Suzuki TU250X User Manual

ENGINE 3-37
PISTON TO CYLINDER CLEARANCE
Subtract the piston diameter from the cylinder bore diameter. If
the piston-to-cylinder clearance exceeds the service limit,
replace the cylinder or the piston, or both.
 Piston to cylinder clearance
Service Limit: 0.120 mm (0.0047 in)
PISTON PIN AND PIN BORE
Measure the piston pin bore diameter using the small bore
gauge.
If the measurement is out of specification, replace the piston.
 Piston pin bore I.D.
Service Limit: 18.030 mm (0.7098 in)
 09900-20602: Dial gauge
09900-22403: Small bore gauge (18 – 35 mm)
Measure the piston pin outside diameter at three positions using
the micrometer.
If any of the measurements is out of specification, replace the
piston pin.
 Piston pin O.D.
Service Limit: 17.980 mm (0.7079 in)
 09900-20205: Micrometer (0 – 25 mm)
PISTON RING GROOVE CLEARANCE
Measure the side clearance of the 1st and 2nd rings using the
thickness gauge. If any of the clearances exceed the limit,
replace both the piston and piston rings.
 Piston ring to groove clearance
Service Limit (1st): 0.180 mm (0.0071 in)
(2nd): 0.150 mm (0.0059 in)
 Piston ring groove width
Standard (1st): 1.01 – 1.03 mm (0.0398 – 0.0406 in)
(2nd): 1.21 – 1.23 mm (0.0476 – 0.0484 in)
(Oil): 2.51 – 2.53 mm (0.0988 – 0.0996 in)
 Piston ring thickness
Standard (1st): 0.975 – 0.990 mm (0.0384 – 0.0390 in)
(2nd): 1.170 – 1.190 mm (0.0461 – 0.0469 in)
 09900-20205: Micrometer (0 – 25 mm)
09900-20803: Thickness gauge
NOTE:
Remove any carbon from the piston crown and ring grooves
using a soft-metal scraper.

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.)