Suzuki TU250X Manuel utilisateur

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.



* 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

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

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

BBDC : Before Bottom Dead Center

BTDC : Before Top Dead Center

B+ : Battery Positive Voltage

CKP Sensor : Crankshaft Position Sensor

(CKPS)

CKT : Circuit

CLP Switch : Clutch Lever Position Switch

(Clutch Switch)

CO : Carbon Monoxide

CPU : Central Processing Unit

DC : Direct Current

DMC : Dealer Mode Coupler

DRL : Daytime Running Light

DTC : Diagnostic Trouble Code

ECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ET Sensor : Engine Temperature Sensor

(ETS)

FI : Fuel Injection, Fuel Injector

FP : Fuel Pump

FPR : Fuel Pressure Regulator

GEN : Generator

GND : Ground

HC : Hydrocarbons

HO2 Sensor : Heated Oxygen Sensor (HO2S)

IAP Sensor : Intake Air Pressure Sensor (IAPS)

(MAP Sensor)

IAT Sensor : Intake Air Temperature Sensor

(IATS)

IG : Ignition

LED : Light Emitting Diode

(Malfunction Indicator Lamp)

LH : Left Hand

MAL-Code : Malfunction Code

(Diagnostic Code)

Max : Maximum

MIL : Malfunction Indicator Lamp

(LED)

Min : Minimum

NOX : Nitrogen Oxides

OHC : Over Head Camshaft

PAIR : Pulsed Secondary Air Injection

PCV : Positive Crankcase

Ventilation (Crankcase Breather)

RH : Right Hand

ROM : Read Only Memory

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)

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

Air Cleaner ACL Air Cleaner, Air Cleaner Box

Barometric Pressure BARO Barometric Pressure, Atmospheric

Pressure (APS, AP Sensor)

Battery Positive Voltage B+ Battery Voltage, +B

Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),

Crank Angle

Data Link Connector DLC Dealer Mode Coupler

Diagnostic Test Mode DTM ––––

Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code

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)

Fuel Level Sensor –––– Fuel Level Sensor, Fuel Level Gauge

Fuel Pump FP Fuel Pump (FP)

Generator GEN Generator

Ground GND Ground (GND, GRD)

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

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

On-Board Diagnostic OBD Self-Diagnosis Function

Diagnostic

Open Loop OL ––––

Programmable Read Only Memory PROM ––––

Pulsed Secondary Air Injection PAIR Pulse Air Control (PAIR)

Random Access Memory RAM ––––

Read Only Memory ROM ROM

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)

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)

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

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