Suzuki RM250 - Service Data Tables

18-2 SERVICING INFORMATION
SERVICE DATA
CYLINDER + PISTON + PISTON RING
CONROD + CRANKSHAFT
CLUTCH
ITEM STD/SPEC. LIMIT
Piston to cylinder clearance 0.045 – 0.055 mm
(0.0018 – 0.0022 in)
0.120 mm
(0.0047 in)
Cylinder bore 66.400 – 66.415 mm
(2.6142 – 2.6148 in)
Measure 20 mm (0.79 in) from the top surface.
Nicks or
scratches
Piston diam. 66.350 – 66.365 mm
(2.6122 – 2.6128 in)
Measure 19 mm (0.75 in) from the skirt end.
66.280 mm
(2.6100 in)
Cylinder distortion
—
0.05 mm
(0.002 in)
Cylinder head distortion
—
0.05 mm
(0.002 in)
Piston ring free end
gap
1st & 2nd R Approx. 8.2 mm (0.32 in)
6.6 mm
(0.26 in)
Piston ring end gap
1st & 2nd
0.30 – 0.45 mm
(0.012 – 0.018 in)
0.80 mm
(0.031 in)
Piston ring to groove
clearance
1st & 2nd
0.02 – 0.06 mm
(0.0008 – 0.0024 in)
—
Piston pin bore 18.002 – 18.008 mm
(0.7087 – 0.7090 in)
18.030 mm
(0.7098 in)
Piston pin O.D. 17.995 – 18.000 mm
(0.7085 – 0.7087 in)
17.980 mm
(0.7079 in)
ITEM STD/SPEC. LIMIT
Conrod small end I.D. 23.003 – 23.011 mm
(0.9056 – 0.9059 in)
23.040 mm
(0.9071 in)
Conrod deflection
—
3.0 mm
(0.12 in)
Conrod big end side clearance 0.1 – 0.8 mm
(0.0039 – 0.0315 in)
1.0 mm
(0.04 in)
Crank web to web width 59.9 – 60.1 mm
(2.358 – 2.366 in)
—
Crankshaft runout
—
0.05 mm
(0.002 in)
ITEM STD/SPEC. LIMIT
Clutch lever play 10 – 15 mm
(0.4 – 0.6 in)
—
Drive plate thickness 3.07 – 3.23 mm
(0.121 – 0.127 in)
2.77 mm
(0.109 in)
Drive plate claw width 13.85 – 13.95 mm
(0.545 – 0.549 in)
13.35 mm
(0.514 in)
Driven plate distortion
—
0.10 mm
(0.004 in)
Clutch spring free length 51.94 mm
(2.04 in)
49.4 mm
(1.94 in)