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jim250 · 05-28-2010, 08:07 PM

Hi,

I just recently bought a new suzuki TU 250. With 600 miles on the bike I decided to change the oil myself. Like a %&*ass I did not look at the owners manual. When I loosened the oil drain plug which I found out later that it wasn't, a spring and another part that looks like a bolt with no threads came out. Can some one please tell me how this goes back together in the correct order? I learned my lesson not to do any work on the bike with out a manual if I'm not sure about something. Any help would be appreciated. THANKS. Jim

jim250 · 05-28-2010, 08:15 PM

I think I removed the crankcase plug?

mscuddy · 05-28-2010, 08:27 PM

That's the detent spring that on older models with a kick starter held the kick start shaft in the correct posiiton, but on yours it most likely held the shift cam in place, the threadless bolt is the follower that holds resistance against the shift drum/cam, works on grooves in the shift cam/drum to stop it from moving without any input from the shift lever.

If you didn't try to shift it, or turn the motor over, very carefully put it back in the way it came out, and you'll most likely be OK. If you experience any unusual resistance screwing the main bolt back in, stop right there and buy a manual. Hope you don't have to spit the cases or anything.

You might be able to get a flashlight and peer into the hole, and see if you can stick a long skinny phillips screwdriver in the hole to line up the cam so the threadless bolt goes into it. Same thing happened to me with a Jawa 90. I was able to fix it with the screw driver method.

Good luck.

jim250 · 05-28-2010, 08:33 PM

I'm not sure how it came out. The thing that fell out that looks like a bolt with no threads. Which direction does it go in? I'll try to look up in there with flashlight.

seruzawa · 05-28-2010, 09:44 PM

Look up the exploded parts diagrams of your bike on bikebandit. If that doesn't help get a manual. You should have one anyhow. Sounds like you removed the device that holds the shifting drum in place. The unthreaded bolt would probably go with the rounded end in first, the spring next then the bolt. At least that's how it goes in my old DR400.

Safest thing is to get a manual.

jim250 · 05-28-2010, 11:37 PM

Thanks for the info guys. I'll go to the dealer first thing in the morning to find out for sure how it goes back together. bikebandit shows a diagram. It looks like it goes back together like you explained it. Thanks again. Jim

jim250 · 05-29-2010, 12:31 PM

Got it back together and works fine. Followed the diagram on bikebandit. Learned my lesson. Thanks for all the help. Jim

Kenneth_Moore · 05-29-2010, 02:22 PM

Don't let that turn you off from doing your own maintenance Jim. For me, working on the bike is as much fun as riding it. I won't do an engine rebuild, but brakes, chain and sprockets, lube, filters...and accessories, are all great fun.

MOKE1K · 05-30-2010, 04:38 AM

Perfect diag guys. Listen to Seru and perform your own maintenance. a year from now you'll be laughing about this.

A Star Ride · 05-30-2010, 10:36 PM

When I was younger I "helped" a friend change the oil in his car and drained the transmission, added 3.5 qts. oil and couldn't find out why I couldn't get a clean reading on the dipstick. Live & learn.

05-28-2010, 08:07 PM	#1
jim250 Registered Member Join Date: May 2010 Location: pittsburgh, PA Posts: 12	removed wrong oil drain plug? Hi, I just recently bought a new suzuki TU 250. With 600 miles on the bike I decided to change the oil myself. Like a %&*ass I did not look at the owners manual. When I loosened the oil drain plug which I found out later that it wasn't, a spring and another part that looks like a bolt with no threads came out. Can some one please tell me how this goes back together in the correct order? I learned my lesson not to do any work on the bike with out a manual if I'm not sure about something. Any help would be appreciated. THANKS. Jim

05-28-2010, 08:27 PM	#3
mscuddy MODERATOR X Join Date: Jun 2007 Location: Next to my still checkin the temp. Posts: 5,444	That's the detent spring that on older models with a kick starter held the kick start shaft in the correct posiiton, but on yours it most likely held the shift cam in place, the threadless bolt is the follower that holds resistance against the shift drum/cam, works on grooves in the shift cam/drum to stop it from moving without any input from the shift lever. If you didn't try to shift it, or turn the motor over, very carefully put it back in the way it came out, and you'll most likely be OK. If you experience any unusual resistance screwing the main bolt back in, stop right there and buy a manual. Hope you don't have to spit the cases or anything. You might be able to get a flashlight and peer into the hole, and see if you can stick a long skinny phillips screwdriver in the hole to line up the cam so the threadless bolt goes into it. Same thing happened to me with a Jawa 90. I was able to fix it with the screw driver method. Good luck. __________________ A gun is a tool, Marian; no better or no worse than any other tool: an axe, a shovel or anything. A gun is as good or as bad as the man using it. Remember that.

05-28-2010, 09:44 PM	#5
seruzawa Robby Join Date: Nov 2001 Location: 8501 ft. Posts: 16,803	Look up the exploded parts diagrams of your bike on bikebandit. If that doesn't help get a manual. You should have one anyhow. Sounds like you removed the device that holds the shifting drum in place. The unthreaded bolt would probably go with the rounded end in first, the spring next then the bolt. At least that's how it goes in my old DR400. Safest thing is to get a manual. __________________ I've seen things you people wouldn't believe. Attack ships on fire off the shoulder of Orion. I watched c-beams glitter in the dark near the Tanhauser Gate. All those moments will be lost in time, like tears in the rain.

05-29-2010, 02:22 PM	#8
Kenneth_Moore Registered Member Join Date: Jun 2007 Location: VIsiting the GIft Shop in the Pit of DIspair Posts: 7,118	Don't let that turn you off from doing your own maintenance Jim. For me, working on the bike is as much fun as riding it. I won't do an engine rebuild, but brakes, chain and sprockets, lube, filters...and accessories, are all great fun. __________________ www.kennethmoore.org

05-30-2010, 04:38 AM	#9
MOKE1K Registered Member Join Date: Jul 2008 Location: Kalapana, Big Island Posts: 3,956	Perfect diag guys. Listen to Seru and perform your own maintenance. a year from now you'll be laughing about this. __________________ "YOU CAN'T BOLT ON SKILL" "The only thing limiting your bike, is you" We survived Bush you'll survive Obama! "the most fundamental fact about the ideas of the political left is that they do not work. therefore we should not be surprised to find the left concentrated in institutions where ideas do not have to work in order to survive." --thomas sowell

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05-28-2010, 08:15 PM	#2
jim250 Registered Member Join Date: May 2010 Location: pittsburgh, PA Posts: 12	I think I removed the crankcase plug?

05-28-2010, 08:33 PM	#4
jim250 Registered Member Join Date: May 2010 Location: pittsburgh, PA Posts: 12	I'm not sure how it came out. The thing that fell out that looks like a bolt with no threads. Which direction does it go in? I'll try to look up in there with flashlight.

05-28-2010, 11:37 PM	#6
jim250 Registered Member Join Date: May 2010 Location: pittsburgh, PA Posts: 12	Thanks for the info guys. I'll go to the dealer first thing in the morning to find out for sure how it goes back together. bikebandit shows a diagram. It looks like it goes back together like you explained it. Thanks again. Jim

05-29-2010, 12:31 PM	#7
jim250 Registered Member Join Date: May 2010 Location: pittsburgh, PA Posts: 12	Got it back together and works fine. Followed the diagram on bikebandit. Learned my lesson. Thanks for all the help. Jim

05-30-2010, 10:36 PM	#10
A Star Ride Registered Member Join Date: Oct 2009 Location: central Va Posts: 1,126	When I was younger I "helped" a friend change the oil in his car and drained the transmission, added 3.5 qts. oil and couldn't find out why I couldn't get a clean reading on the dipstick. Live & learn. __________________ White Trash Hick from Appalachia