1999-2009 Suzuki GZ250 Service & Repair Manual

HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on the first page of each section to help you find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel ® ITEM N·m kg-m ® 65 6.5 @ 23 2.3 © 23 2.3 Ib-ft 47.0 16.5 16.5 CD Dust cover ® Spacer ® Bearing o Front wheel ® Spacer ® Bearing (£) Brake disc ® Speedometer gearbox o Front axle ® Axle pinch bolt @ Brake disc bolt

SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION SYMBOL DEFINITION ~ Torque control required. ,. Apply THREAD LOCK "1360". Data beside it indicates specified torque. 99000-32130 -rr Apply oil. Use engine oil unless e Apply or use brake fluid. otherwise specified. ;IiI Apply molybdenum oil solution (mix- ~ Measure in voltage range. ture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 : 1). ~ Apply SUZUKI SUPER GREASE ~ Measure in resistance range. "A". 99000-25030 J0t Apply SUZUKI SILICONE GREASE. ~ Measure in current range. 99000-25100 ~ Apply SUZUKI MOLY PASTE. ~ Measure in diode test range. 99000-25140 1II(!207S Apply SUZUKI BOND "1207B". 99104-31140 ~ Measure in continuity test range. • Apply THREAD LOCK SUPER '{oiu Use special tool. "1303". 99000-32030 .. Apply THREAD LOCK "1342". Use fork oil. .. 99000-32050 99000-99001-SS8

GENERAL INFORMATION ~------------------CONTENTS------------------~ WARNING/CAUTION/NOTE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 1 GENERAL PRECAUTIONS ..................................... 1- 1 SUZUKI GZ250X ('99-MODEL) .................................. 1- 3 SERIAL NUMBER LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 3 FUEL AND OIL RECOMMENDATIONS... . ...... . .... . . .... . ..... 1- 3 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 3 ENGINE OIL ................................................ 1- 4 BRAKE FLUID .............................................. 1- 4 FRONT FORK OIL ........................................... 1- 4 BREAK-IN PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 4 INFORMATION LABELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1- 5 SPECIFICATIONS ............................................. 1- 6 COUNTRY AND AREA CODES ................................. 1- 8

1·1 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. AWARNING Indicates a potential hazard that could result in death or injury. I A CAUTION I Indicates a potential hazard that could result in motorcycle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety prin- ciples. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice. GENERAL PRECAUTIONS AWARNING * Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle. * When 2 or more persons work together, pay attention to the safety of each other. * When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors. * When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the manufacturer's instructions. * Never use gasoline as a cleaning solvent. * To avoid getting burned, do not touch the engine, engine oil and exhaust system until they have cooled. * After servicing fuel, oil, exhaust or brake systems, check all of the lines and fittings related to the system for leaks.

GENERAL INFORMATION 1·2 IA CAUTION I * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order. * Be sure to use special tools when instructed. * Make sure that all parts used in reassembly are clean. Lubricate them when specified. * Use the specified lubricant, bond, or sealant. * When removing the battery, disconnect the negative cable first and then the positive cable. * When reconnecting the battery, connect the positive cable first and then the negative cable, and cover the positive terminal with the terminal cover. * When performing service to electrical parts, disconnect the battery negative cable unless the service procedure requires the battery power. * When tightening cylinder head and crankcase bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts from the inside working out, in a crisscross pattern and to the specified tightening torque. * Whenever you remove oil seals, gaskets, packing, O-rings, self-locking nuts, locking washers, cotter pins, circlips, and certain other parts as specified, be sure to replace them with new ones. Also , before installing these new parts, be sure to remove any left over material from the mating surfaces. * Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. * Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. * After reassembling, check parts for tightness and proper operation. * To protect the environment, do not unlawfully dispose of used motor oil and all other fluids, batteries, and tires. * To protect the earth's natural resouces, properly dispose of used motorcycles and parts.

1·3 GENERAL INFORMATION SUZUKI GZ250X ('99-MODEL) RIGHT SIDE LEFT SIDE * Difference between photographs and the actual motorcycles depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.LN. (Vehicle Identification Number) CD is stamped on the right side of the steering head pipe. The engine serial number @ is located on the left side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts. FUEL AND OIL RECOMMENDATIONS FUEL 1. Use only unleaded gasoline of at least 87 pump octane (R ~ M) method or 91 octane or higher rated by the research method. 2. Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% ethanol. Gasoline/alcohol fuel may contain up to S% methanol if appropriate cosolvents and corro- sion inhibitors are present in it. S. If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. 6. Failure to follow these guideline could possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above.

ENGINE OIL SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 10W/40. If an SAE 1 OW I 40 oil is not available, select an alternative according to the right chart. BRAKE FLUID ~ Specification and classification: DOT 4 AWARNING GENERAL INFORMATION 1·4 . . MULTIGRADE , .. . 10W 30 TEMP. OF -22 -4 14 32 50 68 86 104 This motorcycle uses a glycol-based brake fluid. Do not use or mix different types of brake fluid such as silicone-based and petroleum-based fluids for refilling the system, otherwise serious damage will result to the brake system. Never use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from a last servicing or which has been stored for a long period of time. FRONT FORK OIL Use SUZUKI fork oil SS-08 (#10). BREAK-IN PROCEDURES During manufacturing only the best possible materials are used and all machined parts are finished to a very high standard. It is still necessary to allow the moving parts to "BREAK-IN" before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows . • Keep to this break-in throttle position. Initial 800 km (500 miles) : Less than 1/2 throttle Up to 1 600 km (1 000 miles) : Less than 3/4 throttle • Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation for short periods of time.

CD Noise label (For E-03, 24, 33, 34) - I~ z ® Information label (For E-03, 28, 33) ." 0 G) m ® Vacuum hose routing label (For E-33) J:J z m o Fuel information label (For E-02, 24) ® Manual notice label (For E-03, -33) ® T ire pressure label o Warning safety label s: :c l> ~ r- Z - "TI 0 0 :c Z 3: ~ ® ICES label (For E-28) r 0 l> z ® 10 label (Except for E-03, 28, 33) OJ @ Safety plate (For E-03, 28 , 33) m r en :8

SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............................. . Overall width .............................. . Overall height ............................. . Wheelbase ................................ . Ground clearance .......................... . Seat height ................................ . Dry mass ................................. . ENGINE 2 160 mm (85.0 in) 815 mm (32.1 in) 1 090 mm (42.9 in) 1 450 mm (57.1 in) 125 mm ( 4.9 in) 680 mm (27.8 in) 137 kg (302 Ibs) GENERAL INFORMATION 1-6 Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Four-stroke, air-cooled, OHC Number of cylinder . . . . . . . . . . . . . . . . . . . . . . . . .. 1 Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 72.0 mm (2.835 in) Stroke ..................................... 61.2 mm (2.409 in) Displacement .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 249 cm 3 (15.2 cu. in) Compression ratio. . . . . . . . . . . . . . . . . . . . . . . . . .. 9.0: 1 Carburetor ................................. MIKUNI BSR32SS, single Air cleaner ................................. Non-woven fabric element Starter system .............................. Electric Lubrication system .......................... Wet sump TRANSMISSION Clutch ................... . .... ...... ....... Wet multi-plate type Transmission .......... . .................... 5-speed constant mesh Gearshift pattern ....... .. ................... 1-down, 4-up Primary reduction ratio ...................... 3.238 (68/21) Final reduction ratio ......................... 2.733 (41/15) Gear ratios, Low ........................... 2.636 (29/11) 2nd ........................... 1.687 (27/16) 3rd .. . . . . . . . . . . . . . . . . . . . . . . . . .. 1.263 (24/19) 4th. . . . . . . . . . . . . . . . . . . . . . . . . ... 1.000 (20/20) Top .... ... .................... 0.818 (18/22) Drive chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. DID 520VC5, 110 links

1999-2009 Suzuki GZ250 Service & Repair Manual

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