Segment:
Dual-sport motorcycle, trail bike.
Target Audience:
Enthusiasts, mechanics, owners seeking to maintain or restore their Suzuki TS250 motorcycles.
Competitors:
Honda Elsinore series, Yamaha DT series, Kawasaki KE/KDX series during the same era.
Significance:
The TS250 was a popular and versatile dual-sport motorcycle, known for its robust two-stroke engine and off-road capability. This manual is crucial for preserving and maintaining these classic machines.
Manual Benefit:
Provides essential technical knowledge to perform all necessary maintenance, repairs, and diagnostics, saving time and money compared to relying solely on guesswork or expensive dealer services.
Applicable Years:
1972, 1973, 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981
Regions Covered:
Global (designed for wide applicability, but may reference specific regional variations)
Estimated Pages:
Over 400 pages (typical for comprehensive workshop manuals of this era)
Type:
Workshop Service Repair Manual
Engine:
Complete engine overhaul, diagnosis, tuning, carburetion, lubrication, cooling system (air-cooled), exhaust system.
Transmission:
Gearbox overhaul, clutch service, lubrication, troubleshooting, shift mechanism.
Chassis:
Frame inspection, suspension (front forks, rear shock absorbers), steering system, wheel bearings, spokes.
Brakes:
Front and rear brake system service (drum brakes), hydraulic fluid, adjustment, cable maintenance.
Electrical:
Ignition system (points, condenser, coil), lighting, charging system (alternator/generator), wiring diagrams, battery maintenance.
Fuel System:
Fuel tank, fuel lines, fuel tap, carburetor service (Mikuni VM series typically), jetting, float adjustment.
Bodywork And Trim:
Fenders, seat, fuel tank, side covers, handlebars, controls, basic body panel repair.
Routine Maintenance:
Oil changes, spark plug replacement, air filter cleaning/replacement, chain lubrication and adjustment, brake adjustment, tire pressure checks.
Engine Rebuild:
Piston and ring replacement, cylinder honing, crankshaft and bearing inspection, valve adjustments (if applicable, though likely reed valve for this model).
Troubleshooting:
Step-by-step diagnostic procedures for common running issues, electrical problems, and mechanical failures.
Repair And Overhaul:
Detailed instructions for disassembling, inspecting, repairing, and reassembling all major motorcycle components.
Wiring Diagrams:
Comprehensive electrical schematic diagrams with component identification and wire color coding.
Depth:
Comprehensive, covering everything from basic owner maintenance to complete engine and transmission overhauls. Includes specifications for tolerances, clearances, and torque values.
File Type:
PDF (Portable Document Format)
Searchability:
Likely searchable text, enabling quick location of information.
Quality:
High resolution, ensuring clarity of diagrams, photos, and text.
Binding:
N/A (Digital Download)
Paper Quality:
N/A (Digital Download)
Engine Type:
2-stroke, single-cylinder, piston-reed valve induction
Displacement:
Approx. 247 cc (exact figures may vary slightly by year/sub-model)
Bore X Stroke:
Typically around 66.0 mm x 72.0 mm
Cooling System:
Air-cooled
Compression Ratio:
Typically around 6.8:1 to 7.0:1 (check specific year)
Horsepower:
Approximately 20-25 HP (varies by year and tuning)
Torque:
Approximately 20-24 Nm (varies by year)
Carburetor Type:
Mikuni VM series (e.g., VM30SC, VM32SS)
Fuel Type:
Unleaded gasoline with 2-stroke oil mixture (e.g., 20:1 or 30:1, refer to manual for exact specification)
Fuel Capacity:
Typically around 9-10 liters (2.4-2.6 US gallons)
Overall Length:
Varies by year, but typically around 2100-2200 mm
Overall Width:
Varies by year, typically around 850-900 mm (handlebar width)
Overall Height:
Varies by year, typically around 1150-1200 mm
Wheelbase:
Approximately 1400-1450 mm
Dry Weight:
Approximately 120-130 kg
Wet Weight:
Approximately 135-145 kg
Safety Certification:
N/A (Vehicle safety ratings as understood today were not prevalent for motorcycles of this era; manual focuses on mechanical safety).
Braking System:
Drum brakes front and rear, cable-actuated.
Suspension Stability:
Telescopic front forks, swingarm rear suspension with dual shock absorbers, designed for stability in varied terrain.
Lighting System:
Headlight, taillight, brake light, turn signals (may vary by market/year), providing visibility.
Oil Change Engine:
Refer to manual; typically every 1,000-2,000 km or annually for transmission oil.
Spark Plug Maintenance:
Inspect every 1,000-2,000 km, replace as needed (typical gap: 0.6-0.7 mm, use NGK B8ES or equivalent).
Air Filter Service:
Clean/inspect every 1,000-2,000 km, depending on operating conditions.
Chain Maintenance:
Lubricate and adjust chain tension every 500-1,000 km.
2 Stroke Oil:
Suzuki High Performance 2-Stroke Oil, or equivalent JASO FD/API TC rated oil. Mixture ratio typically 20:1 or 30:1 (always verify in manual).
Brake Fluid:
DOT 3 or DOT 4 brake fluid (for drum brake actuation, check specific year for compatibility).
Fork Oil:
Suzuki Fork Oil SAE 10W (capacity per fork leg specified in manual).
Carburetor Gumming:
Carburetors can become gummed up with stale fuel; regular use or proper fuel stabilization is recommended.
Piston Ring Wear:
As a 2-stroke, piston rings can wear over time, leading to loss of compression. Regular checks are important.
Electrical Connections:
Corroded or loose electrical connections can cause intermittent issues; regular inspection and dielectric grease application are beneficial.
Suspension Seals:
Fork and shock seals can degrade with age, leading to leaks. Manual provides replacement procedures.
Manufacturer:
Suzuki Motor Corporation, Japan.
Ts Series:
The TS series represented Suzuki's strong entry into the dual-sport market, offering reliable two-stroke performance for both on-road and off-road use. The TS250 was a core model in this popular line.
Production Period:
The TS250 was produced for many years, with the 1972-1981 period covered by this manual representing a significant phase of its development and popularity.
