75 Suzuki TS250 engine disassembly part 1

Disassembly of the lower end of the TS250, using self fabricated case seperation tool. Next video will cover transmission removal and inspection. Along with inspection of the crankshaft.

[@malcolmbrady1958]

Hey !! Thank you for taking the time & effort to produce and post these videos !! Workshop Manuals are o.k. !! But your videos are invaluable to anybody running or restoring these 2 stroke bikes !! I have a Beauty myself its a Suzuki TS 250 M it has 4,305.5 genuine miles on the clock and since owning the bike for 4 years now have done about 1,500 miles on forest tracks, the bike always draws attention from other bikers !! I am 64 years old and used to ride this exact same model of bike when I was 17 and 18 years old !! So when I turned 60 spent a little of my pension and treated myself because I remember having so much fun on it as a youngster, Ride it regularly in the Summer and enjoy it just as much as I did all those years ago. Malcolm from North Wales in the U.K.

[@montana2strokeracer]

Hi Malcolm, thank you very much for the kind words. I am having fun making the videos and getting to know folks all over the world that have like interests. These TS250's are wonderful bikes. I have lots of miles under my belt riding them and worked for a Suzuki/Hodaka dealership in the early 70's, that is when I got hooked on bikes. Nice to have you aboard and I sure appreciate you hanging out in the shop with me.

[@marlonbrando9279]

Excellent instructional vid , thank you 🤙, will use this as I pull down my tm250 for the first time .

[@montana2strokeracer]

Thank you, thanks for stopping by, TM250 that sounds like a super project.

[@ShmeegleSon]

Thanks for the upload!! Keep the history alive!!

[@montana2strokeracer]

Trying to, appreciate you hanging out in the shop with me.

[@jeffsilver4730]

As always Dale, great video, thanks for posting it.

[@montana2strokeracer]

Thanks Jeff.

[@jamesws3]

Amazing how much good learning can be packed into 24 1/2 minutes!

[@montana2strokeracer]

Thanks buddy, hey thanks for sharing that video, got me maybe 10 new subscribers...cool. Got a luggage rack for the tc125 from the forum. Dont have it yet but it in the mail. My customer is happy. Appreciate the help with that too.

[@mattdomenic4814]

Been looking for a good video to give me confidence to give it a shot on mine. Great vid thanks Dale.

[@montana2strokeracer]

Thanks Matt, you can do it. Grab a good manual and go to work.

[@schelty9233]

Great vid , thanks. Just about to do my '78.

[@montana2strokeracer]

Thank you, I hope these videos can be of some help during your engine rebuild. Let me know if I can be of any help. Thanks for hanging out in the shop with me.

[@schelty9233]

Thanks Dale, I'm motivated by your vids and can't wait to start the restoration. I'll let you know if I hit a technical roadblock. Love your workshop, I'm envious.

[@caingrant5959]

Thanks for sharing brother.

[@TweetFPV]

Great video.

[@montana2strokeracer]

Thank you, thank you for watchin.

[@retromechanicalengineer]

Great video Dale, I love the dry humour. You could be honourary English with that! I've seen that black residue in a crankcase before when the piston rings had been blowing, so the top end could be suspect, especially if it's been run without an air filter. Best wishes, Dean in Oxfordshire, UK.

[@montana2strokeracer]

Think your right Dean. If I was honorary English would I have to drink tea?

[@retromechanicalengineer]

@@montana2strokeracer Dale, you would want to drink tea! The universal restorer of body and mind.

[@craigkennedy5328]

Nice and informative video. Thanks for posting. I have a 1976 Suzuki TS250A which is all original with 2000 km. All good but I think the crankshaft seals need replacing evident by excessive smoke and gear oil loss. Attribute this to being a 44 year old bike! Researching to build confidence in tackling the job myself one day so your excellent video is really helpful with advice and explains the correct process. Buying the tools at the moment. Look forward to learning more from your other videos. Kind regards Craig.

[@montana2strokeracer]

Thanks Craig, I have just gotten the seals and bearings installed. Will be starting the crankshaft rebuild and assembly soon. So follow along, you will be able to build yours too. Thanks for your comment and for watchin.

[@craigkennedy5328]

Hi Dale. It’s really great that experts like yourself are kind and take the time to create such helpful videos on KZbin. I’ve learned a lot and it’s good to see the process in a repair. I like to see if I can possibly achieve the right outcome with the right tools or to best leave all or part of the repair to experts. There’s a certain satisfaction on achieving the right outcome and learning out of your comfort zone. Please keep adding to your interesting channel. Kindest regards, Craig (Sydney, Australia).

[@montana2strokeracer]

@@craigkennedy5328 Thanks Craig, I am so glad folks are getting some good from these videos. I enjoy doing them and talking to people such as yourself. I just cant believe how many folks are still interested in these old bikes. Thanks for your comment and for watchin.

[@craigkennedy5328]

Hi Dale. In my 50s now and so my interest is mostly nostalgic. I had an Australian made mini bike called a “Deckson Daredevil” - solid frame with lawnmower engine as a youngster and then had my first “real” bike a 77 Suzuki TS125B as a teenager. Used to thump around the bush/single tracks/fire trails. The bike was quiet so no never really bothered anyone. I later rode around town on a 79 TS250ER in my 20’s. All seems so long ago. Years pass and in 2017 found my 76 TS online, drove to Melbourne to pick it up from the original owner. So old Suzuki TS’s are special for me! I imagine there’s lots of guys out there who had similar experiences in their youth. The smell of two stroke fumes take me back! Engine has never been opened and so learning as much as I can. Kindest regards, Craig

[@kalemathews1899]

@@montana2strokeracer where did you get the bearings? I can’t find the correct ones for my 1972

[@garyfyvie9490]

I went through all that them skinny M6 bolts, wide slots and rusty cast iron threads I didnt want go back to hardware.

[@quitethe2stroke881]

Well, I was a little scared about doing it on my 78 250, but with these videos out, I'm feeling a little more confident. I'm still not gonna touch my 185 though, too much attachment if I mess up

[@montana2strokeracer]

Bet you will do just fine, what a great project. Give me a holler if you get in a jam. Thanks for watchin the channel

[@GREEVES246]

i done a dt400b lots of the bearings are not slip fit and used a trick by warming brass pieces to expand inner ring then whip the pieces out and then slap the sealer on with gasket and clap it together then bearings settel in middle of the bearing rings engine was so heavy i lay the frame over then lowered the frame on the engine engines in now and looking good

[@montana2strokeracer]

That sounds like an awesome trick, will have to keep it in mind. I have installed a frame on an engine before it does work well. Thanks for hanging out in the shop with me.

[@rhsleigh]

Hi Dale, I have been enjoying watching your videos and found them very useful. I especially like how you explain what you are doing step by step. I am in the process of restoring a 1970 Suzuki T200 and need to purchase some tubing for the oil reservoir and carburetors. Can you recommend the type and size of oil hose and fuel hose that you have used on your Suzuki? The shop manual doesn't give any information on these. Many thanks and keep those great videos coming.

[@montana2strokeracer]

Thank you for watching the channel, I sure appreciate it. I use Tygon tubing, because it is fuel resistant and stays flexible. I like the yellow see thru, however it is available in black also from Amazon. I am not sure of the size on the T200, some of the older bikes are larger. Just measure the petcock and oil tank hose fittings and order that size ID tubing. It will either be 3/16 or 1/4 ID, you don't care about the OD really, it is what it is.

[@GREEVES246]

and a ts 400 was used in the chase in the film "THE CAR"

[@montana2strokeracer]

Not sure I have ever seen that movie. Will have to keep an eye out for it. Thanks again for following the channel.

[@user-iv1sf2cw2q]

Dale, would it help to put nuts next to flywheel, on threaded stud, to steady it up? Mark.

[@montana2strokeracer]

Hey Mark, yes, think that would help in that regard. Never thought of it. Good idea.

[@pembo1974]

The stand you've got that engine mounted on, did you make that yourself or buy it?

[@montana2strokeracer]

It's a Motorsports Products Mx stand. They are available on Amazon and Ebay. It works pretty good, some mods are required on some engines. You can see the vertical bracket that is unfinished. That was needed for this engine. Easy enough to do. Thanks for your comment and for watchin.

[@funkysawmanwright5077]

Hey do you take on work? Over here in North Idaho, no body left to work on old tc125's

[@montana2strokeracer]

Hi there, yes I know, a lot of the bike shops dont want to work on the older stuff, I do take on some work, what are you needing. You can either reply here or go to my youtube "about" page and click on "for busniness inquiries" and you will find my email. It will get removed if I post it here. Thanks for following the channel.

[@amirhaiman9378]

Hi, I would like to change the Kickstart shaft of TS50ER 1984. does it make sense that i need to open to block (the engine) and it's not enough to do it by taking only the clutch cover off ? tnx

[@montana2strokeracer]

Hi Amir, I have never worked on one of those bikes, the only information I could find on line was for a 1983 model. The parts break down does look like you could change it by just pulling off the clutch cover. But I cant say for sure. Below is a picture I found for a 83 model. Wish I could be of more help. Thanks for following the channel. www.bike-parts-suz.com/thumbs/s/moto_img/suz_img_27/930_930/KICK-STARTER-Suzuki-MOTO-50-TS-ER-1983-TS50ERKD-Z-D--DP028117.png

[@xxjusxstarxx]

Hey boss, what would you recommend I do, at 13:17 the screw hole to the right of the rubber grommet, it's above the clutch push rod, had been snapped off, what you think I should do to put the cover back on?

[@montana2strokeracer]

Hey thanks for watchin, If the screw boss is broken off there is not much you can do, except a total teardown and have the screw boss remade with a TIG welder and retapped . But to be quite honest there are enough other screws holding it on that it should be ok. When you pull the clutch does it move the case out without that screw, That would be the biggest concern I think.

[@xxjusxstarxx]

@@montana2strokeracer I just bought this bike it didn't have the cover, once mine comes in I'll tell you, I appreciate the help

[@xxjusxstarxx]

There is a hole slightly higher and too the side where it looks like someone may have used a bolt and nut to hold it in

[@jorgeantoniosalazargiler4086]

Alguien sabe en que parte se puede conseguir repuestos de la suzuky ts 250 del año 82

[@montana2strokeracer]

Sorry not good with spanish, I think you are looking for parts for a suzuki ts250. 1982 model. You can get them from the manufacture and on ebay. Thanks for following the channel

[@kenhagen5488]

Do you have an assembly video?

[@montana2strokeracer]

Hi Ken, yes, here is the complete Playlist for the TS250 restoration. Suzuki TS250 restoration: kzbin.info/aero/PLQyl8BUThyaLSSwO3fwuoyz_8RSWeXPRb

[@kenhagen5488]

@@montana2strokeracer not really finding a complete assembley is is just all in different videos?

[@montana2strokeracer]

@@kenhagen5488 yes its broken down in 3 videos I think