Question about 2003 Suzuki RM 250

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Im having trouble with my 2002 rm 250 clutchs... when i start to run the bike the cluth get like stuck or something and wildly releases at any moments and the bike runs off... its barely imposble to run the bike on this conditions... i can only run the bike properly if i push the bike and then release the clutch.. another thing the clutchs plates ans springs are almost new.. please help me with this problem! thank you..

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  • A couple of things could be wrong. The clutch cable center wire could be frayed and catching up on the outer shell.
  • The clutch cable is bent or has been hit and crushed.
  • The outer and/or inner clutch hub is grooved and the friction plates are hanging up in the grooves.
  • You changed the gearbox oil and put in synthetic oil or an oil with "Special" additives. Synthetics can swell the cork on the friction plates and cause problems. Only use 10w40 motor oil in the gearbox.
  • A bad needle bearing at the pressure plate or on the shaft
  • The clutch was re-assembled incorrectly.
Go to the following website for an exploded view of your clutch. Please rate my answer. Thanks.
www.babbittsonline.com/pages/parts/viewbybrand/default.aspx

Posted on Aug 25, 2010

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Posted on Jan 02, 2017

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Can I fit a SUZUKI RM 250 Engine into a 2000 RM 125 frame?


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Hey I have a 1985 rm 250 and its been siting for about 3 months with all fuilds removed ....I have cleaned the carb and other areas on the bike ......but when I reset up the cluch it is stuck ingaged and...


hi.
a clutch sticking on after storage is not unusual. i find that if i put the bike in 2nd gear, pull the clutch lever in and rock the bike back and forth quite hard a few times that the clutch will free off. just make sure that the ingintion is turned off, or the lead is removed from the spark plug, to make sure that the bike cannot start. this has never failed me yet, and some of the bikes i have done this with were stored for quite a number of years. hope this helps

Aug 16, 2011 | 2008 Suzuki RM250

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Toque spec for clutch springs


You can play an adjustment with your spring,the best adjustment is when your bike does't have a running cluth situation, and once you press the cluth lever and release it you'll have power just like jumping .and thats it.

May 26, 2010 | 2001 kawasaki KMX 125

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A fterI warm up my 01 rm 250 my bike don't start


Possibly the choke is getting stuck internally, Even thoug the leaver may be in the closed (normal) position, it may be sticking internally. Try removing the choke and cleaning the passage with some carb cleaner, then replace the lever. The bike could run with a partially cloged choke but would be tough to start when warm due to too much fuel. Another thing to check, when it is hard to start, just after kicking it over a few times, remove the spark plug and see if it is wet with gas. My guess is that's it's soaked. Good luck.

Apr 04, 2010 | 2003 Suzuki RM 250

1 Answer

What kind of parts are insde the chain sprket cover where the cluth line enters the case . My cluth line is tight not engageing. I looked at pictures on the ent apartently im missing like a a piece of...


This is inside the casing cover. Just a lever for the clutch cable to connect to, a spring, The clutch release mechanism, a seal and a clutch push rod. The clutch release has a threaded screw for adjusting the clutch and a locking nut for the screw. The only other thing is a metal bracket.

What exactly is the problem? The lever is hard to pull? The clutch won't engage to make the bike go forward? The clutch will not dis-engage, the motor will not stop driving the bike forward? What?

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Aug 14, 2009 | 2002 Suzuki GSX-R 600 M

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What type oil in your crankcase? Wet clutches go on strike with wrong oil. Engine oil is a no no.

Jul 10, 2009 | 2003 Suzuki RM 250

1 Answer

I got a 1995 rm 250 that the gears are stuck.


Sorry to have to say this, you have a bent shift fork. The repair means taking the engine out of the frame then removing the top end, removing the flywheel and electrics, removing the clutch , shift mechanism and kick starter and a few other parts. THEN you are ready to split the gearbox to remove the crankshaft and then the bent shift fork. Next you get to put it all back together. This is a pretty big job for the home mechanic.

You will need an impact driver, flywheel puller, case splitter and torque wrench plus the normal screwdriver, pliers, etc.. Alternate to the special tools is taking it to the dealer and say "Fix it".
I normally tell people to take it to the shop just so they don't get into such an involved project.

Please rate this solution. Thanks

Apr 08, 2009 | 2005 Suzuki RM 250

1 Answer

I have a93 rm 250 clutch not engaging


I am going to stick my neck out here and hope I can help.
The springs are not at all likely to be the problem. Any chance the cable is hanging up and not releasing fully? Disconnect the cable at the gearbox, put the bike in gear with the motor not running and see if the motor puts a major drag on pushing the bike. If pushing the bike makes the wheel lock up or the engine turn over it tends to say the cable is bad.

It could be you were given the wrong hub. Compare the old hub to the new one. Do the various measurements match? Contact the dealers parts department and ask how many fiber and how many steel clutch plates are in your clutch. Did your 9 year old son play with a funny looking frisbie and leave it in the back yard?
Ask what plate goes into the clutch hub first > Fiber or steel? Did you install the plates that way? Did the outer clutch cap go on properly and rest against the outer plate? Do any of the fiber disks have a gap wider than the other disks?

Food for thought. I hope this helps.
Please rate this answer. Thanks!

Mar 30, 2009 | 2003 Suzuki RM 250

2 Answers

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does not seem like the waterpump. is the clutch set too loose?
usually in wire based clutches, if the clutch cable is set to be too loose, or if it is frayed, and needs replacement, the bike will jump and stall.
check that.

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