New Project - Suzuki TU 250 X - But can we fix it? 

Hi mate, I watched it twice and looked online. I know you put the parts in your sonic cleaner but I think you still have a blocked pilot jet. The choke on and the main jet raised are compensating the fuel flow at idle/part throttle. I have seen similar symptoms from sitting with stale fuel as the jet is tiny. Cheep to replace. Hope this helps 👍🍺🍺

mine is a newer 2011 TU250x, fuel injected so no carb issues. It is an awesome little bike.

Blocked pilot jet. Guaranteed. I just did a GL1100 bigger motor, same symptoms. Found all 4 pilots plugged. Yes, check valves too. That bike had sat for 20 years before I got it and it's running very well now. You can get this one running well again.

Hiya Mackie, do like that you don't choose expensive bikes for your projects, real bikes that interest real people, as for your carb I would suggest it is the pilot jet circuit, think you may well find it is dirt in the pilot jet or more likely the emulsion tube above it, a tiny bit of crap will have that effect and several Suzuki models suffer that problem, worth blowing all the jets and airways a blow through with an airline, also brake or carb cleaner squirted everywhere before blowing through helps but getting the pilot jet and emulsion tube out and clean is the best thing to check

As mentioned in the other comments, air leak, blocked jet etc, also worth checking timing & valve clearances as well matey. Good luck

Ive had ZZR 11's and CBR 1000's but ringing the neck out of a small bike is a hell of a lot of fun. Looks a nice little bike Mackie. Stay cool.👍

In Sri Lanka, we have a community of Volty riders. It's one of the dream bikes of any rider. So glad that I'm a proud owner of one! ❤️

Hiya.I would be checking the carb again.Rip it to bits and make sure all jets are clear.Blow through them with your compressor.It would be worth checking for an air leak aswell.Perhaps squirt some wd on the inlet manifold,see if the revs rise.All the best.

Looking forward to how your project turns out. I personally prefer the TU back to factory. Plus that seat colour is hidious! Great bike. I have one 😂

Hallo from hong kong volty owner, looking forward on your project💪🏻

Kool Li'l bike, I'd start with a rebuild kit, especially that diaphragm....and more beer! :)

Hi Mackie, Put all the jets in a jar of thinners and then put it in the sonic washer full of water. Your pilot jet is choked for sure and most other fluids in the washer don't work well for this problem, petrol works too but not as good as thinners, Soap only cleans oily dirt on the outside. If you can get the carb body in paint thinners do it as well as the galleries can be blocked too.

BTW, about intake air filter systems: In general you are absolutely right with what you said about air box. But, different from many comments of private persons in internet, intake air filters and air boxes are NOT always designed to make the motor run perfect or even near to that. Reason for that often is space conditions due to design of bike. But, surprise, even more frequently it´s about costs. With bikes we have a better chance to get a good system, same as with exhausts. With cars, situation is much worse. Guess why I know.

Double check the rubber between the carb and motor bro. Could have a little air leak. Cool little bike mate, you'll crack it 🤘

The diaphragm might have a whole in it. If it does it won'r raise the jet needle so it can get more fuel. Good luck on the build. you need to strip it down put a solo seat on it and make a mini bobber out of it.

Nice bike reminds me of GT250 used to own. Good luck with solving the puzzle. Seems like you are treading in someone else's footsteps. My guess would be a faulty boot or diaphragm, Possibly wrong float height. Gripped!

Hi Mackie: if I may, the first thing to do is to return all of the settings to the factory specs (you do have a manual right)? Then inspect the jets very carefully - it sounds like something is still blocked (perhaps the emulsion tube - but when cleaning it do not use wire as that can enlarge the tiny holes. The other thing to check is the carb mounting boot (the flexible thing that screws to the cylinder head) if there is a leak in that boot-head joint or with the fit of the carb in the boot - you won’t get it to run correctly. There is lots of info online on rebuilding Amika I carbs - do some research and you’ll find it.

Already now (only 11 comments yet) others already pointed out about pilot jet and poissible air leaks. Let me add that also passages of pilot jet which are casted in the carb housing can be blocked. Especially these are sometimes hard to clean.

Hi Mackie, have you checked the float bowl at all ? The float bowl needle, needle adjuster and float bowl height ? failing that it seems to only happen when the throttle plate / butterfly valve opens and closes, could that be loose at all, the 2 screws holding it in place maybe they came loose or the plates not sitting correctly in the valve chamber or the plate could just be worn out, just a few ideas, good luck

when you cleaned the carb parts, I am sure you removed the main jet , this is also were the slide needle goes up and down into. ok so when you remove the main jet from fuel bowl area, there is a washer use a pick to remove the washer and this will expose a long tube jet that the needle from the slide pin goes in and out of this must be cleaned as well, it well drop out when the washer that sits between this tube and the main jet. is removed. it has about 8 to maybe 16 little holes running along the sides that must be clean and open, use a safety pin, as they are very small. ok the only reason I am posting all of this is because every time some one comes to me for help its like no one ever cleans this part. If you already know this a apologize, for my assumption. :)

Is the float level/movement looking ok? Is the rubber line going from the carb to the tank (now the "Mackie tank" lol) positively not gunked up/kinked with an internal unseen restriction of fuel actually getting into the carb? How is the spark plug colour and condition- showing lean? I love these resurrection videos. I feel mildly guilty, because often they can lead to a bit of frustration trying to suss out the problem, but the final satisfaction surely makes it worthwhile, eh? I just love them nonetheless, a big thank you for doing these :D

How many bloody bikes you got lol. Another great video

I had a '98 model...... Wish I still had it... Good little commuter bikes..

The three basics, air, fuel and spark, check all, also, I think the pilot jet is blocked.

Check the condition of the diaphragm...new jets might help...What was the colour and condition of the old plugs..

Any luck yet? Personally, looking at that Diaphragm for starters, it shouldn’t be all wrinkly. They don’t suck even pressure to raise the needles. I would get a new one anyway if you could.

Oh man, I should have looked at this video of the Suzuki first! Dude! It’s the Fuel System! The 250 is starving for fuel in the transition from cold start (choke) to idle circuit. May have issue with other carb circuits too. The carb has issues. Ultrasonic cleaner not enough. The when system is starved for fuel like that, I like to eliminate leak issues. Vacuum will lean it when various carb parts warp due to overheat, or cold water/rain while engine was hot, etc. Anyway, to test for issues, start the bike and get it idling with full choke if necessary. Then use carb spray (good) or Starting fluid spray (better) and make really short sprays all around the carb and note changes in idle speed to find leaks. Sometimes you can fix the leaks with new gaskets, but sometimes you cannot. Excessive play in linkage pivots etc., just can’t be easily fixed. I am dead certain this is carb fault. Other stuff may need to be optimized, but this is a fuel delivery issue. 100% my friend. Shit, I wish I had seen this before you went down all those other rabbit trails. Shit. It’s the carb. Focus on the carb.

Glad that you have another project on the go, back to standard or are you going to pimp it.

The pilot jet is blocked. Try cleaning it with some Carb cleaner solution.

愛車がVOLTY（TU 250）なので、こういう動画はなんかうれしい♪

Hi Mackie I would check 4 things, the jets are clear i.e. you can see through them both slow running and main jet, the diaphragm has no holes in it, i.e.pin holes or little cuts especially where it joins the metal parts (a little stretch will highlight these), float height (see the manual) and air adjusting screw is turned out usually about 1 1/4 or 1 1/2 turns, it's not the first time I have come across these turned in tight. Make sure all orifices are clear throughout the carb. I would put the slide needle back where it was, its possible but unlikely someone has moved it from its original factory set position. This bike is almost certain to have electronic ignition i.e. no points or advance retard unit so not included in the 4 if it does then its 5 things to check. It should make a really nice project, i.e. flat tracker, you did the cafe racer and you did a fine job though I guess you have your own idea's. www.bikebound.com/wp-content/uploads/2017/10/Suzuki-TU250-Grasstracker-6.jpg www.bikebound.com/2017/10/01/suzuki-grasstracker-custom/ though with a flat tracker seat or similar. renax-motorbike.blogspot.com/search/label/Dominator%20NX650%20kit.

I’ve never heard of one. There is a lot of the bike that reminds me of my Suzuki GT250.

Maybe an air leak somewhere? Years ago when I had twin carb cars I always found colourtune plugs very helpful for this sort of thing.

Hey Mack. I see your problem mate. You need to drink more beer, not use it as fuel !!! Seriously though, all everyone says and check that vacuum rubber, looks a bit puckered. Also check the slide is lifting with vacuum. Blow some air through and the slide should lift. Good luck!

Those valves are a bit ticky by the way.

Hi Mackie get a carb rebuild kit Andy at NRP in Manchester is the Dogs Danglies when it comes to Carburettors.

I like that Mackie boy...

"Don't try this at home", thanks for the laugh, I do that shit all the time, safety third ! Hey message me on insta @bryontapp would like to send you some things to look over for a build.

I hope not. 😂 😂 😂 😂

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