Suzuki 2 Strokes

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?

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.

Thanks for the info jabcb

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.

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