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