Suzuki TU250X Manuals

Suzuki TU250X Manuals

Manuals and User Guides for Suzuki TU250X. We have 1 Suzuki TU250X manual available for free PDF download: Service Manual

Suzuki TU250X Service Manual

Suzuki TU250X Service Manual (370 pages)

Brand: Suzuki | Category: Motorcycle | Size: 36.1 MB

Table of Contents

General Information 1

11
- Table of Contents
  11
- Warning/Caution/Note
  12
- General Precautions
  12
- Suzuki Tu250X ('09-Model)
  14
- Serial Number Location
  14
- Fuel and Oil Recommendation
  15
  - Fuel
    15
  - Engine Oil
    15
  - Brake Fluid
    15
  - Front Fork Oil
    15
- Break-In Procedures
  15
- Information Labels
  16
- Specifications
  17
  - Dimensions and Curb Mass
    17
  - Engine
    17
  - Drive Train
    17
  - Chassis
    18
  - Electrical
    18
  - Capacities
    18
Periodic Maintenance

19
- Periodic Maintenance Schedule
  20
  - Periodic Maintenance Chart
    20
  - Lubrication Points
    21
- Maintenance and Tune-Up Procedures
  22
  - Air Cleaner
    22
  - Valve Clearance
    23
  - Spark Plug
    25
  - Throttle Cable Play
    26
  - Engine Idle Speed
    26
  - Fuel Line
    27
  - Clutch Cable Play
    27
  - Pair (Air Supply) System
    27
  - Engine Oil and Oil Filter
    28
  - Drive Chain
    29
  - Brakes
    32
  - Steering
    36
  - Tires
    37
  - Front Fork
    38
  - Rear Suspension
    38
  - Exhaust Pipe Bolts and Muffler Mounting Bolts
    39
  - Chassis Bolts and Nuts
    40
- Compression Pressure Check
  42
  - Compression Test Procedure
    42
- Oil Pressure Check
  43
  - Oil Pressure Test Procedure
    43
- Sds Check
  44
Engine

48
- Engine Components Removable with Engine in Place
  49
- Engine Removal and Installation
  50
  - Removal
    50
  - Installation
    55
- Engine Disassembly
  58
- Engine Components Inspection and Service
  72
  - Cylinder Head Cover
    72
  - Cylinder Head
    73
  - Camshaft
    82
  - Cylinder
    82
  - Piston
    83
  - Conrod and Crankshaft
    85
  - Starter Clutch and Starter Driven Gear Bearing
    87
  - Balancer Driven Gear
    88
  - Generator
    89
  - Gearshift Shaft
    89
  - Oil Filter
    90
  - Oil Strainer
    90
  - Oil Pump
    91
  - Transmission
    92
  - Clutch
    95
  - Crankcase Bearing and Oil Seal
    96
  - Clutch Release Camshaft
    101
  - Clutch Cover
    102
- Engine Reassembly
  103
Fi System Diagnosis

122
- Precautions in Servicing
  124
  - Electrical Parts
    124
  - Fuse
    125
  - Switch
    125
  - Ecm/Various Sensors
    125
  - Electrical Circuit Inspection Procedure
    127
  - Using the Multi Circuit Tester
    130
- Fi System Technical Features
  131
  - Injection Time (Injection Volume)
    131
  - Compensation of Injection Time (Volume)
    132
  - Injection Stop Control
    132
  - Fi System Parts Location
    133
  - Fi System Wiring Diagram
    134
- Ecm Terminal
  135
- Self-Diagnosis Function
  136
- Sensors
  189
  - Ckp Sensor Inspection
    189
  - Ckp Sensor Removal and Installation
    189
  - Iap Sensor Inspection
    189
  - Iap Sensor Removal and Installation
    189
  - Tp Sensor Inspection
    189
  - Tp Sensor Removal and Installation
    189
  - Tps Adjustment
    190
  - Et Sensor Inspection
    191
  - Et Sensor Removal and Installation
    191
  - Iat Sensor Inspection
    191
  - Iat Sensor Removal and Installation
    191
  - To Sensor Inspection
    192
  - To Sensor Removal and Installation
    192
  - Stp Sensor Inspection
    192
  - Stp Sensor Removal and Installation
    192
  - Stp Sensor Adjustment
    192
  - Ho2 Sensor Inspection
    192
  - Ho2 Sensor Removal and Installation
    193
Fuel System and Throttle Body

194
- Fuel Delivery System
  195
- Fuel System
  196
  - Fuel Tank Removal
    196
  - Fuel Tank Installation
    196
  - Fuel Pressure Inspection
    197
  - Fuel Pump Inspection
    198
  - Fuel Discharge Amount Inspection
    198
  - Fuel Pump Construction
    199
  - Fuel Pump Removal and Disassembly
    200
  - Fuel Mesh Filter Inspection
    201
  - Fuel Pump Reassembly and Installation
    202
- Throttle Body
  203
  - Construction
    203
  - Throttle Body Removal
    204
  - Throttle Body Disassembly
    205
  - Throttle Body Cleaning
    207
  - Throttle Body Inspection
    207
  - Throttle Body Reassembly
    208
  - Throttle Body Installation
    210
  - Stp Sensor Adjustment
    211
  - Fast Idle
    212
  - Fuel Injector Removal
    212
  - Fuel Injector Inspection
    212
  - Fuel Injector Installation
    212
Exhaust System

213
- Exhaust System
  214
  - Removal
    214
  - Inspection
    216
  - Installation
    216
Chassis

221
- Exterior Parts
  223
  - Removal
    223
  - Installation
    223
- Front Wheel
  224
  - Construction
    224
  - Removal
    224
  - Inspection and Disassembly
    226
  - Reassembly and Installation
    227
- Front Brake
  231
  - Construction
    231
  - Brake Pad Replacement
    232
  - Brake Fluid Replacement
    233
  - Brake Caliper Removal and Disassembly
    233
  - Brake Caliper Inspection
    234
  - Caliper Reassembly and Installation
    235
  - Brake Disc Inspection
    237
  - Master Cylinder Removal and Disassembly
    237
  - Master Cylinder Inspection
    238
  - Master Cylinder Reassembly and Installation
    239
- Handlebars
  241
  - Construction
    241
  - Removal
    241
  - Inspection
    242
  - Installation
    243
- Front Fork
  245
  - Construction
    245
  - Removal and Disassembly
    246
  - Inspection
    248
  - Reassembly and Installation
    249
- Steering
  253
  - Construction
    253
  - Removal and Disassembly
    253
  - Inspection
    256
  - Reassembly and Installation
    257
  - Rear Brake Pedal Removal
    262
  - Rear Brake Pedal Installation
    262
- Rear Shock Absorber
  263
  - Construction
    263
  - Removal
    263
  - Inspection
    264
  - Installation
    264
  - Rear Suspension Setting
    264
- Rear Wheel
  265
  - Construction
    265
  - Removal
    266
  - Inspection and Disassembly
    268
- Swingarm
  273
  - Construction
    273
  - Removal
    274
  - Reassembly
    276
  - Installation
    278
- Tire and Wheel
  279
  - Tire Removal
    279
  - Inspection
    279
  - Tire Installation
    280
Electrical System

282
- Cautions in Servicing
  284
  - Connector
    284
  - Coupler
    284
  - Clamp
    284
  - Fuse
    284
  - Switch
    285
  - Semi-Conductor Equipped Part
    285
  - Battery
    285
  - Connecting the Battery
    285
  - Wiring Procedure
    286
  - Using the Multi Circuit Tester
    286
- Location of Electrical Components
  287
- Charging System
  289
  - Troubleshooting
    289
  - Inspection
    290
- Starter System and Side-Stand/Ignition Interlock System
  293
  - Troubleshooting
    293
  - Starter Motor Removal
    294
  - Starter Motor Disassembly
    295
  - Starter Motor Inspection
    296
  - Starter Motor Reassembly
    297
  - Starter Motor Installation
    298
  - Starter Relay Inspection
    299
  - Side Stand/Ignition Interlock System Parts Inspection
    300
- Ignition System
  302
  - Troubleshooting
    303
  - Inspection
    304
- Speedometer
  307
  - Removal and Disassembly
    307
  - Inspection
    308
- Lamps
  311
  - Headlight
    311
  - Brake Light/Taillight
    313
  - Turn Signal Light
    314
- Relays
  315
  - Turn Signal/Side-Stand Relay
    315
  - Main Relay
    315
  - Check Relay
    315
- Switch
  316
  - Ignition Switch Removal
    316
  - Ignition Switch Installation
    316
  - Switch Inspection
    317
- Battery
  318
  - Specifications
    318
  - Initial Charging
    318
  - Servicing
    320
  - Recharging Operation
    320
Servicing Information

321
- Troubleshooting
  322
  - Fi System Malfunction Code and Defective Condition
    322
  - Engine
    322
  - Chassis
    328
  - Brakes
    329
  - Electrical
    330
  - Battery
    331
- Wiring Harness, Cable and Hose Routing
  332
  - Wiring Harness Routing
    332
  - Throttle Cable Routing
    335
  - Speedometer Cable Routing
    336
  - Front Brake Hose Routing
    337
  - Pair (Air Supply) System Hose Routing
    338
- Cylinder Head Rubber Pad Installation
  339
- Exhaust System Construction
  339
- Throttle Body and Fuel Pump Installation
  340
- Rear Brake Pedal Installation
  341
- Torque Link Installation
  341
- Side-Stand Installation
  342
- Front Turn Signal Light Installation
  343
- Rear Turn Signal Light Installation
  343
- Special Tools
  344
- Tightening Torque
  347
  - Engine
    347
  - Fi System and Intake Air System
    348
  - Chassis
    348
  - Tightening Torque Chart
    349
- Service Data
  350
Emission Control Information

359
- Emission Control Systems
  360
  - Fuel Injection System
    360
  - Crankcase Emission Control System
    361
  - Exhaust Emission Control System
    362
  - Ho2 Sensor Inspection
    363
  - Ho2 Sensor Removal and Installation
    363
  - Noise Emission Control System
    363
- Pair (Air Supply) System and Emission Control System Inspection
  364
  - Pair Hoses
    364
  - Pair Reed Valve
    364
  - Pcv Hose
    365
  - Pair Control Solenoid Valve
    365
- Pair (Air Supply) System Diagram
  367
- Pair (Air Supply) System Hose Routing
  367

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