliper. It goes between the pads and caliper, and has a slot to where the disc fits. It kinda fits into a recessed rectangle hole. (Opposite the brake pad pin.)
The longer clip has two small tabs on it's back, near the center, that clips towards the top center of the caliper, and it puts pressure downward on the pads. One end rests on the top of the pads, as the other ends up resting on the "pin" that holds the pads in place.
Look close, and you should see marks where they were, as they can only go on one correct way.
Good luck!

If you have the stock valving, I would run 2.5w Motorex in the damper to compensate for the stiff feel stock, and thicker oil in the spring chamber such as Mobil1 5w20 to allow the oil lock ring to do its job on bottom-outs. I'm at 375ml in the spring chamber and I weight 155lb.

8 clutch plates.
7 slip discs

The '03 and '04 K1, K2, and K3 models use the SKU# 59480-36E30. The '03 and '04 K4, K5, and K6 models use the SKU# 59480-37F00. Personally, I would take the old hose to a dealer and match it up to a new one. The difference in SKU numbers could be simply the supplier or the finish on the metal fittings. If you want to see what K number your bike is, go to the following site and input the VIN number. NOT THE ENGINE NUMBER.
Please rate my answer. Thanks.
http://www.motoverse.com/tools/vin/kawasaki.asp

Hi mate
I'm no professional but when was the bike last rebuilt? it could be piston slap!?! I think this is when the piston wears too much and moves side to side in the barrel. try taking the spark plug out and gently turning it over you should be able to hear a knock as the piston goes up and when it comes down again.
Another method is when its running put a screwdriver on the barrel and put your ear to the other end, sounds mad but you can hear all the little knocks!
I hope this helps a bit good luck James

Your air jetting is defective or maybe need to clean.It's not a big problem..Let me know if ok.

take your float out and see if it will float if it sinks replace it also replace the needle set.

petrol can often work, or gas if your from that other place.

a hair dryer or heat gun might work but dont do it near the gas tank

The RM250 kickstart will not fit.

Undo bolt, bang a suitable flat bladed screwdriver (or similar) gently into the **** & pull off

Hope this helps (if so please mark as very helpful)

Ride Safe
Bike-Doc

Try and contact your suzuki dealership or if possible try and get hold of a workshop manual .for your make of bike .It will have all the info you need.well worth having ,if you intend to keep it as the workshop manuals are rather on the pricy side .

only if the splines are the same

you need to remove and drain the fuel tank, remove the carb. and clean it out, and replace the spark plug and it should start for you.

Ask your dealership mechanic ,or if possible get hold of the suzuki workshop manual for your bike ,it will have all the settings and jet hights in there .