The 1979-1989 Suzuki TS100, TS125, TS185, TS250 enduro (dual-purpose) bike repair manual by Haynes covers the following models:
Suzuki TS100ERN (TS100), U.K. only 1979
Suzuki TS100ERT, U.K. 1980, U.S. 1979
Suzuki TS100ERX, U.K. 1980, U.S. 1980
Suzuki TS100ERZ, U.K. only 1982
Suzuki TS125ERN (TS125), U.K. only 1979
Suzuki TS125ERT, U.K./U.S. 1979
Suzuki TS125ERX, U.K./U.S. 1980
Suzuki TS125ERZ, U.K. only 1982
Suzuki TS185ERN (TS185), U.K. only 1979
Suzuki TS185ERT, U.K./U.S. 1979
Suzuki TS185ERX, U.K./U.S. 1980
Suzuki TS250ERN (TS250), U.K. only 1979
Suzuki TS250ERT, U.K./U.S. 1979
Suzuki TS250ERX, U.K./U.S. 1980
Note: the liquid-cooled TS models ARE NOT covered in this manual.
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Suzuki Ts 250 Manual
BRAKE PROBLEMS
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BRAKES ARE SPONGY OR INEFFECTIVE | DISC BRAKES
AIR IN BRAKE CIRCUIT. This is only likely to happen in service due to neglect in checking the fluid level or because a leak has developed. The problem should be identified and the brake system bled of air.
PAD WORN. Check the pad wear against the wear lines provided and renew the pads if necessary.
CONTAMINATED PADS. Cleaning pads which have been contaminated with oil, grease or brake fluid is unlikely to prove successful: the pads should be renewed.
PADS GLAZED. This is usually caused by overheating. The surface of the pads may be roughened using glass-paper or a fine file.
BRAKE FLUID DETERIORATION. A brake which on initial operation is firm but rapidly becomes spongy in use may be failing due to water contamination of the fluid. The fluid should be drained and then the system refilled and bled.
MASTER CYLINDER SEAL FAILURE. Wear or damage of master cylinder internal parts will prevent pressurization of the brake fluid. Overhaul the master cylinder unit.
CALIPER SEAL FAILURE. This will almost certainly be obvious by loss of fluid, a lowering of fluid in the master cylinder reservoir and contamination of the brake pads and caliper. Overhaul the caliper assembly.
BRAKE LEVER OR PEDAL IMPROPERLY ADJUSTED. Adjust the clearance between the lever end and master cylinder plunger to take up lost motion, as recommended in Routine maintenance.
FUEL SYSTEM AND LUBRICATIONEXHAUST SYSTEM: REMOVAL AND FITTING
The exhaust system can be removed from the machine as a complete assembly after full access has been gained to its frame attachment points. This will require removal of the right-hand sidepanel. If working on TS185 and 250 models, access to the middle mounting point of the pipe assembly will be made easier by removal of the left-hand sidepanel also.
Reference to the figures contained in this Chapter will show that the design of the exhaust system fitted to TS100 and 125 models differs from that of the system fitted to TS185 and 250 models. Nevertheless, the same basic procedure for removal, and the precautions involved, apply equally to each system type.
Commence removal of the exhaust system by unscrewing the two bolts which serve to retain the exhaust pipe to the cylinder head. If working on a TS185 or 250 model, unhook the pipe retaining spring by using a pair of pliers. Note the condition of the spring washer fitted beneath the head of each retaining bolt and, if it is flattened or broken, replace it with a new item.
Written from hands-on experience gained from the complete strip-down and rebuild of a Suzuki TS250, Haynes can help you understand, care for and repair your Suzuki TS250. We do it ourselves to help you do-it-yourself, and whatever your mechanical ability, the practical step-by-step explanations, linked to over 900 photos, will help you get the job done right. Regular servicing and maintenance of your Suzuki TS250 can help maintain its resale value, save you money, and make it safer to ride.