Suzuki GW250 Manuals

Suzuki GW250 Manuals

Manuals and User Guides for Suzuki GW250. We have 1 Suzuki GW250 manual available for free PDF download: Service Manual

Suzuki GW250 Service Manual

Suzuki GW250 Service Manual (478 pages)

Brand: Suzuki | Category: Motorcycle | Size: 64.05 MB

Table of Contents

General Information 1

7
- Fi System Diagnosis
  2
- General Information
  2
- Periodic Maintenance
  2
- Servicing Information
  2
- Electrical System
  2
- Warning/Caution/Notice/Note
  8
- General Precautions
  8
- Suzuki Gw250L3 ('13-Model)
  10
- Serial Number Location
  10
- Fuel, Oil and Engine Coolant Recommendation
  11
  - Fuel
    11
  - Engine Oil
    11
  - Brake Fluid
    12
  - Front Fork Oil
    12
  - Engine Coolant Recommendation
    12
- Break-In Procedures
  13
- Cylinder Identification
  13
- Information Labels
  14
- Specifications
  15
  - Dimensions and Curb Mass
    15
  - Engine
    15
  - Drive Train
    15
  - Chassis
    16
  - Electrical
    16
  - Capacities
    16
Periodic Maintenance

17
- Periodic Maintenance Schedule
  18
  - Periodic Maintenance Chart
    18
  - Lubrication Points
    19
- Maintenance and Tune-Up Procedures
  20
  - Air Cleaner
    20
  - Exhaust Pipe Bolts and Muffler Bolts
    21
  - Spark Plugs
    22
  - Valve Clearance
    24
  - Engine Oil Replacement
    27
  - Engine Oil and Oil Filter
    27
  - Fuel Line
    28
  - Oil Filter Replacement
    28
  - Pair (Air Supply) System
    29
  - Throttle Cable Play
    29
  - Engine Idle Speed
    29
  - Clutch Cable Play
    30
  - Cooling System
    31
  - Drive Chain
    33
  - Brake
    35
  - Tires
    39
  - Tires Condition/Pressure
    39
  - Steering
    40
  - Front Forks
    40
  - Rear Suspension
    40
  - Chassis Bolts and Nuts
    41
- Compression Pressure Check
  43
  - Compression Test Procedure
    43
- Oil Pressure Check
  44
- Sds Check
  45
  - Data at the Time of Racing
    46
Engine

49
- Engine Components Removable with Engine in Place
  50
- Engine Removal and Installation
  51
  - Engine Removal
    51
  - Engine Installation
    56
- Engine Disassembly
  60
- Engine Components Inspection and Service
  73
  - Cylinder Head Cover
    73
  - Pair Reed Valve
    73
  - Camshaht Housing
    74
  - Cylinder Head
    75
  - Camshaft
    82
  - Camshaft Runout
    83
  - Cam Chain Tension Adjuster
    84
  - Cam Chain Tensioner and Cam Chain Guide
    84
  - Cylinder
    84
  - Piston
    85
    
    Piston Diameter
    85
    
    Piston Ring Groove Width
    86
    
    Piston Ring Thickness
    86
    
    Piston Ring End Gap
    87
  - Clutch
    88
  - Oil Pump
    89
  - Starter Clutch
    90
  - Generator
    92
  - Water Pump
    92
  - Gearshift System
    93
  - Clutch Release Camshaft
    94
  - Oil Pressure Regulator
    95
  - Oil Strainer
    95
  - Transmission
    96
  - Crankcase
    99
  - Crank Balancer
    106
  - Crank Balancer Journal Bearing
    107
  - Crankshaft and Conrod
    109
  - Crankshaft Journal Bearing
    113
  - Crankshaft Thrust Bearing
    116
- Engine Reassembly
  118
Fi System Diagnosis

142
- Precautions in Servicing
  144
  - Electrical Parts
    144
  - Fuse
    145
  - Switch
    145
  - Ecm/Various Sensors
    146
  - Battery
    146
  - Electrical Circuit Inspection Procedure
    147
  - Using the Multi Circuit Tester
    150
- Fi System Technical Features
  151
  - Injection Time (Injection Volume)
    151
  - Compensation of Injection Time (Volume)
    152
  - Injection Stop Control
    152
  - Fi System Parts Location
    153
  - Fi System Wiring Diagram
    155
- Ecm Terminal
  156
- Self-Diagnosis Function
  157
  - User Mode
    157
  - Dealer Mode
    158
  - Tps Adjustment
    160
- Fail-Safe Function
  161
- Fi System Troubleshooting
  162
- Sensors
  232
  - Ckp Sensor Inspection
    232
  - Ckp Sensor Removal and Installation
    232
  - Iap Sensor Inspection
    232
  - Iap Sensor Removal and Installation
    232
  - Tp Sensor Inspection
    232
  - Tp Sensor Removal and Installation
    232
  - Tps Adjustment
    232
  - Ect Sensor Inspection
    233
  - Ect Sensor Removal and Installation
    233
  - Iat Sensor Inspection
    233
  - Iat Sensor Removal and Installation
    233
  - To Sensor Inspection
    233
  - To Sensor Removal and Installation
    233
  - Ho2 Sensor Inspection
    234
  - Ho2 Sensor Removal and Installation
    234
Fuel System and Throttle Body

236
- Fuel System
  237
  - Fuel Tank Removal
    237
  - Fuel Tank Installation
    238
  - Fuel Pressure Inspection
    238
  - Fuel Pump Inspection
    239
  - Fuel Discharge Amount Inspection
    239
  - Fuel Pump Relay Inspection
    240
  - Fuel Pump and Fuel Level Gauge Removal
    241
  - Fuel Pump Disassembly
    243
  - Fuel Mesh Filter Inspection and Cleaning
    244
  - Fuel Pump and Fuel Level Gauge Reassembly and Installation
    244
- Throttle Body
  246
  - Construction
    246
  - Throttle Body Removal
    247
  - Throttle Body Disassembly
    248
  - Throttle Body Cleaning
    250
  - Inspection
    250
  - Throttle Body Reassembly
    251
  - Throttle Body Installation
    252
  - Fuel Injector Removal
    253
  - Fuel Injector Inspection
    253
  - Fuel Injector Installation
    253
  - Isc Valve Removal
    253
  - Isc Valve Inspection
    255
  - Isc Valve Installation
    255
  - Isc Valve Reset
    256
  - Tp Reset
    257
  - Throttle Valve Synchronization
    258
Exhaust System

261
- Exhaust System
  262
  - Removal
    262
  - Inspection
    263
  - Installation
    263
  - Engine Coolant
    265
  - Cooling Circuit
    267
    
    Cooling Circuit Inspection
    267
  - Radiator and Cooling Fan Motor
    268
    
    Radiator and Cooling Fan Motor Removal
    268
    
    Radiator and Cooling Fan Motor Installation
    269
    
    Water Hose Inspection
    270
    
    Radiator Cap Inspection
    270
    
    Radiator Inspection and Cleaning
    271
  - Cooling Fan
    271
    
    Inspection
    271
    
    Cooling Fan Relay Inspection
    272
  - Ect Sensor
    272
    
    Removal
    272
    
    Inspection
    273
    
    Installation
    273
  - Thermostat
    274
    
    Removal
    274
    
    Inspection
    274
    
    Installation
    275
  - Water Pump
    276
    
    Construction
    276
    
    Removal and Disassembly
    277
    
    Inspection
    279
    
    Reassembly and Installation
    280
  - Lubrication System
    283
    
    Oil Pressure
    283
    
    Oil Filter
    283
    
    Oil Pressure Regulator
    283
    
    Oil Strainer
    283
    
    Oil Jet
    283
    
    Oil Pump
    283
    
    Oil Pressure Switch
    283
    
    Engine Lubrication System Chart
    284
Chassis

285
- Exterior Parts
  
  287
  - Fastener
    287
  - Frame Cover
    288
  - Frame Front Cover
    288
  - Fuel Tank Center Cover
    288
  - Fuel Tank Cover
    289
  - Seat
    289
  - Frame Upper Cover
    290
  - Pillion Rider Handle
    290
- Front Wheel
  
  291
  - Construction
    291
  - Removal
    292
  - Inspection and Disassembly
    292
  - Reassembly and Installation
    295
- Front Fork
  
  299
  - Construction
    299
  - Removal and Disassembly
    300
  - Inspection
    302
  - Reassembly and Installation
    303
- Steering
  
  307
  - Construction
    307
  - Removal
    308
  - Inspection and Disassembly
    309
  - Reassembly
    310
  - Installation
    310
- Steering Tension Adjustment
  
  311
- Handlebars
  
  312
  - Construction
    312
  - Removal
    313
  - Installation
    314
- Rear Wheel
  
  316
  - Construction
    316
  - Removal
    317
  - Inspection and Disassembly
    318
  - Reassembly and Installation
    320
- Rear Shock Absorber
  
  324
  - Construction
    324
  - Removal
    325
  - Inspection
    325
  - Bearing Replacement
    326
  - Rear Shock Absorber Disposal
    327
  - Insallation
    328
  - Suspension Setting
    328
- Rear Suspension
  
  329
  - Construction
    329
  - Installation
    334
- Front Brake
  
  335
  - Construction
    335
  - Brake Pad Replacement
    336
  - Brake Fluid Replacement
    338
  - Caliper Removal
    338
  - Caliper Disassembly
    339
  - Caliper Inspection
    340
  - Caliper Reassembly
    341
  - Caliper Installation
    342
  - Brake Disc Inspection
    342
  - Master Cylinder Removal and Disassembly
    343
  - Master Cylinder Inspection
    344
  - Master Cylinder Reassembly and Installation
    345
- Rear Brake
  
  347
  - Construction
    347
  - Brake Pad Replacement
    348
  - Brake Fluid Replacement
    349
  - Caliper Removal
    350
  - Caliper Disassembly
    350
  - Caliper Inspection
    351
  - Caliper Reassembly
    352
  - Caliper Installation
    353
  - Brake Disc Inspection
    353
  - Master Cylinder Removal and Disassembly
    353
  - Master Cylinder Inspection
    355
  - Master Cylinder Reassembly and Installation
    355
- Tire and Wheel
  
  357
  - Tire Removal
    357
  - Inspection
    357
  - Tire Installation
    359
  - Balancer Weight Installation
    360
- Drive Chain
  
  361
  - Drive Chain Cutting
    361
  - Drive Chain Connecting
    362
Electrical System

365
- Cautions in Servicing
  367
  - Connector
    367
  - Coupler
    367
  - Clamp
    367
  - Fuse
    367
  - Switch
    368
  - Semi-Conductor Equipped Part
    368
  - Battery
    368
  - Connecting the Battery
    368
  - Wiring Procedure
    368
  - Using the Multi Circuit Tester
    369
- Location of Electrical Components
  370
- Charging System
  372
  - Troubleshooting
    372
  - Inspection
    373
- Starter System
  376
  - Troubleshooting
    376
  - Starter Motor Removal
    377
  - Starter Motor Disassembly
    378
  - Starter Motor Inspection
    378
  - Starter Motor Reassembly
    379
  - Starter Relay Inspection
    381
  - Side-Stand/Ignition Interlock System Parts
    382
  - Inspection
    382
- Ignition System
  385
  - Troubleshooting
    385
  - Inspection
    387
- Combination Meter
  390
  - Description
    390
  - Removal and Disassembly
    391
  - Inspection
    392
- Lamps
  399
  - Headlight and Position Light
    399
  - License Plate Light
    402
  - Brake/Tail Light
    403
  - Turn Signal Light
    404
    
    Turn Signal Relay Inspection
    406
    
    Switches Inspection
    407
    
    Initial Charging
    408
    
    Recharging Operation
    410
Servicing Information

411
- Troubleshooting
  413
  - Fi System Malfunction Code and Defective Condition
    413
  - Engine
    413
  - Radiator (Cooling System)
    419
  - Chassis
    420
  - Brakes
    421
  - Electrical
    422
  - Battery
    423
- Wiring Harness, Cable and Hose Routing
  424
  - Wiring Harness Routing
    424
  - Cable Routing
    427
  - Intake System Hose Routing
    428
  - Fuel Tank Drain Hose Routing
    429
  - Cooling System Hose Routing
    430
  - Ignition Coil Installation
    432
  - Front Brake Hose Routing
    433
  - Rear Brake Hose Routing
    434
  - Pair (Air Supply) System Hose Routing
    435
  - Fuel Tank Installation
    436
  - Muffler & Exhaust Pipe Installation
    437
  - Seat Lock Cable Routing
    438
  - Front Fender Installation
    439
  - FRONT LICENSE PLATE INSTALLATION (Only for P-12)
    439
  - FRONT SIDE REFLEX REFLECTOR INSTALLATION (Only for P-24)
    440
  - Frame Cover Installation
    441
  - Frame Installation
    442
  - Side-Stand Installation
    442
  - CENTER STAND INSTALLATION (for P-12)
    443
  - Rear Brake Pedal Installation
    444
  - Handlebars Installation
    445
  - Headlight Cover Installation
    446
  - Headlight Installation
    447
  - Front Turn Signal Light Installation
    448
  - Rear Combination Light Installation
    449
  - Regulator/Rectifier Installation
    450
  - Special Tools
    451
- Tightening Torque
  454
  - Engine
    454
  - Fi System and Intake Air System
    456
  - Cooling System
    456
  - Chassis
    456
  - Tightening Torque Chart
    458
- Service Data
  459
  - Emission Control Systems
    470
    
    Noise Emission Control System
    470
    
    Ho2 Sensor Inspection
    470
    
    Ho2 Sensor Removal and Installation
    470
  - Pair (Air Supply) System and Emission Control System Inspection
    471
    
    Pair Hoses
    471
    
    Pair Reed Valve
    471
    
    Pcv Hose
    472
    
    Pair Control Solenoid Valve
    472
    
    Pair (Air Supply) System Hose Routing
    474

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