SUZUKI SERVICE MANUAL TS250VIEW OF SUZUKI TS250 Right SideSUZUKI TS250 SERVICE MANUAL FOREWORD Information contained in this Manual is primarily for those whose job it is to Inspect, adjust and service Model TS250 motorcycles, but users experienced in do-it-yourself servicing of SUZUK| two-cycle machines too wil find this Manual useful as-a guide. Model S260 manufectured to standard specifications is the main subject | matter of this Manual. However, the TS250 machines distributed in your country might differ in minor respects from the standard-specification TS250 and, if they do, it is because some minor modifications (which are of no con- sequence in most cases as far as servicing is concerned) had to be made to comply with the statutory requirements of your country. This: Manual contains up-to-date information at the time of its issue. Later made modifications and ‘changes will be informed to each SUZUKI distributor in respective markets, to whom YOU aré kindly requested to males quary about updated information, if any, SUZUKI MOTOR CO.,LTD, Service Department Overseas Marketing Di sion. Auetion. copying or otherwise using any part of this manual without explicit authorization fram SUZUKI MOTOR CO. is nat pecmitted,GENERAL INFORMATION 4 ELECTRICAL ignition type tian tendo ‘Spark clap artery Generator Fuwe Hasdtone ‘Tal/Seake tome Turn signal lomo Sosecomneter lar “Tachometer lee Netra indicator lamp High beam indicator lamp ‘Tur signal pilot ame caracivies Fuol tank cluding reserve Engine oll tank Fant fork of ‘Tranemision off ‘SUZUK “PEI* (Peintles Electronic Ignition) 2 87 D6. ¥16,000 rom NGK B8ESar NIPPON DENSOW2HES. BV 4AHNG Hour Free magneto 1A ev 25/250 8V JOrSHN (U.3.A., Conade) BV 8 3/26 (2192 sp) Ov 170 (21! sv3w evan evan Bu arw By iW 10 (2,672.2 USI all 20 ft 2.1/4.8 US/iemp ath 1.2 (2.8/2.1 US|im 217 e¢(7.3907.64 USImp ol kn wach log ‘Gil bath, 680 ce (180/150 US/Imp pt)4 GENERAL INFORMATION SPECIAL TOOLS Saetial tools assure three things: 1) Improved warkmanshi are meant: and 3) protestion of parts and components ot seribed for the Model TS250: 2) speedy execution of jobs for which thay. ist damage. Here are the special tools pre 7 a 8 ny sad iting oat ram st intling to an sa nomr (caste. ra7to, (taBr0-19610) ooota204 a) 4 5 6 ‘Crankeace separating taal rom hexagon & type (i seal rornover ‘oooroorra) vronch (08811 74840) toes 0110 7 a 00: 50min) 25.2 mm, 00:24 wh Dearing ter ‘Bearing ard ai sal inna Searing aol ol nea. (an9+3 F006) lingo t9813-Torza ‘ig ton 00013801111 10 u 12 | Clutch eave nut ht Snap sig open io) per Ses rng pana ea ng opener as) i |__teseao7arr ‘eoen7010) 19 hha = @ we? ‘Soark plum wench Rotor remover shaft Shaw sho et Sotoe reaver tachment Me % (c29s0-20104) L_ teasso3ara0ing too! 108540-53311) tool eat (08840.3454 0) GENERAL INFORMATION 5 16 Ww 18 eects and reseed oe Sato wr (oossb-nrTa) eee ‘Gessceornat 19 20 oxsoo.onion een | By Sag Feces my | a 22 Engine taeharnatar lac nt (ype $8 sne00-26002) (09000-28104) ra) 26 oF ¥ (46min 8: 4 mm) tome From fr of ra Front fore splng§ GENERAL INFORMATION REQUIRED SERVICING MATERIALS ‘The materials listed below are needed in maintenance work an the TS250 machines. They should be kept on hand for ready use. In addition, such standard materials as cleaning fluids, lubricants, etc, 100 should ba made available. How ane! when to use them are explained in the text of he rmanual, Ret a Materia! Ue 1 | THREAD LOCK CEMENT For locking sl screws inside the {99000:22040) ‘transmission case, For locking reed valve fitting screws, For locking front fork spring seat bolts, 2. | SUZUKI SUPER GREASE A’ For lubricating oi seal lips. (99000-25010) REPLACEMENT ANO SPARE PARTS Use replacement parts supplied rom SUZUKI: it Is safer, more convenient and economical. Any eco omy achieved by using imitation parts is imaginary; they often prevent the machine from alving its full ertornance or give rise to trouble. ‘Always insist on GENUINE SUZUKI REPLACEMENT AND SPARE PARTS.GENERAL INFORMATION CONTENTS SPECIFICATIONS SPEGIAL TOOLS...;-.c.00.c000 REQUIRED SERVICING MATERIALS, , REPLACEMENT AND SPARE PARTS OaaNGROUP INDEX GROUP TITLE | 1 | GENERAL INFORMATION 16 C= = me 3 cHassis 16 | 4 | ELECTRICAL SYSTEM na | |5 | TIGHTENING TORQUE 82 | 6 | PERIODIC INSPECTION cHarT| 13 |2 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND WEIGHT Piston cliplacemene oirected compres rate vera tenoth 2.180 am (86.8 0 (vara wes 1870 men (94.3 ink vera height 41,190 men (44.8 in) \heetbace 1,00 en (85.1 nh Grou! cawranee 1240 men ( 8.4 inb Dry wlohe 118 ky (260 es) ENGINE Tee “Twostrake eyele, alrcoaled Intake ayatem Piston are 08d wale [Number af evindsr 1 Baw 70 rm 12.78%) Stroke 54.0 mm t2Bzin) 286 ec 195,0 eu, fo} 8:1 erburesor MIKUN! VOIZBSS, sing ‘Airelaner Polyurethane four siemart Starter eaten Primary kik LLubeication aystem SUZUKI “cey" “TRANSMISSION lueen Wet multiplets type Tranerieten Bapoad constant mash Gears naearn doen 4p Primary recast, Biaaiszien) reduction 2.600 140/15) rates, Low 2448 (29/12) 2nd 100 (22/16) Bec 1.27 gana) ath 1.000 (21/21) Top 0.826 (19/23) | Deve chain BAIDO #5287, 100 links CHASSIS rane suspension Telescopic ll darmpenes Freer sxpention Swinging tm, gato damoaned, soring Barey adjutsble Steering angle 49" tight Sate Coster sitog Trai 142 ram (5:58 in) Turning radiun 24m (79 Front arake Intamal expanding Few brake Intornal expanding Front tra siee 3.0021 4PR, ea tee ise 490-18-40R, From tre pressure 1-Sp/em? 121 pall (Normal soto riding) ‘lew tir presure {75 kale? (25 pal {Moral solo rinaENGINE CONTENTS DESCRIPTION 22... os: ese eeree ‘Cylinder : POWBI-ROGd...0s ese sseseceeec eee ee ENGINE REMOVAL AND DISASSEMBLY. Preparation aeons Engine Disassembly ee ae ENGINE COMPONENTS INSPECTION AND SERVICING. . Cylinder Head Cylinder... Piston... Piston Ring Crankshaft. Reed Valve ‘Transmission . . Clutch. Oil Pump. .... Air Cleaner Element Carburetor. REASSEMBLY Ol Seal. Crankshaft. Kick Stert Transmission , Tachometer Driven Gear. Gearshifting Mechanism .. . Chimera css Engine Sprocket . . Piston sess: Piston Ring, Cylinder . . is Cylinder Head... ,4 ENGINE DESCRIFTION Cylinder The mixture is admitted into the swept volume of the cylinder through six (6) scavenging ports, to ‘which the mixture reeches from the crankcaso side in four (4) streams, This arrangement assures smowth scavenging action and contributes to the high-power perfarmance of the TS250 engine. Powar Reed Intake System ‘The mixture is drawn into the seavenging space of crankcase through twa intake paths, one opening into {he lower part of the cylinder, partially under the piston. and the other opening direet into the erankewse through a reed valve “The mixture ta the farmer path Is devwn in by conventional “piston vilveaétion” and the mixture in Fregattet path by the action of the reed valve. This feature, illustrated in Fig. 3, i named “POWER, FEED Intako System”, Fla. 3. POWER REED detail in wieENGINE 3 Combined Action of Piston Valve and Reed Valve Reed valve opens and cloves in tesponse to mixture requirement of the engine. Piston valve pens and loves at given crank angles during each cycle: mixture flowing into under the piston on compression stroke emeounters litte résistance, Rater to Fig. 4 showing the timing relationship between these two valve actions LOWSPEED 78cm HIGH SPEED Fig. 4. Part timing dfegrams Thi ifot port (subject ta niston valve action) is located to open later and to close earlier than in ordina- Ty motoreycle engines, This feature iscalculated to improve torque performance in the intermediate. end ‘ow-spaed regions, How the impravement is accomplished will be sen in the fact that, with this port ‘losing eater, the tendency of mixture edmitted inta the scavenging space to blow back into tha intake Postage is minimized inthe intermadiate-and low-speed regions. |i the high-speed region, hovrever, this inlet part does not past enough mixture Becaute of its retarded ‘pening actian, This drawback is offset by tha reed valve, which epans ahesd of the inlet port 2ven when ‘tha eeqine is running very Fast.ENGINE ENGINE REMOVAL AND DISASSEMBLY Proparstion Before diamounting the engine from thé frame, clean It In place With steam, This is necessary for pre venting dir from entering the engine during disaskamby, NOTE: To tuciiate engios rmmovs!, ave the ‘magpeto rota and stator removed, 3t | shown ip Figs throwh 7: A Fig. & Hold the rotor mith spsciet too! (03820 40113), ancl unscrew che nut securing the rator, Fig, 6 Draw out the rotor by operating the Fig. 7. Remove the stator, special tools (®) &) (09930-30103, (09930 ~80190) 4s shown, Engine Disassembly The sequence of steps for disassembling the engine taken down from the chats i as follows. x Fig & Remove oil drain plug amd lot owt ol Fis. & Loosen cylinder head nuts sequentially, loosening eact nest just a little ato time, and take off the head.ENGINE 11 Fle. 10: Disconnect ol! pipe trom eylinder and ip 11. Detach and remove the cyitnder. cvankease, Fig, 12. Remove pistan ln circlizs (Plug up Fig 13, Draw out she pin, erankcate with wiping cfath, as shown, ‘and then remove the ciretios #0 that they will not fall inta erankease.) Fin 4, Hold the sprocket sandy with soncil fig. 16, Takeout cer too! A) (0993060173), and remove = Srocketnrt12_ ENGINE aa = Fig. 18. Remove oi! pump trom erankcase, Fig. 12 Biscommect and remove the neutral witch, . 2 a Fig. 18, Remove kick starter lever. Fig. 19, Remove right-side caver, Fig. 20. remove the Botts balding down clutoh Fig. 21. Using special tool ® (09920.63710), sorlgs. hold! stoove hub steady. Loosen end re. ‘move the hu mut,ENGINE 13 Fig. 22 Remove primary arive gear nut: se Fig. 232 Remove kiak driven gear. special too! (4) (0990-201 4}, Fie 24, Using soecfel ool (3: (09820-70181), Fig, 26, Draw gear shifting shaft out of erenke remove the circlip, and draw out kek ca. ‘le gear Fig. 26. Remove gear shifting carn guide, Fl, 27. Remave cam driven goar. (Be corctul ‘not to lee pins and springs ty off.)U_ ENGINE Fig, 29. Remove the screns fastening the two crankcase halves together. MOTE: Remove sores A) 100, Fla. 30. Using special too! (2) (09810-80113) as shown, separate tho 140 halve, Fig. $2. Draw gear shitting fork shaft ovt of crankcase, and take out shifting forks. Fig. $2. Draw gear shifting fork shaft fon deive (pear skie) out of erankeae,ENGINE 15 Fig. 34, While keeping the goer shifting cima Fig. 38, Take ous the clusters of gears comolete stopper separsted from gear shitting with share, am By pushing it wich a fingertip, take out the cam a ‘ Fig. 36, Using 2 plastic hammer, dive the erank- shaft out of crankcase, 8) (09920-70111), re- move the clrciia and take ovt spring auide Fig. 39. Remove kick shaft,16 ENGINE ENGINE COMPONENT INSPECTION AND SERVICING Cylinder Head (Gbsorve the combustion-chamber surtaco of the removed eylinder head, noting the amount and oolor of the sarbon deposit ax data for telling the quality of fuel combustion: the ides formed by this exami jation about fuel combustion is one of tha raferoncos naoastary for earburstor adjustment, Ramave the carbon, taking cere not to nick oF mar the metal surface. Carboned surfaces are often responsible for tha tendeney of an engine to overheat oF ta produce less power than it ‘ought te be capable of giving ‘Using & surtece plate ond red lead paste, check ‘Wn gasketed sutfece of the cylinder head for ‘latness. If high and fow spats are notad, remove them by rubbing the surface against an emery Paper (af about #400) laid flet on the surface plate in a lapping manner. The gatksted surface ‘Must be smooth and perfectly fiat in order to Ssacure a tight joint: & leaky joint ean be the cause of reduced! power output and increased fuel con- sumption, Cylinder Carbon is mora likely to accumulate in the ex- haust port bore as shown. Sueh accumulations should be camaved by scraping with the flat tip ‘Of 8 rod: a plain screwdriver may bo used for this purposa CAUTION: tun’ eearbening the exhaust Port as shown, be ‘careful mot ta id the evtinter Fig. 40. De-carboning the eplindr heed ar Fig. 41. Repairing warped surface of cylinder hes oA ] ool S| ae Fig. 42. Decarboning the exhaust portENGINE 17 ‘The wear ef cylinder wall Is determined from diameter readings taken, es shown in Figs. 43 and 44, at a ‘otal of 6 ptacas with a cylinder gauge. Elevations at which the bore is to bs checked are indiasted as (a), (Band ©; at each elovation take rasdings in two directions (Fig. 44). Fea, 43. Checking hore demeter for Fig. 44, Cylinder bore check poinis ‘The amount of waar is tho differenés between largest resding and smallest reeding, If the wear thus Gerermined exceeds the limit indicated below, rework the bore to the next oversize by using a boring machine or replace the eylinder by « new one. Oversize pistons are avaliable in two sizes: 0.8 mmm {10.0196 in) and 1.0. me (0.0298 in) oversizes. After reworking the bore to an oversize, be surs to chamfer the edges of ports and emacthen the “tarnfaree eeges with sandpaper. To charnfar, use » eeraper, taking care not ta nick the wall surface, ler bor O41 NOTE: thinor surface Fave on the cylinder well due to eizue or smi mleondlilons ean be corecied by wining te flaws off wit finegrain secpaper, Ifthe Hwa ar desp graces or ethers parti, the ‘ner most be mort with s boring machine to the next arson, = [Wear timit on ovii FLintet te piston cloarance i tne difference betwen piston darnter, reo atthe elevation ineicted in Fig. 48, and bore diameter, raad at the elevation indicated in Fla. 46 fter finishing the bore by honing, the oversize piston18 ENGINE O L t a LL Fig. 45, Piston dismeter for cylinderto-piston olesrance determination Referring to Fig. 45, be aure to take the miked mater Bt right angles to piston pin. The value olevation (Is prescribed to be 26 mm (1.024 in). The elevetion at which the bore diameter is to be read is about § mm (0:20 jn.) above the exhoust Gylinder-to-pistan 9.080 -0.070 mm Clearance speciticstion | (0.0024 -0,0028 in Piston Remove the carbon, if any, on the alston crown by scraping es shown in Fig. 47, Fig, 46, Bora diamater for cylinder to-piston clearance deterrmination Fig. 47, De-carboning the piston crown,‘De-carbon the piston ring grooves, as shown in Fig. 48. After cleaning the groaves, fit the rings and rotate them in respective grooves ta be sure ‘that they move smoothly. ‘Carbon in the groove is liable to cause the piston ring to get stuck in the groave, and this condition ‘will lad to reduced engine power output. A piston whose sliding surface le badly graovod ‘1 scuffed due to overheating must be replaced. Shallow greoves or minor scuff can be removed by prinding with emnery paper of about #400, Piston Rings Check each ring for end gap, reading the gap with 4 thickness gauge, as show in Fig. 50. the end Sap is found to exceed the limit, indicated below, replace it by a new one, ‘The end wap of each ring is to be measured with the ring fitted squarely into the oylinder bore And held at the least worn part naar eylinder top, ts shown in Fig. 60. ‘As the piston ring wears, its end gep increases 10 Feduce ongine power output beeauss of the ‘retultant blowby through the enlarged gap. Here figs the importance of using piston rings whats ‘9998 are within the limit, emery paper. Piston ring end gap specification Sendai Limit 0.2~04mm 085mm (2008~aeren) | t0.08a in)1 ENGINE Crankshaft After visually pecting the crankshaft, check it particularly carefully for 1) shaft deflection, 2 can- ition, ofall bearings at shaft ends, and 3) conditian af connectinarod bia end bearing, as follows: 1} Crankshatt deflection Support crankshaft by '"V" blacks, as shown In Fig, 51, with the dial gauge rigged to reid) the runout. Deflection is half the runout read on the gauge, ond is specified to be within the following i Limit on cranksnatt ene 0.05 (0,002 in) Excessive crankshaft deflection is often responsi- bie for sbnormal engine vitretion. Sueh vibration shortens engine life, 2) Condition of erankshatt ball bearings After washing the bearings clean, spin the outer race of each bearing to see if itrototes smoothly 13 It should, without any abnormal noise. A bear- lng sound to rattle, grate or give any abnormal noise er to present @ color signifying buming ‘must be replaced. To wash tne crankshett, use kerosene. Ac the time af installing it, ba sure ta oil It with the prescribed lubricant, 3) Condition of big end bearing In the sondition shown in Fig. 54, tum the Grankshaft with the connecting rod to feel the Smoothness of rotary mation in the big end. Move the rod up and down while holding the crankshaft rigidly to be sure that there is no rattle In the big end, Reed valve A: ¥ Bock 8: Oia cause sou e thickness gauge, check the cleorance between reed valve ard its seat W this clearance (neat 55-8 Fig 3) is noted 1 exceed 0.2 mm (0.008 in) replace the whcle ceed valve ossembty. ‘The reed valve sesernbly is treated a2 8 unit in the ‘supply of replacernant parts: fs indvidus! parts are not supplied 95 such, However. it is per- ‘issble ta disassernble the reed valve csvmbly in lace, a8 shown in Fig. 53, tor servicing; if Ithos to be disastambled, be sure to adhere to the ‘following two rules In reassembly: 41) Tighten screws CD to a torqus of anywhere ‘between 7 and 8 kgm {0.80 - 0.66 tb-ft) with LOCK CEMENT (98000-32040) appa 40 torew threads, (2) Check to bo-sure that the dimension @), Fig 3, is at feast 1 mm (0.04 in).ENGINE 2 Transmission Upon diatsembling the engine, Immediately inspeet the vansmission internals, visually axaminiag Wye jars for gamage end checking the mashed condition of goa teth. Using o thickness gpuge (8 109800 20804), Fig, 54, check the shifting fork clearance in une groove of its gear. This clearance for each of the three shifting Forks plays an important rale in the smoothness and positivoness of shifting action. Each fork has Its range fitted into the annular groove pravided in Hs gaar. In operation, thare Is sliding contact between fork and geer and, when a shifting action is initiated, the fork pusher the gear axilly, Too much a ciearanca is, therefore, table ‘to caute the mashed gears to sip apart, Fig. 54. Shifting tork clearance in the groove, HH the clearance checked is noted to exceed the limit specified, replace the fark: or its gear, or both. Shifting fork clearance specification Fork and gear ‘Standard Limit 3rd drive gear & fore 4th driven gear & fork Sth driven gear & fork 04-06mm 0.8 mim {0.016 - 0.024 in.) a ind22 ENGINE Clutch 1) Drive plates and atriven prates ‘Clutch plates in service remain in ily condition: as condition, both drive and driven plates are subject 10 if they were jubricatod with all. Because of this but little wearing action and therefore last much eae at ie-debends largely on the quality of ol uséd in the elutch an also on the way the clutch is opereted, “These plates are expendable: they are meant 10 ba replaced when found worn down et Warped to the espective limit: use w caliper ta check thickness Warpane, as shown in Figs 55 and 56, Drive plate thickness specification Stondart 3mm 10.138 io.) Ft6. 85. Checking for thickness 2) Cluten release bearing Inspect this thruststype beating for any malcon- dition, “particularly. broken eondition, upon famoval trom the clutch, to decide whether ft ‘an be re-used oF ehould be replaced. Smooth tnpagement and cisengegement of th clutch depends much on the condition of this bearing, ed @ thickness gauge end surface piste to’ check ‘Thickness and warpage specifications for driven pistes iam ‘Standard Limi 5 20mm 1.85 mm |_ Thickness, | (oo7ai (o.073 in) 0.1 mm Werpege | Loe than 0.1 mm] Calm SO, Ww ig 85. Cheng for waco Fle 57. Thruee-type release besringENGINE 23 Oil Pump 4) Air blosdina 7 Whenever avidanee If noted of some air having leaked into the ol pit brought in for servicing or if the of! pump hed ta be removed for servicing, be sure to carry ott biteding operation with the oil pump in place before releasing the rnachine to the usar. ipo from the oil wank in the machine ‘an air Hore’s how to blaed the air out: Hold the engine in standstill condition: looser: screw (A), Fig, 88, ‘ta let out the air; and, after making sure that the trapped air has all been bled out, tighten the sero good and hard a caiwalebivadpanion Fi. 88. Bleeding alr out of tonk-to-pump oil pipe “This ediustment refers ta the oll pump control cable, and js to be effected by means of cable adjuster 7), Fig, 9, Three alignment marks are involved: mark) for mark. , and mark () for hole @ ‘As the throttle grip is turned to actuste the throttle value, thereby bringing dent mark () ofthis valve ta the upper part of carburetor alignment hole ®). mark(®) should come into regibr with index mark’ ‘This requirement jz satisfied by adjusting cable adjuster‘). After setting the adjuster, bo sure to secure it firmly by tightening its lock nut Fig. 69. Of] pump acfustment Fig. 60: Corburetor alignment hole 31 Checking the oi! pump capacity Ure the snecial too! ( (09900-21602), Fig. 61, to check the pump for capacity by measuring the {amount of al the pump draws during the specified interval, The checking procedure follows: Have the taat cA tiled with GCI oil, and con- g r ‘act It to the suction side of tha pump. 2 Run the engine at 2,000 rara, {Hold the oif contro! lever in full-open position, and let the pum draw the oil for one minute The pump is working property if the spacial tool indicates anywhere Between 0.9 and 1.3 . @ Holding engine speed at the same 2,000 rpm, ove the laver down to the middie pasitien (omare an engraved ling mark is provided) and let the pump draw for ont minute, For this pecation, the reading taken on the device should be from 0.80 0.9 ce. . Fig. 61. Cepecity checking too!Oil pump capacity specification at 2,000 rpm er angle Pumpingurstion | —_Delivany 0) | One minute 05-08 i One minute 09-13cc a al F&@. 63, Ol conérot lever in bal¥-opan position Fig. 62. Oit contra! lever in Fullopen pasition Alr Cleaner jan taking the element out of the air cleaner, ingpsct it for evidence of Fissure oF breakage, and replace tas necessary. To clean the element, procead at follows: © ropere-s nan or receptacio Irae enough to wath the eisment a. Fil the reesptacte with gasotina, immorte the element init and wash it clean, & Saveeze the pasoling aff, end dry the element, Bie the dried element inte a pool af SUZUKI CCI oil * Slueeze the oll off, making the clament wet with oi Make qure ‘hat no oil is dripping from the clement, Install the wet elem in the air cleaner wringing wot hare von ‘oth both hands, 6th elament may fall ‘hands 10 squeeze the liquid of, Washing intarval for air cleaner element _[___ Spore. Bie ite al = | is ; aeCarburetor 1) Carburetor construction A single-barrel MIKUNI VIN28SS carburetor is used, work, be sure-te refer to the — Fig 65. Exploded view ofthe carburetor = SSSS~S~S 2) Carburotar jatting ENGINE 25 ‘After disassembling the earburetor for overhaul ie 2 3 | « 5B 6 4 a 8. 0, 1" 12 13 it 18 6 a | 1%. eeees m. -eploded view, Fig. 65, of the carburetor in ordarto rabuile it correctly. Serwe Plate Fin Pin Pin Spring Connestor Gaxet Beeckot Clip det nasal iron wae Guket Spring “Throttle sjuster Sering Garket Seeing “Throne assur Bue a" ning spring Starter vale Needle jet al ain je [Needi vale ase Float arm owt pis Fost verfiow tube 25 )__f away [146 mm (0.575 n)) 1-1/2 turn backed Number irene) sa26 ENGINE 3} Corburetar flost height adjustment Brlenced carburetion at soch feel of speed dopinds much on the oat imal setting, Checking and Adiustment of this height (level) is partiaulany importent ‘To check the float height, invert the carburetor [., foay dis fae am nese hat nein | Piwiyn an ‘wll oot slip off. Wirth the togt arm kent tro, | mh. meaiure the dimension ® , Fig. 66, while float Bb 1m fe in contact with needie valve,” Fer the i— | ‘measuring teal, use a calipar. Bend the torque\fh sion to this ‘a necessary, to bring the value: Standard flost height | 14,6 mm (0.875 in) —— ee Fla tor Host height 4 Diegnosis on earturetion [tbethet the earburtor is producing » proper mixwe of fuel end air can be told by making a road test {Fimalating the way the user operates the machine| ith » Standard spark plug (NGK B-8ES or NIPPON SENSO W24ES) fitted to the engine. After the soa ‘est, remove the spark plug, end observe the sere ance of the plug as wall as the surfaces of cylinder hao ane Piston crown. The colar observed ‘ellsswhether the mixture is toa rich or too lean, 5] Mixture adjustment mrhine at that throtle postion for a distance of abcne 10-km, after whlah the spark plug, evlinder head and piston crown should be inspeated for color ane sepearance. The mints can be made “richer” or ‘Teanay* by three scjusting means: namely, main jet, jet needle and pilet air screw, tetvenss of thre maans doer ont aot piney ‘shown in this ehart: Mery effective Fairly effective Little effective +s INot affective at aENGINE 2] How these theee adjusting meant are affective will be exolaineds A MALI JE en te map fa 314 filer, te ant feel for butions eon by this jet, Hf the mixture is too rich {indigated by a black color due to carban}, replace the men jet by a ney rane lr ir rsh x whi ay, rane hatte me ‘two lean and, in such a case, 3 main jet with a larger number should be used instead to enrich the mixture, [aoa [08] [Larger number: ‘Richer mixture ‘Smatir number Hig Tuaaaae mostra 8, JET NEEDLE ‘The rate of fuel supply for carburetion ie cantralied by the jetneedie when thrattle grip isin the range from 1/4 to 3/4, To enrich the mixture, set the needle by a lower notch, and vice versa, Removing the clip allows the needie to be repositioned. There are a total of five notches for selectively setting the needle by clipping, eee Standard fet needie sating | drdretch | Jase Adjusting by means of the jet needle affects the carburetion for the aetian for te lowe For adjustment in this range, reposition the pilot air screw as shown: SETS RE EE Pitot sir Aajusting Sere Standard pitat aie | BU" in ll the way end] wma eee saa back it away 1 & 1/2 urns.28 ENGINE '8) Throttle cable installation Pass wo cables through two tapped holes Provided in the carburetor and tie them to the ‘throttle cable pulley. Mount the return spring on the pulley, and wcure me pulley tothe carburetor, Be sure to discriminate Between the ‘wo cables: ane js for opening and the other is for closing the throttle valve NOTE: The optning cable thet Which ‘somptete with the oH] pump contral able After installing the tio cables, be sura to adjust them by means of their respective odjusters 0 Produce the specified play, and sizo ta adjust the oll pump at oxttinad before, For bath cables, the play (i, Fig. 68, i specified 15 bo between 0.8 andl 1,0.mm (0.02— 0.04 in}, a then [ Three cob pay | asi mm” [teach sides | 0.020,zs ENGINE 23 ENGINE REASSEMBLY efabling steps that demand Reeassembly is generally reverse af disassembly but there are a numbor of eaass for raspective parte and toc daserve detalled explanation or amphasis. Theos steps will be taken up ‘components. Oil Seals it ls @ wise practice to discatd all oil seals ramaved in engine disassembly and use neve oil seals in reaiséenbly: economy gained by re-using the removed oll sels is imaginary in rmost e888, 11 el seals removed in disassembly have to be re- Used, then make sure thot their lip portion’ are in good condition — unbroken and undistorted, ce Just before installing each oll sal, be sure to LN apply SUZUKI SUPER GREASE “A” to 1 lip i ji ‘be aure 10 use the oil seal installing too! (special 100!) to fit the oil seal Fig 69. Ollseal Crankshaft ‘Tho crankshaft is 8 bullup essembly eansisting atthe parts identified in ference to the exploded view below. e sure ta consult this illustration when reassembling theerankshatt. ‘il seat Bening Spacer ll guide pane [LM eranasnart “Ths ovisher Grankeia Bearing Connseting roe “Thrust washer |. RH exact Ol seal Besring Primary drive soar Washer Nut Ke30__ ENGINE When mounting the crankshaft in the crankcase, It is necessary to drive its lett 4nd into the ‘eranksase, Use a plastic hammer or a seft-metal hammer for this purpose. NOTE: Be careful mot 10 allow tha cit guide late to separate from the eranks what ‘whan setting the crankshatt in pion, Fig. 71. Instating the erankshatt Kick Starter ‘Te Mek fart parts for model TS250 are shown in Fig. 72. Combine the part to form the kick shett ‘suirastambly 4 shown in the photo, and then insert it into the sight crankeaw hel from suteate a ae] 4. soning Spring wuide Pi 1 =Care must be exercised in installing the return sering, a coll spring whose ends are hooked, Here's how to install it: After fitting the spring holder to kick shaft, hitch the and (on the for ‘ide in the phota) of return spring to crankcase stopper! tum ovar the shaft (counterclockwioe in the photo) ac far ar it will tum; rotate the return ‘spring about 180 dep, clockwise; and hitch the other end to the hole provided in Kick starter shaft, Agtar installing the roturn spring, fit the spring ‘guide and retain it by installing the circ, ‘Transmission In reassembling the transmission, attention must be given to circlips. The cross sectional view glven hare will serve as a reference for carreetly mounting the gsers, washers and citclips 2 locations and positions of washers snd Fig, 78, Transmissian cross section20_ ENGINE Oil reservoir Kick startar eriven Washer Bearing noiger Being Coumtershatt ‘$19 deve pear ‘Ie dive sear 5th dre omer 2rd drive pear Bearing 4th ceiver gear 2 celen par th driven gear 2nd driven gear Drive shan Bearing Oitsest 2. Spacer > Fi 78. Exploded view oF tranemission gwar clastorg Zhe Lsbreeting oll forthe transmission is preserlbad 16 be 8 mult ace moter oll aF SAE 20W/a0, To iit up the tranimision shar reassembly, pour the oi slowty ‘through the filler until the oil begins to ‘overflow from the oil level screw hole (i on cpa] 650 ce 1.80/10 USM i 1 fe Swe | Intervals of trenemissia sil change Lin ‘aaa 7 (600 rites) | Fie cance | After initia 1,000 i [Sere T accannaramocn at Fig 77. Olt Filter cap FG 78 OW drain pagENGINE 33 Tachometer Driven Gear “Tachometer driven gear sleeve has @ hele A, Fig 79, and the crankcase has a hale, When Jnstalling this driven gear in the crankcase, be sure to align these two holes lengthwise of the sleeve, Gearshifting Mechanism ‘The exploded view af tha machaniam given in Fig. 80 carves asa reference for renssembling work. 1. Seeing 2. Washer 3. Gear siting eam stopper Bolt 5. Gaar shifting for: shaft Siting eam stopper plate Geer shittingcarn Cam arbvan goar Cem stsnper sing naor Gor shifting fork "8 Gear shitting fork shat NOTES: 1 De wary of the fet thet the two paves (each bing urged by’ @ sting nd pin) 6 not identical the ‘ope with lary ih (tas is position fscing the outs of the ear. by angularly dlapacing the stator. NOTE: in the TS2H0 motorevates martial ia the U.S.A urd Cansda, the lghtiog e twitch in-flaed in “ON” postion. For “this razon, index line J reat be beought Inia alignment. with screw 'F) . Thus, indox tie I) tor the machines market- ‘td in ether countries. < ® Secure the stator right there by tightening its ‘hee securing screws, @Puron the rotor, marks (KOKUSAW.make magneto) For machines in te VBA, and Gann L Fig, 128 Gosinloning tha stator by matching marks (KOKUSANemace magneto) Fig. 130. Positioning the stetorby matching marks (BENSO-make (10 J magneto ‘used only in TS250 maetrines ‘marketed in the U.S.A. and Canada)56 ELECTRICAL SYSTEM SPARK PLUG ‘The 8-8ES (NGK make) or W24ES (DENSO make) spark plug standardly fitted to the engine of the Model, 5250 wil satisfactorily serve undor most of duty conditions g¢ far a5 the spark plug heat range ie Provided that the earburetar and ongine are tuned correctly for proper fuel carburetion, Two'optional plugs are aeilable: HOT type and COLD type, Wf the standard plug is noted to serve 100 hot or toe cold, replace it by the cold type or by the hot type plug, Spark plugs for model T5260 uae moke | DENSO make Hot B7ES W22ES: Surcia| BaEs | W24ES ee i ae ‘Chock the spark oap with a thieknass gauge and, se necessary, adjust it to the specification: Spark pion gop | 08.0.7 mon ee | (0.024 0.028 in} Fig. 131, Spark pivg gap CHARGING SYSTEM COMPONENTS Je be Inspected ara 1) silicon reetificr, 2) lrnp coll ae 3) charging system at a Whole. Note shat the Sharbing system ditfers slightly for the two categories of morkats: a) the U.S.A, and Canada, sod b} ‘thar than the U.S.A, and Genada, ie Ihe niin ISA Nigh toon nate | we caer TL Taillame Shloan wee Yo: Yani a on 788, tin een i | beau vin ‘Comer for moi orecrsing | s.087 eh Nahe Me OHBIL HL MoM FL | Higher) — {Lom beamd ones 8 — Sam ‘Pig. 132 Charging system for other than the U.S.A. and CanadaELECTRICAL SYSTEM 51 WL Heda are H.BLLL : High beam inalcoor tp HAL Meera & Tall lamp ‘Siieon Rectier ‘YIW: Yellow ite G Green " ‘VIR : Yelle | se | | via HOW BIR HL ML MAL (High beara) (Lew bea) Fig. 133. Charging system for the U.S.A, and Canada Silicon Rectifis ‘The silicon rectifior is loestad in the pabitive (+) line eanneeted to the the rectifier with 4 6.wolt bulls to. eee if fe is ruptured. A ruptured rc bbe replaced, itive sida of the battary. Test ier does not "rectify" ane must Apply battery voltage to the rectifier in two diractions, with the bulb placed in the circult, shown in Figs. 194 and 136. If the bulb burns when the rectifier Is blared in forward direction (Fig. 124), but doss ‘pox burn when the rectifiar is bised in reverse direction (Fig. 135), then the ractifier is in sound cone dition; otherwise the rectifier must be replaced L LoL Fig, 194. Checking the recttior In forward doe ‘16135, Qhecking the eer nrovereELECTRICAL SYSTEM Lamp Coil Performance: Connect an AC voltmeter between the Y/R lead and pround, as shown in Fig, 196, A circut teste (with its selector knob st for the AC 10-V range) may be used instead of the AC voltmeter, {Close the lighting switches to turn ae the following imps: © HEAD LAMP (281) oo. esos. (BOW forthe USA, and Conta) @ TAIL LAMP (6.3) 4 SPEEDOMETER LAMP (304) © TACHOMETER LAMP (3WI © NEUTRAL INDICATOR LAMP {3 W) CAUTION: Beaure te have: hes lamps ture on or the tartar wilt utter mage. @ Start up the engine, and run jt at 2,500 rpm first_and at 000 rpm next, Read the tester at these fara speeds. The lamp coil i working properly if at least §,7 vols is read at 2,800 rpm andl not higher than 9 volts is read at B,000 pen. Fig, 198 Testing the larnp call for performance Charging Coit Performance ett an atieeter between the rectifier and the battery, as shown in Fla, 137, A circu tester (with ite solecter knob set for the BC. 10-A range) may be used instead. Giese the lighting switches ta tun on the following lamps ‘© HEAD LAMP (25W).. orn (SOW for the USA, and Canada) © SPEEDOMETER LAMP (2w) © TACHOMETER LAMP (aw) # NEUTRAL INDICATOR Lamr (aw) * TAIL Lame isa) NOTE: In She U5.A, or Canad, hve the tif amp bth romowedELECTRICAL SYSTEM 59 Store up the engine, and run it at 2,000 rpm fist and at 8,000.pm next, Reed the ammeter at these twa speads, Tha charging Gall Is working progerly if at leat 12 A isteod a 2,000 rpm and anywmere between 1.7 and 2.3 Ais read at 8,000 epm Nene ‘Anwar icon Recttior Fi 19? Testing the charging cal tor performance NOTES: 1) The’;000-rpm run should be effected inthe short! duration possi. 2) The hamery should ba in Fully charged state As wo the method of telling whethar the battery i in fully era stata oF nt, refer So the part titled. “BATTERY” ln the subsequent section. CHASSIS ELECTRICAL COMPONENTS ‘There are a total of six (6) snitches to be chocked tor eireult curitinuity through their eantacts, For the ‘eating instrument, use an ohmmeter or a circuit tester in the menner sleaady outlined for other elect. cal devices. Ignition switeh ‘Check the switch in two positions, ON sad OFF, fn refertnen to the chert, below, in which continuity between twa or more load wires is represen ted By 6 line the instrument does not shane continuity for any two wires indicated, the switch must be replaced, Ignition switch closure ehert p> ‘con | et Seal Re oe ee oa edge’ |, 138 Chet ntn sw — je om Sarina ff reess | eo] [ete :60 ELECTRICAL SYSTEM Rear Brake Lamp Switch Have the testing prods or pointers of the instr: ment connssted to the the tetminals af this swith, and pull Its pull-rod to aie if the instrw ment shows continuity at it should, Releasing the pull-rod should ehange the indlestion to in- finity. A switch net rasponding in this manner Xo the movement of ts pull-rod must be replaced, Horn Switch Digeonneet the gretn wire fextending from the left handle switch) inside the headlamp hau 'nd connect en ahmmetar between tho tarminel this wire at the switen and ground, The horn switch if sound condition if we chmmeter Indicetes continuity only when the horn button Isdepresied, Engine Kill Switch Cheek the kill switch in reference te the chart, below, and if no continuity occurs in OFE Position, replses the switch, Engine kill switch closure chart [ee ete [ ad al a [stn | sation | adr or | eet flr Turn Signal Lamp Switeh Check this switeh in three positions. tf contin ity does not oceur ae shawn, replace the switch, ‘Turn signa lomip itch clomure chare ¥ , Fig, 139 Checking the brake lamp switch h Fiz 140. Checking the horn button Green wile B: Ground Fig 141, Checking the kill switch A: ground — B: black yellow wiee Fp. 142, Checking the turn sgnat tama stay A® light ve wire 8: black wireELECTRICAL SYSTEM 61 Lighting / Dimmer Switch By referring to the chart below, check this mitch for the indicated continuity: Lighting switch closure chart rc oT Switch position | NOTE: For the machines marteted in the USA. e ‘nd Canad, the switch i locked in ON postion, w Dimmer switch closure chert [avis [- ANE I P Fig. 14% Cheeiking the lighting switch Ai gray wire 8: yollow/red wire BATTERY. & YUASAmake or FURUKAWA.make battery is used in the madl TS250 The some type designe tion, GN4B-2A, is given to thee twa makes because thay ara pertestly interthangeabsle with each other. Th battery fof dry-2htiot type and, er such, is meant tobe iniilly charge befor it is wlced in| service in the new machine, Be sue to charge the batery st the rate preveribed until the specific gravity of hs elctwolyt ras 0 1.260, {aes eT [nti ee 944,100 12hours tactalyie specific i =| ie 1.260 as curerted 10 20°C (68h wovity | To ell the state of charge in a battery In service, a fairly reliable method is to messure the specie ‘sravity of its electrolyte vue a hydrometer and ta refer the resding to the-chart, shawn below, which tats: the relationship between speeifie gravity arid state of charge, [seaaiewe | Sonotawm | ieiainans 1.250 1.080 | Fully zea 220 and ve Alun down Rocherae oF replace,WIRNG DIAGRAM (for USA and Canade markets)WIRING DIAGRAMWIRNG DIAGRAM (For USA and Canada markets)TIGHTENING TORQUE CHART liner ead mut Engine sacocket nut °C Wteh soses hls mot Primary drive gear nut Front beaks cam laver bot Front Ax nut Frome ate cavip pet Steering stem head tart ‘teeing stem upper clamp walt Trantfork umoer clamp boie (Left, Right) ronedork cap Bott Fane fore tne Fase Ane nut fr shock sbsorber iting bait Feil seingarm pivot ut Hanctsoar ciamp tole Rew brake cam fever bolt esr torque link aut (Fron) (mean TIGHTENING TORQUE hem 200~ 250 550~ 850 500~ 600 500 ~ 6.00 8.00 7.00 0.80 ~ 0.80 00~ 520 200 ~ 2.50 4.00~ 5.50 200~ 2.00 2.00~ 3.00 2.00~ 200 3.00~ 3.60 8.00~ 300 200~ a0 500~ 9.00 120~ 2.00 a50~ 0.80 | 1100~ 1.50 200~ 3.00 ‘ter Bett and nuts not listed above, retorto thischart es 3 ~ | a0. a40 8 940-0.70 5 090-140 we 99-220 Conventions Batt cum) Fishing Faraue _ Conventional gon ‘| T Ca 16-28 20-61 86-100 430. 20.0 mew met 4s~ wo 400~a7.0 365~a20 35 ~a30 #a0~s05 40~ 35 290~378 145~180 290~208 145~215 vas~2i5 Mews 218~250| a30~s78 s~215 4a0~s75 90~ 14.0 t0~ 08 75~108 145~215PERIODIC INSPECTION CHART eal ‘Tho msintenanee schedule, Which flloeet, based on this shltoeaphy, 2 ie timod by edomets indication, and in calculated to achieve the uimate goal of motereyche malntthence in the most @:onamical mannor, ™ Dievanes) Initint 1,000 en Every 3,000 Km — Initial GOO Miles | Every 2,000 miles a TT = esti See ees es me eer | Se Clutch Aajuat Tait beh Cytineer tac Fietighien cylinder | Fetighian eyinder lies andeylindsr heed nuts Naad nuts: Heenova vortion | juer | Drive chain | Ath, wa mutter | Ramee carbon Cheek operation, F operation, 0 parnp ssjust control lever |acust contol lever aipning marks anigning mars Spark pia ch Check ane perce Bartwery eetrolyte yelution # a yt ay | eer 3) a | ato 7 has [pote we [ue Bom ae ee {