2004 rmz250 service bulletins + warrenty.

[zuki dave]

customer satisfaction program. hard starting igniter c.d.i replacement. v.i.ns jkskkxcpc-aa000009 through jkskxcpc-4a005265. as we all no very hard starting. hot starter plunger corrosion. really what gets done here a zip tie goes on cable boot at carb to stop water. but is warrenty. important one here. air cleaner housing flame arrester. it,s possibly not sealing properly there is a replacement part and is warrenty. vin.# jkskxcpc-4a000001 thru jkskxcpc-4a003960. also a bulletin was sent about valve lapping. suzuki bikes have a hope i spell this right. stellulite coating is on valves lapping compound removes it and valves wear rirht out. you,ll notice valve clearence always tightening up. also owners manual correction. page 56 cam timming is shown wrong. punch marks should be linned up with head surface they show it off a little. probally be safe to ck with local shop if yours is right. affected vins. jkskxcpc-4a000009thru jkskxcpc-4a005265. as i get them i,ll post if it,s all right.

 

[Rich Rohrich]

Thanks for the info Dave.

 

[ochster]

While tearing down a new one last night, I saw a couple things that should be checked. The crankcase/transmission breather hose, runs up and over the intake, then back down to the outlet on the center case before going down out the back. They attached a ziptye where the breather tube crosses itself at the center case. This ziptye was pulled so tight, it crushed the tube down easily 70% of it's already small capacity. I would cut one off (ziptye) if it is was that tight, and install a loser fitting one. The coil is also mounted to a bracket, the bracket is then mounted to the downtube of the frame. Where this bracket is mounted to the frame, it had practically no metal to metal contact as the frame is painted. You could see where there was an attempt to clean a little paint off, but not nearly what I would consider adequate for this to ground properly.

 

[madcoweater]

service bulletins

Hey zuki dave!
Since I'm not hav'n my RMZ-250 K5 tuned by a Suzuki dealer,
would you be so kind as to send me, or post any service bulletins you get?
Sincere thanks,