T250 Crankcase Bolt Length & Location Drwg

[Syd]

Hello - Does anyone have a crackcase drwg or can refer me to a link for the T250 showing the bolt size & length for each bolt location when you assemble the crankcase back together?

[jabcb]

The service manual is pretty bad.

But the parts manual is useful. A printed parts manual can be really helpful too. It will have the original part numbers & not the superseding #s, which are sometimes wrong.

Suzuki uses a 10-digit part #: 12345-67890
Digits 1—5 tell you the type of bolt.
For most bolts, digits 6-7 is the bolt size, digits 8-9 is the length, & the 10th digit may indicate bolt finish.
For some bolts, digits 6-0 do not describe the size. The parts manual lists the size for some of these bolts.

Its a good idea to test fit the empty crankcase with your new bolts. I followed this approach with our GT550 cafe build & used all new bolts. A few of the bolts & screws were too long, and we had to use shorter ones.

All of the bolts are JIS. The heads are a bit smaller than standard metric bolts & there is only one thread pitch option.
Most of the bolts are standard lengths, but there are a few oddball lengths.

[Syd]

Thanks for the info jabcb

[dollydog]

you probably know to do this anyway, but before i mate the 2 crankcase halves together i always run down all the threads with an m6 or m8 tap, just to clean them out. they get a lot of crap, oxide and old gasket goo in them over the years. and i also put a smear of copper grease on each bolt, it helps stop the build up of ali oxide. the next engine builder will love you for it
cheers, dd.

[Syd]

Yep, everything is cleaned up correctly and ready to be assembled