Periodic service of motorcycle Suzuki DR-Z 250 (1996-2007)

Periodic Maintenance Schedule
The table shows the recommended periodic maintenance intervals necessary to keep your motorcycle at peak performance. The main intervals are given in hours. Comment. More frequent maintenance may be due to more severe operating conditions. Periodic...

Air filter
If the air filter is dirty, intake resistance increases, resulting in reduced power and increased gas mileage. Check and clean the filter in the following sequence. Remove the left frame cover. ( Section 5-3 ) Remove the filter. Remove the foam...

Exhaust system fasteners
Tightening the exhaust system bolts and nuts. Downpipe bolt (1): 23 N/m (2.3 kgf-m). Connection between the exhaust pipe and the muffler pipe (2): 23 N/m (2.3 kgf-m). Muffler mount (3, 4): 23 N/m (2.3 kgf-m).

Checking valve clearances
Remove the gas tank ( section 4-2 ). Remove the spark plug cap and unscrew the spark plug ( section 2-9 ). During checks: Disconnect the oil lines. Remove the cylinder head cover. The clearances for the intake and exhaust valves are different. Valve...

Adjusting valve clearances
The valve clearance is adjusted by replacing the shims with thicker or thinner ones. Remove the intake and exhaust camshafts ( section 3-9 ). Remove the pusher and washer by hand or with a magnet ( section 3-22 ). Check the numbers on the shim....

Spark plug
Remove the gas tank ( section 4-2 ). Remove the spark plug cap and unscrew the spark plug. Carbon deposits on the candle Check for carbon deposits on the spark plug. If there is carbon deposits, remove it with a cleaning machine or carefully with a...

Removing carbon deposits from a flame arrester
Remove the flame arrester. Remove carbon deposits from the flame arrester and muffler.

Fuel lines
Check fuel lines for damage or leaks. If there is damage, replace the fuel lines with new ones.

Engine oil and filter
Changing the engine oil Place a suitable container under the engine crankcase. Unscrew the plug (1) and drain the engine oil. Remove the oil filler plug (2). Screw in the oil drain plug (1) at the appropriate moment. Fill in new oil through the oil...

Checking oil lines
Check oil lines for damage and leaks. If damaged, replace the oil lines with new ones.

Adjusting the throttle cable
Adjust the free play of the throttle cable «A» as stated below. Basic adjustment Remove the gas tank ( section 4-2 ). Loosen the nuts (1) return cable (2). Turn the nuts (1) to achieve the required free play. Loosen the nuts (3) pulling rope (4)....

Idle speed adjustment
Note. Make adjustments on a warm engine. Connect the tester to the high voltage spark plug wire. Start the engine and set the idle speed to 1700-1900 rpm by turning the adjusting screw (1). Idle speed: 1600±100 rpm - E-03.28 1500±100 rpm - E-33...

Clutch free play
Loosen the locking nut (1) and turn the regulator (2) all the way. Loosen the locking nut (3) and rotate (4) until the required free movement is achieved (A). Clutch free play (A): 10-15 mm. Tighten the locking nuts.

Checking and adjusting the chain
Raise the rear wheel and put it in neutral. Slowly rotate the rear wheel by hand. Visually assess the condition of the chain for damage: Loose link axles Twisted or jammed links Damaged rollers Bent or jammed links Rusted links Excessive wear...

Cleaning and Lubricating the Chain
Clean the chain with kerosene. If the chain rusts quickly, shorten the service interval. Attention! Do not use trichlorethylene, gasoline or other similar liquids. These liquids are too aggressive and, importantly, they can damage the rubber O-rings...

Brake pads
The degree of brake pad wear is assessed by reaching the plane of the pad with a special groove (1). When the pad plane reaches the groove, replace the brake pads with new ones (chapter 5-39 and 5-48 ). Attention! Pads should be replaced in pairs to...

Brake foot position
Loosen the locking nut (1). Adjust the position of the brake foot by turning the rod (2), until the presser foot is 5 mm (A) below the driver's footrest. Tighten the locking nut (1). Brake foot position: 5 mm.

Brake fluid level
Place the motorcycle upright and turn the handlebars straight. Check the brake fluid level of the front and rear brakes. If the level is below the minimum mark, add brake fluid of the appropriate type to the required level. Brake fluid type: DOT 4....

Removing air from the brake system
Air trapped in the brake system acts like a damper, absorbing much of the pressure developed by the brake cylinder, thereby hindering the full braking performance of the caliper as a whole. Indicates the presence of air «lethargy» brake lever and...

Free play of the brake lever
Check the free play of the brake lever. If the free play differs from the standard, then loosen the fixing nut (1) and turn the regulator (2) until you reach the required free brake lever. Brake lever free play: 0.1–0.3 mm.

Checking the brake hoses
Check the brake hoses for fluid leaks and damage. If there is any damage, replace the hoses with new ones.

Tire tread condition
Driving a motorcycle with worn tires impairs control and often causes an accident. It is strongly recommended to replace the tires with new ones when the remaining tread height is below the permissible level. 09900-20805: Device for measuring the...

Tire pressure
If the tire pressure is higher or lower than normal, the control of the motorcycle deteriorates and tire wear increases. Therefore, maintain the standard pressure value for better handling and maneuverability of the tire. The pressure in a cold tire...

Checking the spokes
Make sure the spokes are tight. If necessary, tighten them using a special wrench. Spoke tightening torque: 4.0 Nm (0.4 kgf-m).

Steering mechanism and suspension
The steering gear must be properly adjusted for smooth steering and safe operation. Tightening of the steering mechanism prevents the steering wheel from turning smoothly, and looseness contributes to poor stability. Check the steering mechanism for...

Fasteners
Check that the fasteners are tightened to the specified torque, (page 2-21 shows mounting location) NUMBER NAME TORQUE Nm TORQUE kgf-m 1 Front axle 65 6,5 2 Front axle bracket nut 12 1,2 3 Lower cross member mounting bolt 26 2,6 4 Upper cross member...

Main lubrication points
Timely lubrication of the main friction units is necessary for the correct and long-term operation of the mechanism. The main lubrication points are shown in the figure below. (1) Brake lever holder (2) Speedometer cable (3) Brake pedal shaft (4)...

Checking engine compression
The compression value is the main indicator of engine condition. The decision to repair an engine is often based on the results of a compression measurement. Records of maintenance performed are maintained by the dealer and should include...

Checking oil pressure
Check oil pressure periodically. This will provide information about the condition of the engine's rubbing parts. Oil pressure (at 3000 rpm, oil temperature 60°C): Over 50 kPa (0.5 kgf/cm 2 ) Below 150 kPa (1.5 kgf/cm 2 ) Lower or higher blood...

Maintenance Schedule DR-Z250K1 (E-24)
The table below shows the intervals for the required periodic maintenance necessary to maintain high productivity and reduce costs. Service intervals are expressed in kilometers, miles or months, whichever occurs first. Note: For motorcycles that...