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Suzuki GZ250 1999 Service Manual
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Suzuki GZ250 1999 Service Manual

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GZ250
99500-32101-03E
SUZUKI MOTOR CORPORATION PRINTED IN JAPAN JULY, 98

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Summary of Contents for Suzuki GZ250 1999

  • Page 1 GZ250 99500-32101-03E SUZUKI MOTOR CORPORATION PRINTED IN JAPAN JULY, 98...
  • Page 225 GZ250Y/K1 (’00/’01-MODEL) 9-1 GZ250Y/K1 (’00/’01-MODEL) CONTENTS SPECIFICATIONS ................9- 2 SERVICE DATA .................. 9- 3...
  • Page 226 9-2 GZ250Y/K1 (’00/’01-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ................2 160 mm (85.0 in) Overall width ................815 mm (32.1 in) Overall height ................1 090 mm (42.9 in) Wheelbase ................1 450 mm (57.1 in) Ground clearance ..............125 mm ( 4.9 in) Seat height ................
  • Page 227 GZ250Y/K1 (’00/’01-MODEL) 9-3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STD/SPEC. LIMIT Valve diam. ——— (1.0) ——— (0.9) Valve clearance (when cold) 0.03 – 0.08 ——— (0.001 – 0.003) 0.08 – 0.13 ——— (0.003 – 0.005) Valve guide to valve stem 0.025 –...
  • Page 228 9-4 GZ250Y/K1 (’00/’01-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 34.990 – 35.040 34.690 (1.3776 – 1.3795) (1.3657) 35.030 – 35.080 34.730 (1.3791 – 1.3811) (1.3673) Camshaft journal oil clearance 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0059) Camshaft journal holder I.D.
  • Page 229 GZ250Y/K1 (’00/’01-MODEL) 9-5 ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 ——— (0.040 – 0.041) 1.21 – 1.23 ——— (0.047 – 0.048) 2.51 – 2.53 ——— (0.099 – 0.100) Piston ring thickness 0.975 – 0.990 ——— (0.0384 – 0.0390) 1.170 –...
  • Page 230 9-6 GZ250Y/K1 (’00/’01-MODEL) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.238 (68/21) ——— Final reduction ratio 2.733 (41/15) ——— Gear ratios 2.636 (29/11) ——— 1.687 (27/16) ——— 1.263 (24/19) ——— 1.000 (20/20) ———...
  • Page 231 GZ250Y/K1 (’00/’01-MODEL) 9-7 CARBURETOR SPECIFICATION ITEM E-03, 28 E-33 E-34, 54 ← ← Carburetor type MIKUNI BSR32SS ← ← Bore size 32 mm I.D. No 13F3 13F4 13F7 ← Idle r/min. 1 300 ± 50 r/min. 1 300 ± 100 r/min. ←...
  • Page 232 9-8 GZ250Y/K1 (’00/’01-MODEL) WATTAGE Unit: W SPECIFICATION ITEM E-01, 02, 17, E-24 E-03, 28, 33 22, 25, 34 ← ← Headlight ← ← Position light ← ← Brake light/Taillight 21/5 ← ← (rear) Turn signal light Front turn signal light/Running light 21/5 ←...
  • Page 233 LIMIT Front fork stroke ——— (4.7) Front fork spring free length ——— (11.9) Front fork oil type SUZUKI fork oil SS-08 (#10) ——— Front fork oil capacity (each leg) 369 ml ——— (12.5/13.0 US/lmp oz) Front fork oil level ———...

  • Page 234: Table Of Contents

    GZ250K2 (’02-MODEL) 10-1 GZ250K2 (’02-MODEL) This chapter describes service data, service specifications and servicing procedures which differ from those of the GZ250K1/K2 (’01/’02-model). CONTENTS SPECIFICATIONS ................10- 2 SERVICE DATA .................. 10- 4 ENGINE MOUNTING NUT TIGHTENING TORQUE ......10-11 WIRING DIAGRAM ................

  • Page 235: Specifications

    10-2 GZ250K2 (’02-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ..............2 160 mm (85.0 in) Overall width ..............815 mm (32.1 in) Overall height ..............1 090 mm (42.9 in) Wheelbase ..............1 450 mm (57.1 in) Ground clearnce ............125 mm (4.9 in) Seat height ..............
  • Page 236 GZ250K2 (’02-MODEL) 10-3 ELECTRICAL Ignition type ..............Electronic ignition (Transistorized) Ignition timing ..............10° B. T. D. C. at 1 300 r/min Spark plug ..............NGK: DR8EA or DENSO X24ESR-U Battery ................12 V 21.6 kC (6 Ah)/10 HR Generator ..............Three-phase A.C.

  • Page 237: Service Data

    10-4 GZ250K2 (’02-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.0) ——— (0.9) Valve clearance (when cold) 0.03 – 0.08 ——— (0.001 – 0.003) 0.08 – 0.13 ——— (0.003 – 0.005) Valve guide to valve stem 0.025 –...
  • Page 238 GZ250K2 (’02-MODEL) 10-5 CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 34.990 – 35.040 34.690 (1.3776 – 1.3795) (1.3657) 35.030 – 35.080 34.730 (1.3791 – 1.3811) (1.3673) Camshaft journal oil clearance 0.032 – 0.066 0.150 (0.0013 – 0.0026) (0.0059) Camshaft journal holder I.D.
  • Page 239 10-6 GZ250K2 (’02-MODEL) ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 ——— (0.040 – 0.041) 1.21 – 1.23 ——— (0.047 – 0.048) 2.51 – 2.53 ——— (0.099 – 0.100) Piston ring thickness 0.975 – 0.990 ——— (0.0384 – 0.0390) 1.170 –...
  • Page 240 GZ250K2 (’02-MODEL) 10-7 TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.238 (68/21) ——— Final reduction ratio 2.733 (41/15) ——— Gear ratios 2.636 (29/11) ——— 1.687 (27/16) ——— 1.263 (24/19) ——— 1.000 (20/20) ———...
  • Page 241 10-8 GZ250K2 (’02-MODEL) CARBURETOR SPECIFICATION ITEM P-22, 24 P-34, 54 ← Carburetor type MIKUNI BSR32SS ← Bore size 32 mm I.D. No 13F2 13F7 ← Idle r/min. 1 300 ± 100 r/min. ← Float height 13.0 ± 0.5 mm ← Main jet (M.J.) #115...
  • Page 242 GZ250K2 (’02-MODEL) 10-9 WATTAGE Unit: W SPECIFICATION ITEM P-24 P-22, 34, 54 P-03, 28, 33 ← ← Headlight ← ← Position light ← ← Brake light/Taillight 21/5 * ← Turn signal light 21 (rear) * 10 Front turn signal light/Running light 21/5 ←...
  • Page 243 Front fork stroke ——— (4.7) Front fork spring free length (12.1) (11.9) Front fork oil type SUZUKI fork oil SS-08 (#10) ——— Front fork oil capacity (each leg) * 336 ml ——— (11.4/11.8 US/lmp oz) Front fork oil level * 120 ———...

  • Page 244: Engine Mounting Nut Tightening Torque

    GZ250K2 (’02-MODEL) 10-11 ENGINE MOUNTING NUT TIGHTENING TORQUE The tightening torque of engine 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. N .

  • Page 245: Wiring Diagram

    10-12 GZ250K2 (’02-MODEL) WIRING DIAGRAM FOR P-03, -28 and -33...
  • Page 246 GZ250K2 (’02-MODEL) 10-13 FOR P-24...
  • Page 247 10-14 GZ250K2 (’02-MODEL) FOR THE OTHERS...

  • Page 248: Wiring Harness Routing

    GZ250K2 (’02-MODEL) 10-15 WIRING HARNESS ROUTING...
  • Page 249 10-16 GZ250K2 (’02-MODEL)
  • Page 250 Prepared by 2nd Ed. May, 2002 1st Ed. July,1998 Part No. 99500-32101-03E Printed in Japan...

This manual is also suitable for:

Gz250 2002Gz250 2000Gz250 2001