Question about 2004 Suzuki RM-Z 250

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2008 rmz 250 4 stroke i was riding it and all of a sudden it cut off and now the kick start wont move but shift through gears just fine i think the top end is locked up i'm not sure could the piston of just seized up or what?

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What you can try and do is jump start it to try and knock it loose

if not you might have to rebuild the top end

Posted on Mar 26, 2011

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Remove the spark plug, put the bike in fourth or fifth gear then try a jump start but with the key turned off. If the rear wheel locks up when you jump on and release the clutch then the piston has probably seized up OR the kick start-to-clutch hub gearing is messed up. The best thing to do is to remove the left engine side cover and look at the kick start mechanism. You may need to remove the clutch assembly for a full inspection. With the clutch removed the rotor ( crankshaft flywheel ) should turn. If it will not turn then a seized piston, broken cam chain or dropped valve is likely. If the rotor does turn then the kick start mechanism is the problem. Please rate my answer. Thanks!

Posted on Mar 26, 2011

  • furman110425 Mar 26, 2011

    well it popped loose i ran it threw all the gears and tried turning the wheel it didnt turn but then i went to kick it and i guess it popped loose i kicked it over and over and i guess it popped loose i'm not real sure you can hear that the piston has compression and would anyone happen to know what the torque is on the outside head bolts on the right side of motor i need to torque them back down

  • tombones Mar 26, 2011

    I strongly suggest you find out exactly what happened. You don't really want to be riding at 40 mph and have the engine lock up on you.

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1 Answer

2004 Suzuki RM-Z 250 hard to shift


Hi, Michael and the usual suspects are:
1. Clutch not adjusted properly.
2. Primary chaincase overfilled with lubricant.
3. Corners wore off shifter clutch dogs.
4. Shifter return spring bent or broken.
5. Bent shifter rod.
6. A loose shift lever on shifter shaft.
7. Shifter forks sprung.
8. Shifter pawl needs adjusting.
9. Heel/toe shifter coming in contact with the floorboard.
10. Transmission oil too heavy.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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http://www.mxguy.com/motorcycle-maintenance/2004-kx250f-rm-z250-service-manual_03-20-2008
https://www.partsfish.com/page/oem-parts-for-suzuki
http://mybikemanuals.com/suzuki

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Think you have simply frozen your piston from lack of proper fuel and 2 stroke oul mixture. Bike will move in neutral and with the clutch in, just won't kick or bumpstart ! Time for a top end rebuild my friend...good luck !

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usually that means a frozen engine I hate to tell you.

I would pull the spark plug, put marvel mystery oil, or 2 stroke oil, something light...then rock the bike and shift until you think you are in
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Well the motor locked up and i couldnt kick it at all shifted threw all the gears just fine but i wuz messing with it and i ran through all the gears trying to turn the back wheel and knock it loose didnt...


If you are running 5th gear mid throttle the compression in the motor wasnt enough to push the piston back down

for the record ( i run a ts 250 savage 2 stroke ) i,ve done it my self it happends

try to keep it the power band you will be fine

good luck.

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I was riding my rmx 250 and it suddenly died! i kicked it again and started and died again. i tried to start it again and the kick shift wouldnt move. what would cause this


Suddenly stopping then starting momentarily again sounds like dirt in the gas to me. It may be in the tank or the filter or, gosh, any place between.

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I have an 04 RMZ 250 I just re-shimmed the valves and put a new piston in and bike was running great started first kick road it all over the street and golf course. went on ONE ride in the heat and...


sounds like maybe valves were shimmed too tight,check service manual for clearances...better a little loose than too tight,can cause alot of damage to cam & head,be careful!!

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Like I told somebody earlier to day lower the octane rating of the gas you are using....repost if you need anything futher......

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Well. I'm a motorcycle mechanic and my 2004 RMZ 250 recently did the same thing, The Shift forks inside my transmission actually bent and were not moving the gears as far as they needed to go and eventually got to where it quit shifting all together, recently also repaired a CR 125 That wouldn't shift at all and it was the shaft the shift forks go on was bent and hung the shift forks. Sounds like your shift forks are bent to me though.

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