Suzuki TU250X User Manual

ENGINE 3-25
ENGINE COMPONENTS INSPECTION
AND SERVICE

CYLINDER HEAD COVER
DISASSEMBLY
• Remove the rocker arm shafts 1.
• Remove the rocker arms 2 and wave washers 3.
CYLINDER HEAD COVER DISTORTION
After removing sealant from the fitting surface of the cylinder
head cover, place the cylinder head cover on a surface plate
and check for distortion with the thickness gauge.
If the distortion exceeds the limit, replace the cylinder head
cover.
 Cylinder head cover distortion
Service Limit: 0.05 mm (0.002 in)
 09900-20803: Thickness gauge
ROCKER ARM SHAFT O.D.
Measure the diameter of the rocker arm shafts.
 Rocker arm shaft O.D.
Standard (IN. & EX.):
11.983 – 11.994 mm (0.4718 – 0.4722 in)
 09900-20205: Micrometer (0 – 25 mm)
ROCKER ARM I.D.
Measure the inside diameter of the rocker arm and check the
wear of the camshaft contacting surface.
 Rocker arm I.D.
Standard
(IN. & EX.):
12.000 – 12.018 mm (0.4724 – 0.4731 in)
 09900-20605: Dial calipers (10 – 34 mm)
Identify the position of each removed part. Organize
the parts in their respective groups (i.e., intake or
exhaust) so that they can be installed in their original
locations.

Suzuki TU250X Specifications

General

Displacement	249 cc
Bore x Stroke	72.0 mm x 61.2 mm
Compression Ratio	9.2:1
Ignition	Electronic ignition (transistorized)
Starter	Electric
Transmission	5-speed constant mesh
Final Drive	Chain
Front Suspension	Telescopic, coil spring, oil damped
Rear Suspension	Swingarm type, coil spring, oil damped
Rear Brakes	Drum brake
Front Tire	90/90-18 M/C 51S, tube type
Rear Tire	110/90-18 M/C 61S, tube type
Overall Length	2070 mm (81.5 in.)
Overall Width	750 mm (29.5 in.)
Overall Height	1075 mm (42.3 in.)
Seat Height	770 mm (30.3 in.)
Ground Clearance	165 mm (6.5 in.)
Wheelbase	1375 mm (54.1 in.)
Curb Weight	148 kg (326 lbs.)
Engine Type	4-stroke, single cylinder, SOHC
Front Brakes	Single disc
Fuel Capacity	12 L (3.2 US gal.)