Suzuki TU250X User manual

GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE 3
FI SYSTEM DIAGNOSIS 4
FUEL SYSTEM AND THROTTLE
BODY 5
EXHAUST SYSTEM 6
COOLING AND LUBRICATION
SYSTEM 7
CHASSIS 8
ELECTRICAL SYSTEM 9
SERVICING INFORMATION 10
EMISSION CONTROL
INFORMATION 11
WIRING DIAGRAM 12
FOREWORD
This manual contains an introductory description on
the SUZUKI TU250X and procedures for its inspec-
tion/service and overhaul of its main components.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the motorcycle and its main-
tenance. Use this section as well as other sections
to use as a guide for proper inspection and service.
This manual will help you know the motorcycle bet-
ter so that you can assure your customers of fast
and reliable service.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2009
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual motorcycle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual motorcycle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI motorcy-
cles. If you do not have the proper knowledge
and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the motorcycle
unsafe for the rider and passenger.

HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find
the first page of the section easily.
4. The contents are listed on the first page of each section to
help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit, is its exploded view. Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front wheel
1Collar
2Bearing
3Front wheel
4Spacer
5Brake disc
6Speedometer gearbox
7Balancer weight
AFront axle
BSpoke nipple
CBrake disc bolt

ITEM N·m
kgf-m lbf-ft
A65 6.5 47.0
B30.32.0
C23 2.3 16.5
FWD
FWD

SYMBOL MARKS AND MATERIALS
Listed in the table below are the symbols indicating instructions and other information. The meaning of each
symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply THREAD LOCK SUPER “1360”
or equivalent.
99000-32130
Apply oil. Use engine oil or transmis-
sion oil unless otherwise specified.
Use SUZUKI FORK OIL SS-08
or equivalent.
99000-99001-SS8
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKI
MOLY PASTE in a ratio of 1:1)
Apply or use brake fluid. (DOT 4)
Apply SUZUKI SUPER GREASE “A”
or equivalent.
99000-25010
Measure in voltage range.
Apply SUZUKI SILICONE GREASE
or equivalent.
99000-25100
Measure in current range.
Apply SUZUKI WATER RESISTANCE
GREASE or equivalent.
99000-25160
Measure in resistance range.
Apply SUZUKI MOLY PASTE
or equivalent.
99000-25140
Measure in diode test range.
Apply SUZUKI BOND “1215”
or equivalent.
99000-31110
Measure in continuity test range.
Apply THREAD LOCK SUPER “1303”
or equivalent.
99000-32030
Use special tool.
Apply THREAD LOCK SUPER “1322”
or equivalent.
99000-32110
Indication of service data.
Apply THREAD SUPER “1342”
or equivalent.
99000-32050

ABBREVIATIONS USED IN THIS
MANUAL
A
ABDC : After Bottom Dead Center
AC : Alternating Current
ACL : Air Cleaner, Air Cleaner Box
API : American Petroleum Institute
ATDC : After Top Dead Center
A/F : Air Fuel Mixture
B
BBDC : Before Bottom Dead Center
BTDC : Before Top Dead Center
B+ : Battery Positive Voltage
C
CKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT : Circuit
CLP Switch : Clutch Lever Position Switch
(Clutch Switch)
CO : Carbon Monoxide
CPU : Central Processing Unit
D
DC : Direct Current
DMC : Dealer Mode Coupler
DRL : Daytime Running Light
DTC : Diagnostic Trouble Code
E
ECM : Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
ET Sensor : Engine Temperature Sensor
(ETS)
F
FI : Fuel Injection, Fuel Injector
FP : Fuel Pump
FPR : Fuel Pressure Regulator
G
GEN : Generator
GND : Ground
H
HC : Hydrocarbons
HO2 Sensor : Heated Oxygen Sensor (HO2S)
I
IAP Sensor : Intake Air Pressure Sensor (IAPS)
(MAP Sensor)
IAT Sensor : Intake Air Temperature Sensor
(IATS)
IG : Ignition
L
LED : Light Emitting Diode
(Malfunction Indicator Lamp)
LH : Left Hand
M
MAL-Code : Malfunction Code
(Diagnostic Code)
Max : Maximum
MIL : Malfunction Indicator Lamp
(LED)
Min : Minimum
N
NOX : Nitrogen Oxides
O
OHC : Over Head Camshaft
P
PAIR : Pulsed Secondary Air Injection
PCV : Positive Crankcase
Ventilation (Crankcase Breather)
R
RH : Right Hand
ROM : Read Only Memory

S
SAE : Society of Automotive Engineers
SDS : Suzuki Diagnosis System
STC System : Secondary Throttle Control System
(STCS)
STP Sensor : Secondary Throttle Position Sensor
(STPS)
ST Valve : Secondary Throttle Valve (STV)
STV Actuator : Secondary Throttle Valve Actuator
(STVA)
T
TO Sensor : Tip-Over Sensor (TOS)
TP Sensor : Throttle Position Sensor (TPS)

SAE-TO-FORMER SUZUKI TERM
This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in
this manual in compliance with SAE recommendations, as well as their former SUZUKI names.
SAE TERM FORMER SUZUKI TERM
FULL TERM ABBREVIATION
A
Air Cleaner ACL Air Cleaner, Air Cleaner Box
B
Barometric Pressure BARO Barometric Pressure, Atmospheric
Pressure (APS, AP Sensor)
Battery Positive Voltage B+ Battery Voltage, +B
C
Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),
Crank Angle
D
Data Link Connector DLC Dealer Mode Coupler
Diagnostic Test Mode DTM ––––
Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code
E
Electronic Ignition El ––––
Engine Control Module ECM Engine Control Module (ECM)
Fl Control Unit, Engine Control Unit (ECU)
Engine Temperature ET Engine Temperature
Engine Speed RPM Engine Speed (RPM)
F
Fuel Level Sensor –––– Fuel Level Sensor, Fuel Level Gauge
Fuel Pump FP Fuel Pump (FP)
G
Generator GEN Generator
Ground GND Ground (GND, GRD)
I
Ignition Control IC Electronic Spark Advance (ESA)
Ignition Control Module ICM ––––
Intake Air Temperature IAT
Intake Air Temperature (IAT), Air Temperature

SAE TERM FORMER SUZUKI TERM
FULL TERM ABBREVIATION
M
Malfunction Indicator Lamp MIL LED Lamp
Malfunction Indicator Lamp (MIL)
Manifold Absolute Pressure MAP Intake Air Pressure (IAP), Intake Vacuum
Mass Air Flow MAF Air Flow
O
On-Board Diagnostic OBD Self-Diagnosis Function
Diagnostic
Open Loop OL ––––
P
Programmable Read Only Memory PROM ––––
Pulsed Secondary Air Injection PAIR Pulse Air Control (PAIR)
R
Random Access Memory RAM ––––
Read Only Memory ROM ROM
S
Secondary Air Injection AIR ––––
Secondary Throttle Control System STCS STC System (STCS)
Secondary Throttle Valve STV ST Valve (STV)
Secondary Throttle Valve Actuator STVA STV Actuator (STVA)
T
Throttle Body TB Throttle Body (TB)
Throttle Body Fuel Injection TBI Throttle Body Fuel Injection (TBI)
Throttle Position Sensor TP Sensor TP Sensor (TPS)
Tank Pressure Control Valve TPC Valve TPC Valve (TPCV)
V
Voltage Regulator VR Voltage Regulator
Volume Air Flow VAF Air Flow

WIRE COLOR
B : Black Gr : Gray R : Red
Bl : Blue Lbl : Light blue V : Violet
Br : Brown Lg : Light green W : White
Dg : Dark green O : Orange Y : Yellow
G : Green P : Pink
B/Bl : Black with Blue tracer O/R : Orange with Red tracer
B/Br : Black with Brown tracer O/W : Orange with White tracer
B/G : Black with Green tracer O/Y : Orange with Yellow tracer
B/R : Black with Red tracer R/W : Red with White tracer
B/W : Black with White tracer R/Y : Red with Yellow tracer
B/Y : Black with Yellow tracer W/B : White with Black tracer
Bl/B : Blue with Black tracer W/Bl : White with Blue tracer
Bl/R : Blue with Red tracer W/R : White with Red tracer
Bl/W : Blue with White tracer Y/B : Yellow with Black tracer
Bl/Y : Blue with Yellow tracer Y/Bl : Yellow with Blue tracer
Lg/W : Light green with White tracer Y/G : Yellow with Green tracer
O/B : Orange with Black tracer Y/R : Yellow with Red tracer
O/BI : Orange with Blue tracer Y/W : Yellow with White tracer
O/G : Orange with Green tracer