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Suzuki GZ250 1999, Service Manual

The Suzuki GZ250 1999 is a reliable and efficient motorcycle that offers a smooth ride. For maintenance and repairs, make sure to have the Service Manual on hand. You can easily download the manual for free from manualshive.com to ensure your Suzuki GZ250 1999 is always in top condition.

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Summary of Contents for GZ250 1999

Page 1: ...99500 32101 03E SUZUKI MOTOR CORPORATION PRINTED IN JAPAN JULY 98 GZ250...

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Page 225: ...GZ250Y K1 00 01 MODEL 9 1 CONTENTS SPECIFICATIONS 9 2 SERVICE DATA 9 3 GZ250Y K1 00 01 MODEL 9...

Page 226: ...load 5 way adjustable Front suspension stroke 120 mm 4 7 in Rear wheel travel 90 mm 3 5 in Steering angle 40 right and left Caster 32 30 Trail 140 mm 5 5 in Turning radius 2 6 m 8 5 ft Front brake Dis...

Page 227: ...0026 Valve stem deflection IN EX 035 0 014 Valve guide I D IN EX 5 500 5 512 0 2165 0 2170 Valve stem O D IN 5 460 5 475 0 2150 0 2156 EX 5 445 5 460 0 2177 0 2150 Valve stem runout IN EX 0 05 0 002...

Page 228: ...66 11 984 0 4711 0 4718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Compression pressure 1 000 1 400 kPa 80...

Page 229: ...rance 0 10 0 65 1 0 0 004 0 026 0 04 Conrod big end width 20 95 21 00 0 825 0 827 Crankshaft web to web width 60 0 0 1 2 362 0 004 Crankshaft runout 0 05 0 002 Balancer spring free length 10 0 0 39 OI...

Page 230: ...05 0 156 0 159 Drive chain Type DID520VC5 Links 110 20 pitch length 319 4 12 57 Drive chain slack 5 15 0 2 0 6 CARBURETOR ITEM SPECIFICATION E 01 02 25 E 17 22 24 E 18 Carburetor type MIKUNI BSR32SS B...

Page 231: ...SPECIFICATION NOTE Spark plug Type NGK DR8EA DENSO X24ESR U Gap 0 6 0 7 0 024 0 028 Spark performance Over 8 0 3 at 1 atm Ignition coil resistance Primary 3 5 terminal terminal Secondary 17 28 k termi...

Page 232: ...dal height 50 2 0 Brake disc thickness Front 5 0 0 2 4 5 0 20 0 01 0 18 Brake disc runout Front 0 30 0 012 Master cylinder bore 12 700 12 743 0 4999 0 5017 Master cylinder piston diam 12 657 12 684 0...

Page 233: ...5 2 25 33 FUEL OIL ITEM SPECIFICATION NOTE Fuel type Fuel tank including reserve 14 L 3 7 3 1 US lmp gal reserve 2 9 L 0 8 0 6 US lmp gal Engine oil type and grade SAE 10W 40 API SF or SG Engine oil c...

Page 234: ...L in specihications and service data are clearly indicated with the asterisk mark This chapter describes service data service specifications and servicing procedures which differ from those of the GZ2...

Page 235: ...ore 72 0 mm 2 835 in Stroke 61 2 mm 2 409 in Displacement 249 cm3 15 2 cu in Compression ratio 9 0 1 Carburetor MIKUNI BSR32SS single Air cleaner Non woven fabric element Starter system Electric Lubri...

Page 236: ...High beam indicator light 12 V 1 7 W CHASSIS Front suspension Telescopic coil spring oil damped Rear suspension Swingarm type coil spring oil damped Front fork stroke 120 mm 4 7 in Rear wheel travel...

Page 237: ...Valve stem deflection IN EX 0 35 0 014 Valve guide I D IN EX 5 500 5 512 0 2165 0 2170 Valve stem O D IN 5 460 5 475 0 2150 0 2156 EX 5 445 5 460 0 2144 0 2150 Valve stem runout IN EX 0 05 0 002 Valv...

Page 238: ...11 984 0 4711 0 4718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Compression pressure 1 000 1 400 kPa 800...

Page 239: ...nce 0 10 0 65 1 0 0 004 0 026 0 04 Conrod big end width 20 95 21 00 0 825 0 827 Crankshaft web to web width 60 0 0 1 2 362 0 004 Crankshaft runout 0 05 0 002 Balancer spring free length 10 0 0 39 OIL...

Page 240: ...0 167 0 171 Shift fork thickness 3 95 4 05 0 156 0 159 Drive chain Type DID520VC5 Links 110 20 pitch length 319 4 12 57 Drive chain slack 5 15 0 2 0 6 CARBURETOR ITEM SPECIFICATION P 03 28 P 33 Carbu...

Page 241: ...ION NOTE Spark plug Type NGK DR8EA DENSO X24ESR U Gap 0 6 0 7 0 024 0 028 Spark performance Over 8 0 3 at 1 atm Ignition coil resistance Primary 3 5 terminal terminal Secondary 17 28 k terminal Plug c...

Page 242: ...disc thickness Front 5 0 0 2 4 5 0 20 0 01 0 18 Brake disc runout Front 0 30 0 012 Master cylinder bore 12 700 12 743 0 4999 0 5017 Master cylinder piston diam 12 657 12 684 0 4983 0 4994 Brake calipe...

Page 243: ...L ITEM SPECIFICATION NOTE Fuel type Fuel tank including reserve 13 L P 33 3 4 2 9 US lmp gal 14 L The others 3 7 3 1 US lmp gal reserve 2 9 L 0 8 0 6 US lmp gal Engine oil type and grade SAE 10W 40 AP...

Page 244: ...ngine mounting nuts have been changed from GZ250K2 model NOTE The engine mounting nuts are self locking Once the nuts have been removed they are no longer of any use ITEM N m kgf m lb ft A 36 3 6 26 0...

Page 245: ...Gr Br G B W O W B O G W B Bl Bl Y Y Y R B W Y Y Y R B W W O W O Y B W Bl G G B W Bl B O G B W Y Gr Lg B B Bl B W Lg Lbl B O W Y Y W Y G Y B W Y Y W B Y B Y B Bl B W Lg Lbl B B B W Dg B B W B W Dgr Dg...

Page 246: ...O O Y B W Gr Br G B W O W B O G W B Bl Bl Y Y Y R B W Y Y Y R B W W O W O Y B W Bl G G B W Bl B O G B W Y Gr Lg B B Bl B W Lg Lbl B O W Y Y W Y G Y B W Y Y W B Y B Y B Bl B W Lg Lbl B O R Lg B W B B W...

Page 247: ...O Y B W Gr Br G B W O W B O G W B Bl Bl Y Y Y R B W Y Y Y R B W W O W O Y B W Bl G G B W Bl B O G B W Y Gr Lg B B Bl B W Lg Lbl B O W Y Y W Y G Y B W Y Y W B Y B Y B Bl B W Lg Lbl B O R Lg B W B B W...

Page 248: ...ide of the clutch cable speedometer cable and brake hose Starter motor lead wire Wiring harness Generator Neutral switch Wiring harness Brake light taillight Seat cable Clamp Clamp Clamp Clamp Clamp C...

Page 249: ...light R To rear turn signal light L Clamp Rear turn signal light R Do not slacken the neutral switch lead wire Starter motor Wiring harness Generator Neutral switch Clamp Rear turn signal light L Brak...

Page 250: ...Prepared by 2nd Ed May 2002 1st Ed July 1998 Part No 99500 32101 03E Printed in Japan 256...

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