SERVICE DATA

Date: February 15, 2006

4 STROKE Model: VL250K7

VALVE + GUIDE Unit: mm

ITEM STANDARD LIMIT
Valve diam. IN. 19.5 —
EX. 22.5 —
Valve clearance (when cold) IN. 0.10 – 0.15 —
EX. 0.18 – 0.23 —
Valve guide to valve stem clear- IN. 0.010 – 0.037 —
ance EX. 0.030 – 0.057 —
Valve stem deflection IN. & EX. — 0.35
Valve guide I.D. IN. & EX. 4.500 – 4.512 —
Valve stem O.D. IN. 4.475 – 4.490 —
EX. 4.455 – 4.470 —
Valve stem runout IN. & EX. — 0.05
Valve head thickness IN. & EX. — 0.5
Valve stem end length IN. & EX. — 2.2
Valve seat width IN. & EX. 0.9 – 1.1 —
Valve head radial runout IN. & EX. — 0.03
Valve spring free length IN. — 37.2
EX. — 37.2
Valve spring tension 118 – 136 N
IN. & EX. (12.0 – 13.9 kgf) —
at length 33.7 mm

CAMSHAFT + CYLINDER HEAD Unit: mm

ITEM STANDARD LIMIT
Cam height IN. 32.90 – 32.94 32.60
Front 33.10 – 33.14 32.80
EX.
Rear 32.96 – 33.00 32.66
Camshaft journal oil clearance IN. & EX. 0.032 – 0.066 0.150
Camshaft journal holder I.D. IN. & EX. 22.012 – 22.025 —
Camshaft journal O.D. IN. & EX. 21.959 – 21.980 —
Camshaft runout IN. & EX. — 0.10
Rocker arm I.D. IN. & EX. 12.000 – 12.018 —
Rocker arm shaft O.D. IN. & EX. 11.973 – 11.984 —
Cylinder distortion — 0.05
Cylinder head distortion — 0.05
Cylinder head cover distortion — 0.05

Model: VL250K7 1/6 E-19, 24

CYLINDER + PISTON + PISTON RING Unit: mm
ITEM STANDARD LIMIT
Compression pressure 800 – 1 200 kPa —
(8 – 12 kgf/cm2)
Compression pressure difference — 200 kPa
(2 kgf/cm2)
Piston to cylinder clearance 0.04 – 0.05 0.12
Cylinder bore 52.000 – 52.015 52.090
Piston diam. 51.955 – 51.970 51.880
Measure at 10 mm from the skirt end.
Piston ring free end gap 1st R Approx. 6.0 4.8
2nd R Approx. 4.9 3.9
Piston ring end gap 1st 0.15 – 0.30 0.50
2nd 0.15 – 0.30 0.50
Piston ring to groove clearance 1st — 0.18
2nd — 0.15
Piston ring groove width 1st 1.01 – 1.03 —
2nd 1.01 – 1.03 —
Oil 2.01 – 2.03 —
Piston ring thickness 1st 0.97 – 0.99 —
2nd 0.97 – 0.99 —
Piston pin bore 15.002 – 15.008 15.030
Piston pin O.D. 14.992 – 15.000 14.980

CONROD + CRANKSHAFT Unit: mm

ITEM STANDARD LIMIT
Conrod small end I.D. 15.006 – 15.014 15.040
Conrod deflection — 3.0
Conrod big end side clearance 0.10 – 0.56 1.0
Conrod big end width 15.95 – 16.00 —
Crank web to web width 66.9 – 67.1 —
Crankshaft runout — 0.080

OIL PUMP
ITEM STANDARD LIMIT
Oil pressure (at 60 °C) 20 – 70 kPa
(0.2 – 0.7 kgf/cm2 ) —
at 3 000 r/min

Model: VL250K7 2/6 E-19, 24

CLUTCH Unit: mm
ITEM STANDARD LIMIT
Clutch cable play 10 – 15 —
Drive plate thickness No. 1 2.92 – 3.08 2.6
No. 2 3.42 – 3.58 3.1
Drive plate claw width No. 1 & 2 15.9 – 16.0 15.1
Driven plate distortion — 0.10
Clutch spring free length 43.0 40.9

DRIVE TRAIN + DRIVE CHAIN Unit: mm Except ratio

ITEM STANDARD LIMIT
Primary reduction ratio 3.173 (73/23) —
Final reduction ratio 2.866 (43/15) —
Gear ratios Low 2.636 (29/11) —
2nd 1.647 (28/17) —
3rd 1.217 (28/23) —
4th 0.952 (20/21) —
Top 0.818 (18/22) —
Shift fork to groove clearance 0.20 – 0.40 0.60
Shift fork groove width 4.25 – 4.35 —
Shift fork thickness 3.95 – 4.05 —
Drive chain Type D.I.D.520V —
Links 114 links —
20-pitch length — 319.4
Drive chain slack 20 – 30 —

CARBRETOR
ITEM SPECIFICATION
Carburetor type MIKUNI BDS28
Bore size 28 mm
I.D. No. 27F5
Idle r/min 1 300 ± 100 r/min
Fuel level 11.0 ± 1.0 mm
Float height 9.9 ± 1.0 mm
Main jet (M.J.) #97.5
Jet needle (J.N.) 4DM11-3rd
Needle jet (N.J.) O-2M
Pilot jet (P.J.) #15
Throttle valve (Th.V.) #140
Pilot screw (P.S.) 2 and 1/4 turns back
Throttle cable play 2 – 4 mm

Model: VL250K7 3/6 E-19, 24

ELECTRICAL Unit: mm
ITEM SPECIFICATION NOTE
Spark plug Type NGK: CR7E
DENSO: U22ESR-N
Gap 0.7 – 0.8
Spark performance Over 8 at 1 atm.
Ignition coil resistance Primary 1.8 – 3.0 Ω - terminai –
+ terminal
Secondary 16 – 26 kΩ + terminal –
Plug cap
Ignition coil primary peak voltage More than 250 V W or B/Y + –
Ground -
Generator coil resistance 0.3 – 1.1 Ω Y–Y
Signal generator coil resistance 180 – 280 Ω Bl – G
Signal generator peak voltage More than 4.5 V B+–G-
Generator Max. output 200 W at 5 000 r/min
Generator no-load voltage More than 60 V (AC) at 5 000 r/min
Regulated voltage 13.5 – 15.0 V at 5 000 r/min
Starter relay resistance 3–6Ω
Battery Type designation YTX7L-BS
Capacity 12 V 21.6 kC (6 Ah)/10HR
Fuse size Main 20 A
Headlight (HI) 15 A
Headlight (LO) 15 A
Ignition 10 A
Signal 15 A
Meter 10 A

WATTAGE Unit: W
SPECIFICATION
ITEM
E-19 E-24
Headlight HI 60 ←
LO 55 ←
Position light 4
Brake light/Taillight 21/5 ←
Turn signal light 21 ←
Speedmeter light 1.7 ←
Neutral indicator light 1.7 ←
Turn signal indicator light 1.7 ←
High beam indicator light 1.7 ←

Model: VL250K7 4/6 E-19, 24

BRAKE + WHEEL Unit: mm
ITEM STANDARD LIMIT
Rear brake pedal free travel 20 – 30 —
Rear brake pedal height 50 – 60 —
Brake disc thickness Front 5.0 4.5
Brake disc runout Front — 0.30
Master cylinder bore Front 12.700 – 12.743 —
Master cylinder piston diam. Front 12.657 – 12.684 —
Brake caliper cylinder bore Front 42.85 – 42.90 —
Brake caliper piston diam. Front 42.772 – 42.822 —
Brake fluid type Front DOT 4 —
Brake drum I.D. Rear — 130.7
Wheel rim runout Axial — 2.0
Radial — 2.0
Wheel axle runout Front — 0.25
Rear — 0.25
Wheel rim size Front 18M/C × MT2.15 —
Rear 15M/C × MT3.00 —

SUSPENSION Unit: mm
ITEM STD/SPEC. LIMIT
Front fork stroke 120 —
Front fork spring free length 300.5 294
Front fork oil level 111 —
Front fork oil type SUZUKI FORK OIL #10 or equivalent fork oil —
Front fork oil capacity (each leg) 388 ml —
Front fork inner tube O.D. 37 —
Rear wheel travel 90 —
Swingarm pivot shaft runout — 0.3

Model: VL250K7 5/6 E-19, 24

TIRE Unit: mm
ITEM STD/SPEC. LIMIT
Cold inflation tire pressure Front 175 kPa —
(Solo riding) (1.75 kgf/cm2)

Rear 200 kPa —

(2.00 kgf/cm2)
Cold inflation tire pressure Front 175 kPa —
(Dual riding) (1.75 kgf/cm2)

Rear 225 kPa —

(2.25 kgf/cm2)
Tire size Front 90/90-18M/C 51P —
Rear 150/80-15M/C 70P —
Tire type Front IRC: GS-21F —
Rear IRC: GS-21R —
Tire tread depth Front — 1.6 mm
Rear — 2.0 mm

FUEL + OIL
ITEM STD/SPEC. NOTE
Fuel type Gasoline used should be graded 91 octane or
higher. An unleaded gasoline is recommended.
Fuel tank including reserve 12.0 L
reserve 3.0 L
Engine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Engine oil capacity Change 1 800 ml
Filter change 1 900 ml
Overhaul 2 100 ml

Model: VL250K7 6/6 E-19, 24