Suzuki PE250 Operating Instruction Download

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Summary of Contents for PE250

Page 1: ...66 TIGHTENING TORQUE 68 SPECIAL TOOLS 71 SPECIFICATIONS 76 SERVICE DATA 78 Instructions d utilisation MOTEUR 7 Inspection et entretien 11 CARBURATEUR 41 EQUIPEMENT ELECTRIQUE Circuit d allumage 47 Cii...

Page 2: ...art oil is the correct gasoline to oil mixture ratio for your engine For proper engine perform ance it is essential that the above fuel oil mixture should be maintained HUILE DE MOTEUR On peut utilise...

Page 3: ...4 0 6 4 9 0 14 4 4 5 7 2 9 5 15 2 5 0 8 0 10 0 16 0 ESSENCE HUILE ESSENCE HUILE Q mQ Q mQ 0 5 25 5 5 275 1 0 50 6 0 300 1 5 75 6 5 325 2 0 100 7 0 350 2 5 125 7 5 375 3 0 150 8 0 400 3 5 175 8 5 425...

Page 4: ...from any other source than SUZUKI if used to replace parts of SUZUKI origin in the machine will lower the inherent capability of the machine and for worse could induce costly mechanical trouble Utili...

Page 5: ...al CD CV Poiqnee de com mande des gaz Levier du frein avant Levier du kick de dernarraqe Pedale de frein arriere Engine stop switch Clutch lever Fuelcock lever Gearshift lever Cornrnutateur d arret du...

Page 6: ...of high performance in competition kilometres 20 m des pieces de se avec la machine pouvez etre cert petition ENGINE STOP SWITCH To stop the engine push the engine stop switch CD as shown in photo 1 I...

Page 7: ...riginal position when the enqine warms up WHEN THE ENGINE IS WARM Using the choke knob is not necessary To start a warm engine open the throttle 1 8 to l 4 and kick start the engine Le moteur sera dur...

Page 8: ...on the sh ift lever once for ea When shifting from low to 2nd is automatically missed When is wanted for the lever a low and 2nd stopping depress half of a stroke b 10 C l a s s i c C y c l e s T e c...

Page 9: ...miles Replace Change Replace Replace I 1 Replace every 10 races i Replace Check clean Throttle brake clutch cable Lubricate Adjust Bolts and nuts Retighten RePlace i I I Spark plug I Piston Front for...

Page 10: ...r a Remplacer _ _ Ecrou de rayon Resserrer j _ _ Filtre aair Nettoyer ier du kick de Appliquer de la demarrage graisse Ciible de papillon des gaz de frein et d embrayage 1 Boulons et ecrous Graisser e...

Page 11: ...20 30 mm 0 8 1 2 in 1 l J V A J 1 8 I f i mm 0 8 a1 2 in Si un reqlaqe est necessaire on augmentera la distance en tournant 11 l oppose du sens des aiguilles l ecrou CV de reglage du frein avant FREIN...

Page 12: ...the brake system is properly adjusted 2 Check to see that the extension line of the index mark is with in the range on the brake panel 3 If the index mark is beyond the range as shown in the figure B...

Page 13: ...s attached in the way that the slit end will face opposite to the turning direction soit telle que les tendeurs indiquent Ie rnerne nurnero Lorsque I on arrive a un flech issement entre 50 a 60 mm 2 0...

Page 14: ...to drain before installation TIRE PRESSURE Inflate the tires properly depend ing on the weight of the rider Too high an inflating pressure makes the machine bounce up and down too Iowa pressure makes...

Page 15: ...element must be replaced I jamais tordre I element car if se dechirerait et presenterait des fis sures 2 Immerger l elernent dans un bain d huile de moteur et a nouveau presser l elernent dans un bain...

Page 16: ...t in the filter will restrict the flow of the fuel and cause the carburetor to malfunction therefore the fuel filter should be serviced peri odically 1 Drain the fuel from the fuel tank 2 Remove the f...

Page 17: ...able faire a I aide du tendeur du cable sur Ie couvercle du carburateur BOUGIE O ALLUMAGE Lorsque de la calamine s accurnule sur la bougie d allurnaqe celle ci ne produit plus une etincelle puissante...

Page 18: ...en installing the spark plug screw in with your fingers to prevent stripping the threads then tighten with a torque wrench to 250 300 kg cm 18 0 22 0 Ib ft NGK BR9EV and BR10EV for Canada ATTENTION 1...

Page 19: ...ating disengagement of the clutch II f 0lIlIIII 0 95 0 79 US Imp qt d huile moteur multigrade SAE20W 40 de bonne qualite et verser celle ci lentement dans la boite de vitesses EMBRAYAGE L embrayage se...

Page 20: ...ighten spark plug avant The wrench is equipped on the right Serrage et desserrage de bougie d al upper bracket lumage Cette cle est instailee sur Ie support superieur droit CD tJl 1 J 22 C l a s s i c...

Page 21: ...the seat and the fuel tank 2 Deposer la selle et Ie reservoir d essence IhP j 4 Loosen the muffler mounting bolt 4 Desserrer Ie boulon de montage du silencieux 6 Disconnect the clutch cable 6 Debranch...

Page 22: ...a chaine secondaire en retirant Ie clip de l attache rapide Deposer ensuite les quatre boulons de montage du moteur 8 Remove the engine sprocket cover and the chain guide plate 8 Deposer Ie cache du p...

Page 23: ...ete en bas sur la table pour eviter la deformation de la butee des ressorts plans du clapet d admission Wllt i l l c U 3 Placer un chiffon propre sur l alesaqe du carter moteur Deposer ensuite Ie circ...

Page 24: ...0 Accessoire F 8 Flatten the engine sproket washer and loosen the nut by using special tool and draw out the engine sprocket P No 09930 40113 Flywheel holder 8 Aplatir la rondelle du piqnon de chaine...

Page 25: ...lle de la noix d em NOTE Un des disques lisses est en fer il se bray age et desserrer i ecrou de la noix trouve sur la position la plus a I interieur d embrayage en utilisant l outil d im mobilisation...

Page 26: ...uilles d une montre Deposer Ie pignon menant primaire et la clavette NO de piece 09910 20115 Butee de bielle NOTE Le repere L se trouvant sur I ecrou du pignon menant primaire signifie ecrou a filet a...

Page 27: ...secondaire avec leurs pignons Retirer et Ie ressort puis retirer arbre de kick NOde piece 09920 13111 la came de selection acres avoir depose la starte r Extracteur de vilebrequin mecanisme butee de c...

Page 28: ...der Check the cylinder bore for wear by using a cylinder gauge Service Limit 67 070 mm 2 6405 in CAUTION After reboring be sure to lightly chamfer the ports edges with a scraper and smoothen the chamf...

Page 29: ...te for th ickness Service Limit 3 1 mm 0 12 in les polissant avec un papier de verre nO 400 Measurer Ie diarnetre de piston Limite de service 66 880 mm 2 6331 in SEGMENTS DE PISTON Verifier l ecartern...

Page 30: ...them is shorter than service limit replace all the springs at a time Service Limit 38 5 mm 1 52 in CLUTCH RELEASE BEARING Inspect the thrust type bearing for any abnormality especially cracks I d t 32...

Page 31: ...selection n 1 se rapporte aI arbre secondaire La fourchette de selection nO 2 se rapporte a I arbre primaire Se Ie jeu des fourchettes dans res gorges de passe la limite de service mesurer la largeur...

Page 32: ...el width with caliper and check its deflection Standard 60 0 0 1 mm 2 36 0 004 in Check the thrust clearance between the piston boss and the connecting rod Service Limit 1 0 mm 0 04 in l 34 C l a s s...

Page 33: ...als and fit the crankshaft on the crankcase 2 Fix the kick starter so that the marking on the kick starter matches the marking on the kick starter shaft 1 Enduire de graisse la levre des joints d huil...

Page 34: ...36 C l a s s i c C y c l e s T e c h n i c a l R e s o u r c e s...

Page 35: ...he cam stopper ly should be position outside properly to the shifting shaft 4 Installer fa boite de vitesses sur Ie carter 6 Installer correcternerit les deux c1iquets 8 Reposer Ie ressort du rappel d...

Page 36: ...primaire et plier la rondelle en deux endroits Couple de serrage 400 a 600 em kg 29 0 a 43 0 lb ftl 38 C l a s s i c C y c l e s T e c h n i c a l R e s o u r c e s...

Page 37: ...ssorts d embrayage comme indique et Ie calage il est 13 The engraved line Q aligned to the center of the stator is secured in 13 La Iigne Q gra iee sur litre en regard de I axe de la vis CV et Ie stat...

Page 38: ...positionnement represente la photo Couple de serrage 230 a270 cm kg 16 5 a19 5 lb ft 7 f t I I J I I II i 1 I rt 1 1 i 1 I t J fro 17 Apply engine oil to the piston surface L and insert the piston in...

Page 39: ...cessaire d adjuster Ie carburateur pour convenir aux conditions climati ques au terrain de la course etc Verifier convenablement Ie carburateur et Ie cas echeant regler les pieces suivantes SPECIFICAT...

Page 40: ...the surface is wet it means that the mixture is too rich in this case the main jet must be replaced by the one with a smaller number If a grey brownish or whitish color is noted it means that the mix...

Page 41: ...le controls the supply of fuel for a throttle range of one quarter 1 4 to three quarters 3 41 Whether the existing jet needle is proper or not is to be checked by testing as in the case of main jet te...

Page 42: ...re Ie pointeau du carburateur convenable ment en pacle Le pointeau presente cinq encoches En temps normal Ie pointeau est retenu ala 2eme encoche NOTE The pilot air screw should be left in the standar...

Page 43: ...lange trop riche Melange trop pauvre Bougie d Faience ll lgElrement brunatre La faienceest cou verte de suie La faience est blanchatre allumage Faience de couleur bronzes La faience est cou verte d hu...

Page 44: ...rew NOTE The length of each shaded pattern represents the effective range and the width represents the intensity of carburetion compte de ces papillon qui a pendant la cou pointeau et la gramme suivan...

Page 45: ...d to the operating characteristic of the engine SYSTEME SUZUKI PEl Sur la PE250 l enerqie requise pour I allumage est alimentee ala bougie par une decharqe de condensateur de clenchee electroniquement...

Page 46: ...Circuit de distribution B H JI C D 1 unit I Unite C D 1 B W BI White with Blue tracer B R Black with B Y Black with Yellow tracer R W Red with B W Black with W BI Blanc avec filet Bleu B R Noir avec B...

Page 47: ...ge resistance or for short infinity CON The indicating hand deflects a little but promptly returns to the infinity end of the scale elements inside the COl unit will suffer rupture NOTE 1 Before putti...

Page 48: ...F CON ou ENVIRON 5 MEGOHMS Le sens de ces differentes indications est Ie suivant Terme Signification ON L appareil d essai indique la continuite dUJ circuit OFF l appareil d essai indique une resistan...

Page 49: ...ohms dans les enroulements primaires que secondaires Des lec tures ohmiques exactes ne sont pas requises car si les enroulements sont en bon etat on pourra noter leur con tinuite par les valeurs ohmiq...

Page 50: ...0 o V Ql 3 s 0 J 0 0 C _ r I S o J ro V C l a s s i c C y c l e s T e c h n i c a l R e s o u r c e s...

Page 51: ...du frein avant 26 0 37 0 lb ft etdu cornpteur journalier DEPOSE 3 Retirer I axe de roue avant Couple de serrage serrer l ecrou de l axe de roue avant 1 Extraire la goupille fendue et des 360 a520 em k...

Page 52: ...sont pas use et rnesurer l epaisseur de bruyants et mesurer Ie d iarnetre macholres de frein lnterieur d u tambour de frein Limite de service minimum Limite de service 1 5 mm 0 06 in 150 7 mm 5 93 in...

Page 53: ...Accessoire 0 NOTE Installer Ie ressort de fourche avant superieur et inferieur Tirer les pattes N de pieces de sorte que son cote a spires serrees soit de fourche vers Ie bas et resserrer les tourne...

Page 54: ...09930 30102 Manche d arrache rotor C P No 09943 74110 Front frok oi level gauge Oil level 193 mm 7 6 in Oil capacity 274 mQ 9 26 US oz for each leg CONTROLE ET REGLAGES Mesurer la longeur libre des re...

Page 55: ...E de direction au moyen de l outil 3 Deqaqer la colonne de direction en 1 Deposer Ie phare Ie guidon et Ie sup special veillant a ne pas laisser tomber les port superieur en desserrant Ie billes d aci...

Page 56: ...stem pivots by its own weight with handlebar and front fork installed Set the handlebars to match its punched mark CD to the mating face of the holder The clearance ahead of and behind the handlebars...

Page 57: ...a figure ci dessous 3 Chaque unite com porte trois gorges DEMONTAGE pour changer la tension du ressort 1 Retirer les boulons superieur et in Plus la position de I attache est fer ieur des amortisseurs...

Page 58: ...depressuriz ing it when it becomes so used up that it no longer serves its purpose To depressurize it place the gas tank in a plastic bag with a corner cut off and drill into the tank at the location...

Page 59: ...de la rna choire de frein Limite de service Diarnetre interieur tam bour 150 7 mm 15 93 in Epaisseur de machoire de frein 1 5 mm 10 06 in 2 Disconnect the rear brake cable and draw out the wheel asse...

Page 60: ...ning or loosening the spoke nipples Service Limit Rim runout 2 0 mm 0 08 in Check the axle shaft for deflection by using dial gauge Service Limit 0 25 mm 0 010 in L r I L H 62 C l a s s i c C y c l e...

Page 61: ...n tensioner for damage o Chain tensioner rollers for wear Deposer la roue arr iere les amort is seurs arr iere et retirer I axe pivot du bras oscillant Retirer Ie cache poussiere et retirer l en treto...

Page 62: ...tool P No 09941 34511 Swinging arm bearing installer Tighten the swinging arm pivot shaft Tightening Torque 500 800 kg em 36 5 58 5 lb ft Apply grease in the grease nipple to lubricate the bearings 64...

Page 63: ......

Page 64: ...and hold it about 7 mm 0 28 in from the cylinder head ground Kick the engine over and see if a spark jumps this gap If so the system is functioning and the problem is probably in the spark plug cap If...

Page 65: ...ugie Si I etincelle refuse de se produire faire verifier Ie svsterne d allumage par un dis tributeur SUZUKI PATINAGE DE L EMBRAYAGE 1 Si Ie levier d embravaqe ne presente pas de eu reqler Ie tendeur d...

Page 66: ...150 250 350 550 350 500 50 80 360 520 Cylinder head nuts 10 5 18 0 Magneto rotor nut 10 5 18 0 Engine sprocket nu I 25 5 40 0 Clutch sleeve hub n 25 5 36 5 Primary drive gear 4 0 5 5 Rear sprocket sc...

Page 67: ...250 10 5 18 0 400 600 29 0 43 0 Boulon de tete de potence de I de potence de direction Ecrou de pignon de rnoteur Ecrou de moyeu de manchon 25 5 40 0 350 550 29 0 43 0 400 600 direction d embrayage 2...

Page 68: ...sont pas repris dans la liste precedents se reporter aee tableau l Boulon eonventionnel Boulon poincorme I ou poinconne 4 au 7 Diarnetre de boulon mm I em kg Ib ft Ib ft em kg 1 5 3 0 20 40 30 60 5 2...

Page 69: ...ndre 09900 20603 Dial gauge Comparateu r acadran I I j I v 1 L 09900 20101 Vernier caliper Jauge mterornetrlque 09900 06104 Snap ring pliers Pinces ajonc I II I e l 09900 09002 Shock d river set Jeu d...

Page 70: ...t Jeu d V I 09900 25002 Pocket tester Verificateur universel 09900 20701 Magnetic stand Support rnaqnetique 09900 20803 Thickness gauge Calibre d epaisseu r 72 C l a s s i c C y c l e s T e c h n i c...

Page 71: ...eurde joint d huile 09920 53710 Clutch sleeve hub holder Outil d Imrnoblllsation de noix d embrayage 09920 13111 Cran kshaft starter cIutch remover Extracteur de vilebrequin 09930 30102 Rotor remover...

Page 72: ...er Outil d immobilisation de rotor I T pour fourche avant Manche en I I 09940 10122 40 34561 Steering stem nut wrench chment D ell aecrou de colonne de direction issoire 0 74 C l a s s i c C y c l e s...

Page 73: ...09941 64910 Front frok oil seal remover Extracteur de joint d huile de fourche avant I 09943 74110 Front fork oil level gauge Jauqe d huile de fourche avant 75...

Page 74: ...1 67 0 mm 2 638 in 70 0 mm 2 756 in 246 cm3 15 0 cu in 7 1 1 MIKUNI VM36SS single Polyurethane foam element Primary kick Fuel oil premixture of 20 1 Wet multi plate type 5 speed constant mesh 1 down...

Page 75: ...n mousse de polyurethane Par kick primire Prernelanqe carburant huile de 20 1 Ernbravaqe humide iJ disques multiples 5 vitesses en prise constante 1 en bas et 4 en haut 2 727 60 22 4 000 52 13 2 666 3...

Page 76: ...e clearance 0 002 tight 0 011 mm 0 000 1 0 0004 Piston pin bore 1 0 17 998 18 006mm 0 7086 0 7089 in Piston pin 0 0 17 995 18 000mm 0 7085 0 7087 in CRANKSHAFT Con rod small end bore 23 003 23 011mm 0...

Page 77: ...024 in No 2 0 2 O 4mm 0 008 0 016 in 0 8mm 0 031 in 0 6mm 0 024 in Shift fork groove width I No 1 4 45 4 55mm 0 175 0 179 in No 2 4 25 4 35mm 0 167 0 171 in No 1 is related with J counter shaft _ NO 2...

Page 78: ...n timing 18 B T D C at 600 Spark plug gap 0 5 0 6mm 0 020 Spark performance Over 8mm 0 3 in Ignition coil resistance primary Approx 0 7 o Ignition coil resistance secondary Approx 10 kilo High speedco...

Page 79: ...Wheel rim runout Radial Axial 2 0mm 0 08 in Tire tread depth Front Rear 4 0mm 0 16 in 4 0mm 0 16 in Tire air pressure Cold inflation pressure Front Rear 0 7 1 0 kg cm 2 10 14 psi SUSPENSION Front fork...

Page 80: ...274 m 9 26 9 6 Premium fuel Octan SAE 20 SAE 5W Front fork oil each leg Fuel type Transmission oil type Front fork oil type 82 C l a s s i c C y c l e s T e c h n i c a l R e s o u r c e s...

Page 81: ...033 in Jeu des segments dans les gorges l e et 2e segment 0 01 a0 05 mm 0 0004 a0 0020 in Jeu de l axe de piston dans l alesaqe 0 002 serre aD 011 mm 0 0001 a0 0004 in 0 080 mm 0 003 in Diarnetre int...

Page 82: ...de selection dans la gorge N 1 0 4 a0 6 mm 0 016 a0 024 N 2 0 2 a0 4 mm 0 008 a0 016 Largeur de gorge de fourchette de selection N 1 4 45 a4 55 mm 0 175 a0 17 N 2 4 25 a4 35 mm 0 167 a0 17 Epaisseur d...

Page 83: ...rincipal 2 5 Gicleaur de ralenti 37 5 Sortie d air de ralenti 0 6 Gicleur d aiguille P 6 By pass 1 4 Gicleur principal 250 ELECTRICITE Reglage de I avance aI allumage 18 avant Ie P M H a6 000 tr mn Ec...

Page 84: ...e frein avant et arrlere Ovalisation de jante de roue radiale et axiale Profondeur de profil de pneu Pression de gonflage des pneus Avant 150 0 mm 5 91 in Arriere 150 0 mm 5 91 in 4 0 mm 0 16 in Avant...

Page 85: ...I CARACTE RISTlQU ES CAPACITES Reservoir d essence y compris la reserve 11 5 Q 3 0 2 5 US Imp gal Huile de la bolte de vitesses Renouvellement 900 mQ 0 95 0 79 US Imp qt Revision 950 mQ 1 00 0 84 US...

Page 86: ...pment Parts Complete Online Diagrams Suzuki PE Series Motorcycle History Technical Specifications Motorcycle Helmet Closeout Sale Suzuki Motorcycle Parts Accessories Suzuki Dirt Bike Parts Accessories...

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Suzuki PE250, Operating Instruction

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