Suzuki TU250X 2nd Generation Repair Manual (2003-now)

Complete PDF version of the Service Manual for the Suzuki TU250X. A MUST for every TU250X owner.

Download: Immediately after payment!

OEM Original factory workshop manual.

Models covered by this manual: 2003 to present

Number of pages: 370 pages

Table of contents:

Suzuki TU250X

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We do not offer printed manuals, for the following reasons:

  1. it is more eco-friendly to use a digital version
  2. your manual never gets dirty or greasy
  3. you can always choose to print the specific page(s) you need to work on your bike
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Suzuki TU250X

The Suzuki TU250, also known as the TU250X, ST250, and ST250 E-Type, is a single-cylinder, air-cooled motorcycle that Suzuki introduced in 1994 as a lightweight street bike.

The TU has a single overhead cam (SOHC), unsleeved, four-stroke engine with chain drive, a conventional riding position, and appearance reminiscent of the Universal Japanese Motorcycle (UJM) of the 1960s and 1970s.

The TU250, now in its second generation, is built in Suzuki‘s ISO 14001 certified assembly factory in Toyokawa, Japan, and is sold in Asia, Oceania, and North America.

Second generation

Suzuki introduced the second generation TU during the 37th Tokyo Motor Show in 2003, describing it at the time as:

“The ST250/ST250 E type is a street motorbike with a conventional, uncomplicated look that is created to produce a sense that is both familiar and nostalgic. Its performance and equipment make it ideal for relaxed, everyday rides.”

The ST250 and ST250 E-Type were formally released to the Japanese domestic market in December 2003 for model year 2004, with the latter featuring a higher level of trim, including a two-tone fuel tank, polished engine, chromed exhaust pipe, CDI ignition, a kick starter, and electronic start. Suzuki Motor America began marketing the second generation motorbike in North America as the TU250X for model year 2009, with a two-year delay between 2010 and 2014 to allow the company to adapt imports to demand. The TU250X model was released in Australia in 2011.

The TU250x was powered by a twin valve, single cylinder engine with a closed-loop Electronic Fuel Injection (EFI) system (marketed as Suzuki Dual Throttle Valve (SDTV)) and a 32-bit ECU, oxygen sensor, catalytic converter, integral cold-start system, 32mm throttle body 10-nozzle injector, and a proprietary air injection system (marketed as Suzuki Pulsed-secondary AIR-injection or PAIR) that introduced fresh air from the airbox The TU does not fulfill California emissions rules and has remained a 49-state vehicle in the United States.

The air-cooled engine has a gear-driven counterbalancer and a custom cylinder wall plating comparable to Nikasil coating. Suzuki Composite Electro-chemical Material, or SCEM, is a nickel-phosphorus-silicon-carbide coating that reduces weight (by removing a steel liner) and improves heat transmission, allowing for tighter and more efficient piston-to-cylinder clearance. Clearance adjustments of the’screw and locknut’ kind are used on valves. The engine has an oil sump sight glass for visual oil inspections and runs on 87 octane fuel.

A five-speed transmission with a cable-actuated clutch, electric starting (with a kickstarter in Japan), clutch and side stand interlocks (cut-outs), electronic ignition system, maintenance free battery, tubular steel frame with load bearing (stressed member) engine, rear drum brake and front 275mm dual-piston caliper disk brake by Tokico, chrome-plated locking gas cap, passenger pillion separate from the driver’s seat, plastic front and rear fenders Cheng Shin tube-type tires are standard, measuring 90/90-18 in the front and 110/90-18 in the back. The drive is provided by a 108-link DID520V chain.

An analog speedometer with trip odometer, indicator lights for turn signal, high beam, and fuel injection status, as well as a low fuel alert and neutral light, are included in the instrumentation.

The bike has a wet curb weight of 148 kg (328 lb), a rake of 25°55′, a trail of 3.62″, and an unladen weight distribution of 47.4 percent front, 52.6 percent rear.


When the bike was first introduced in the United States in 2009, Scott Rousseau of Motorcycle Consumer News characterized it as having “1960s-era British styling” as well as a “rev-happy thumper engine, light handling, and surprisingly adequate suspension.”

In 2013, Canadian Moto Guide wrote, “The only ongoing niggle with the TU was the rear suspension, which is just not that compliant when it comes to dealing with road irregularities.”

In late 2014, the TU250X finished fifth in a five-bike comparison by, behind the Yamaha SR400 (made in Japan), Suzuki GW250 (manufactured in China), Royal Enfield Continental GT (produced in India), and Honda CB300F. (Thailand-built). The TU’s engine produced 14.8 horsepower at 7300rpm and 11.5 lb-ft of torque while producing 67mpg, according to the reviewer. According to the reviewer “The attractively fashioned vintage bike excels in a variety of areas. “Four of the five testers gave it positive feedback,” and it “does what it’s supposed to do – turn, brake, accelerate – with undeniable skill.” The TU is simply the greatest bike for a rookie, especially one of little stature, to learn how to ride a motorbike on.”

In his review of the TU250x, contributor Pete Brissette stated that Suzuki had “returned to the uncomplicated formula of the UJM, and with it brought back the delights of riding a pleasant, plain motorcycle.”

Source: Wikipedia