Suzuki GZ250 Marauder Manuals

Manuals and User Guides for Suzuki GZ250 Marauder. We have 4 Suzuki GZ250 Marauder manuals available for free PDF download: Service Manual, Owner's Manual

Suzuki GZ250 Marauder Service Manual (230 pages)

Brand: Suzuki | Category: Motorcycle | Size: 11.91 MB

General Information

5
- General Information
  2
- Periodic Maintenance
  2
  - Electrical System
    2
  - Servicing Information
    2
  - How to Use this Manual
    3
  - Table of Contents
    5
- Warning/Caution/Note
  6
- General Precautions
  6
- Suzuki Gz250X ('99-Model)
  9
- Serial Number Location
  9
- Fuel and Oil Recommendations
  9
  - Fuel
    9
  - Engine Oil
    10
  - Brake Fluid
    10
  - Front Fork Oil
    10
- Break-In Procedures
  10
- Specifications
  12
  - Dimensions and Dry Mass
    12
- Country and Area Codes
  14
Periodic Maintenance

15
- Periodic Maintenance Schedule
  16
  - Periodic Maintenance Chart
    16
  - Lubrication Points
    17
- Maintenance and Tune-Up Procedures
  18
  - Exhaust Pipe Bolts and Muffler Mounting Bolts
    18
  - Air Cleaner
    18
  - Valve Clearance
    19
  - Spark Plug
    21
  - Adjustment
    21
  - Fuel Hose
    22
  - Engine Idle Speed
    22
  - Throttle Cable Play
    23
  - Starter Plunger Cable Play
    24
  - Clutch
    24
  - Engine Oil and Oil Filter
    24
  - Drive Chain
    25
  - Brakes
    28
  - Tire
    31
  - Steering
    31
  - Front Fork
    32
  - Rear Suspension
    32
  - Chassis Bolts and Nuts
    32
- Compression Pressure Check
  34
- Oil Pressure Check
  35
Engine

36
- Engine Components Removable with the Engine in Place
  
  37
- Engine Removal and Reinstallation
  
  38
- Engine Reinstallation
  
  42
- Engine Disassembly
  
  45
- Engine Components Inspection and Service
  
  55
  - Crankcase Bearings
    55
  - Clutch Release Camshaft
    58
  - Cylinder Head Cover
    59
  - Cylinder Head
    60
  - Cam Chain Guide and Cam Chain Tensioner
    69
  - Camshaft
    69
  - Cam Chain Tension Adjuster
    71
  - Cylinder
    71
  - Piston and Piston Pin
    71
  - Crankshaft and Conrod
    74
  - Balancer Shaft and Balancer Shaft Driven Gear
    76
  - Starter Clutch and Starter Driven Gear Bearing
    77
  - Generator Stator and Pick-Up Coil
    78
  - Transmission
    79
  - Primary Driven Gear
    81
  - Clutch
    82
  - Clutch Cover
    83
  - Oil Filter
    83
  - Oil Sump Filter
    84
- Engine Reassembly
  
  85
  - Crankshaft
    85
  - Balancer Shaft
    85
  - Transmission
    85
  - Gearshift Cam and Gearshift Forks
    86
  - Crankcase
    87
  - Generator Rotor
    89
  - Driveshaft Retainer
    89
  - Primary Drive Gear
    89
  - Balancer Shaft Bolt
    90
  - Gearshift Cam Driven Gear
    90
  - Oil Pump
    91
  - Clutch
    92
  - Clutch Cover
    94
  - Starter Idle Gear
    94
  - Generator Cover
    94
  - Neutral Switch
    95
  - Engine Sprocket Spacer
    95
  - Starter Motor
    95
  - Piston and Piston Ring
    96
  - Cylinder
    97
  - Cylinder Head
    98
  - Camshaft
    99
  - Cam Chain Tension Adjuster
    100
  - Cylinder Head Cover
    101
Fuel and Lubrication System

102
- 103
  - Fuel Tank and Fuel Valve
    103
    
    Removal
    103
    
    Inspection
    103
    
    Remounting
    103
  - Carburetor
    104
    
    Specifications
    104
    
    I.D. No. Location
    104
    
    Construction
    105
    
    Removal
    106
    
    Disassembly
    106
    
    Cleaning
    110
    
    Inspection and Adjustment
    110
    
    Reassembly
    111
    
    Remounting
    111
  - Lubrication System
    112
    
    Oil Pressure
    112
    
    Oil Filter
    112
    
    Oil Sump Filter
    112
    
    Engine Lubrication System Chart
    113
Chassis

114
- 115
  - Exterior Parts
    115
    
    Removal
    115
    
    Remounting
    115
  - Front Wheel
    116
    
    Construction
    116
    
    Removal
    118
    
    Inspection and Disassembly
    118
    
    Reassembly
    120
    
    Remounting
    121
  - Front Brake
    122
    
    Construction
    122
    
    Brake Pad Replacement
    123
    
    Brake Fluid Replacement
    123
    
    Brake Caliper Removal and Disassembly
    124
    
    Brake Caliper Inspection
    125
    
    Brake Caliper Reassembly and Remounting
    125
    
    Brake Disc Inspection
    126
    
    Master Cylinder Removal and Disassembly
    126
    
    Master Cylinder Inspection
    128
    
    Master Cylinder Reassembly and Remounting
    128
  - Front Fork
    130
    
    Construction
    130
    
    Removal and Disassembly
    130
    
    Inspection
    132
    
    Reassembly and Remounting
    133
  - Steering
    137
    
    Construction
    137
    
    Removal and Disassembly
    138
    
    Inspection
    141
    
    Reassembly and Remounting
    142
  - Rear Wheel and Rear Brake
    145
    
    Construction
    145
    
    Removal
    147
    
    Inspection and Disassembly
    148
    
    Reassembly and Remounting
    150
  - Rear Suspension
    153
    
    Construction
    153
    
    Removal
    155
    
    Inspection and Disassembly
    156
    
    Reassembly and Remounting
    158
Electrical System

160
- Cautions in Servicing
  161
  - Connecting the Battery
    162
  - Using the Multi Circuit Tester
    162
- Location of Electrical Components
  163
- Charging System
  165
  - Description
    165
  - Troubleshooting
    166
  - Inspection
    168
- Starter System and Side-Stand/Ignition Interlock System
  171
  - Starter System Description
    171
  - Side-Stand/Ignition Interlock System Description
    171
  - Troubleshooting
    172
  - Starter Motor Removal and Disassembly
    174
  - Starter Motor Inspection
    174
  - Starter Motor Reassembly
    175
  - Starter Relay Inspection
    176
  - Side-Stand/Ignition Interlock System Part Inspection
    177
- Ignition System
  180
  - Description
    180
  - Troubleshooting
    181
  - Inspection
    183
- Speedometer
  187
  - Removal and Disassembly
    187
  - Inspection
    188
- Lamps
  189
  - Headlight and Position Light
    189
  - Brake Light/Taillight
    190
  - Turn Signal Lights
    191
- Relays
  192
  - Starter Relay
    192
  - Turn Signal/Side-Stand Relay
    192
- Switches
  193
- Battery
  194
  - Specifications
    194
  - Initial Charging
    194
  - Servicing
    195
  - Recharging Operation
    196
Servicing Information

197
- Troubleshooting
  198
- Wiring Diagram
  205
  - Cable Routing
    212
  - Front Brake Hose Routing
    215
  - Carburetor Hose Routing
    216
- Frame Rear Cover Set-Up
  217
- Special Tools
  218
- Tightening Torque
  222
- Service Data
  223
  - Tire Pressure
    229

Suzuki GZ250 Marauder Service Manual (230 pages)

Brand: Suzuki | Category: Motorcycle | Size: 12.36 MB

General Information

5
- General Information
  2
- Periodic Maintenance
  2
  - Electrical System
    2
  - Servicing Information
    2
  - How to Use this Manual
    3
  - Table of Contents
    5
- Warning/Caution/Note
  6
- General Precautions
  6
- Suzuki Gz250X ('99-Model)
  9
- Serial Number Location
  9
- Fuel and Oil Recommendations
  9
  - Fuel
    9
  - Engine Oil
    10
  - Brake Fluid
    10
  - Front Fork Oil
    10
- Break-In Procedures
  10
- Specifications
  12
- Country and Area Codes
  14
Periodic Maintenance

15
- Periodic Maintenance Schedule
  16
  - Periodic Maintenance Chart
    16
  - Lubrication Points
    17
- Maintenance and Tune-Up Procedures
  18
  - Exhaust Pipe Bolts and Muffler Mounting Bolts
    18
  - Air Cleaner
    18
  - Valve Clearance
    19
  - Spark Plug
    21
  - Adjustment
    21
  - Fuel Hose
    22
  - Engine Idle Speed
    22
  - Throttle Cable Play
    23
  - Starter Plunger Cable Play
    24
  - Clutch
    24
  - Engine Oil and Oil Filter
    24
  - Drive Chain
    25
  - Brakes
    28
  - Tire
    31
  - Steering
    31
  - Front Fork
    32
  - Rear Suspension
    32
  - Chassis Bolts and Nuts
    32
- Compression Pressure Check
  34
- Oil Pressure Check
  35
Engine

36
- Engine Components Removable with the Engine in Place
  37
- Engine Removal
  38
- Engine Reinstallation
  42
- Engine Disassembly
  45
- Engine Components Inspection and Service
  55
  - Crankcase Bearings
    55
  - Clutch Release Camshaft
    58
  - Cylinder Head Cover
    59
  - Cylinder Head
    60
  - Cam Chain Guide and Cam Chain Tensioner
    69
  - Camshaft
    69
  - Cam Chain Tension Adjuster
    71
  - Cylinder
    71
  - Piston and Piston Pin
    71
  - Crankshaft and Conrod
    74
  - Balancer Shaft and Balancer Shaft Driven Gear
    76
  - Starter Clutch and Starter Driven Gear Bearing
    77
  - Generator Stator and Pick-Up Coil
    78
  - Transmission
    79
  - Primary Driven Gear
    81
  - Clutch
    82
  - Clutch Cover
    83
  - Oil Filter
    83
  - Oil Sump Filter
    84
- Engine Reassembly
  85
  - Crankshaft
    85
  - Balancer Shaft
    85
  - Transmission
    85
  - Gearshift Cam and Gearshift Forks
    86
  - Crankcase
    87
  - Generator Rotor
    89
  - Driveshaft Retainer
    89
  - Primary Drive Gear
    89
  - Balancer Shaft Bolt
    90
  - Gearshift Cam Driven Gear
    90
  - Oil Pump
    91
  - Clutch
    92
  - Clutch Cover
    94
  - Starter Idle Gear
    94
  - Generator Cover
    94
  - Neutral Switch
    95
  - Engine Sprocket Spacer
    95
  - Starter Motor
    95
  - Piston and Piston Ring
    96
  - Cylinder
    97
  - Cylinder Head
    98
  - Camshaft
    99
  - Cam Chain Tension Adjuster
    100
  - Cylinder Head Cover
    101
Fuel and Lubrication System

102
- Fuel Tank and Fuel Valve
  103
  - Removal
    103
  - Inspection
    103
  - Remounting
    103
- Carburetor
  104
  - Specifications
    104
  - I.D. No. Location
    104
  - Construction
    105
  - Removal
    106
  - Disassembly
    106
  - Cleaning
    110
  - Inspection and Adjustment
    110
  - Reassembly
    111
  - Remounting
    111
- Lubrication System
  112
  - Oil Pressure
    112
  - Oil Filter
    112
  - Oil Sump Filter
    112
  - Engine Lubrication System Chart
    113
Chassis

114
- Exterior Parts
  115
  - Removal
    115
  - Remounting
    115
- Front Wheel
  116
  - Construction
    116
  - Removal
    118
  - Inspection and Disassembly
    118
  - Reassembly
    120
  - Remounting
    121
- Front Brake
  122
  - Construction
    122
  - Brake Pad Replacement
    123
  - Brake Fluid Replacement
    123
  - Brake Caliper Removal and Disassembly
    124
  - Brake Caliper Inspection
    125
  - Brake Caliper Reassembly and Remounting
    125
  - Brake Disc Inspection
    126
  - Master Cylinder Removal and Disassembly
    126
  - Master Cylinder Inspection
    128
  - Master Cylinder Reassembly and Remounting
    128
- Front Fork
  130
  - Construction
    130
  - Removal and Disassembly
    130
  - Inspection
    132
  - Reassembly and Remounting
    133
- Steering
  137
  - Construction
    137
  - Removal and Disassembly
    138
  - Inspection
    141
  - Reassembly and Remounting
    142
- Rear Wheel and Rear Brake
  145
  - Construction
    145
  - Removal
    147
  - Inspection and Disassembly
    148
  - Reassembly and Remounting
    150
- Rear Suspension
  153
  - Construction
    153
  - Removal
    155
  - Inspection and Disassembly
    156
  - Reassembly and Remounting
    158
Electrical System

160
- Cautions in Servicing
  161
  - Connecting the Battery
    162
  - Using the Multi Circuit Tester
    162
- Location of Electrical Components
  163
- Charging System
  165
  - Description
    165
  - Troubleshooting
    166
  - Inspection
    168
- Starter System and Side-Stand/Ignition Interlock System
  171
  - Starter System Description
    171
  - Side-Stand/Ignition Interlock System Description
    171
  - Troubleshooting
    172
  - Starter Motor Removal and Disassembly
    174
  - Starter Motor Inspection
    174
  - Starter Motor Reassembly
    175
  - Starter Relay Inspection
    176
  - Side-Stand/Ignition Interlock System Part Inspection
    177
- Ignition System
  180
  - Description
    180
  - Troubleshooting
    181
  - Inspection
    183
- Speedometer
  187
  - Removal and Disassembly
    187
  - Inspection
    188
- Lamps
  189
  - Headlight and Position Light
    189
  - Brake Light/Taillight
    190
  - Turn Signal Lights
    191
- Relays
  192
  - Starter Relay
    192
  - Turn Signal/Side-Stand Relay
    192
- Switches
  193
- Battery
  194
  - Specifications
    194
  - Initial Charging
    194
  - Servicing
    195
  - Recharging Operation
    196
Servicing Information

197
- Troubleshooting
  198
- Wiring Diagram
  205
  - Cable Routing
    212
  - Front Brake Hose Routing
    215
  - Carburetor Hose Routing
    216
- Frame Rear Cover Set-Up
  217
- Special Tools
  218
- Tightening Torque
  222
- Service Data
  223
  - Tire Pressure
    229

Suzuki GZ250 Marauder Owner's Manual (36 pages)

Brand: Suzuki | Category: Motorcycle | Size: 5.12 MB

Table of Contents
1
Fuel and Engine Oil Recommendation
2
Tips on Safety
2
Gasoline/Methanol Blends
3
Fuel Pump Labeling
3
Recommended Engine Oil
3
Location of Labels
4
Location of Parts
4
Handlebars View
4
Instrument Panel
5
Left Handlebar
5
Choke Lever
5
Right Handlebar
6
Fuel Tank Cap
6
Electric Starter Button
6
Throttle Grip
6
Fuel Valve
7
Gearshift Lever
7
Rear Brake Pedal
7
Seat Lock and Helmet Holders
8
Side Stand
8
Seat Removal
8
Rear Suspension - Spring Adjustment
9
Break-In
9
Inspection before Riding
10
Riding Tips
11
Starting the Engine
11
Starting off and Shifting
11
Using the Transmission
12
Riding on Hills
12
Stopping and Parking
12
Carrying a Passenger
13
Accessory Use and Motorcycle Loading
13
Modification of the Motorcycle
14
Inspection and Maintenance
15
Maintenance Schedule
15
Maintenance Chart
16
Tools
16
General Lubrication
16
Battery
17
Air Cleaner
17
Air Cleaner Element Removal
17
Spark Plug
18
Plug Replacement Guide
18
Air Cleaner Drain Tube
18
Spark Plug Removal
19
Spark Plug Cleaning
19
Spark Plug Installation
19
Engine Oil Level Check
19
Engine Oil and Filter Change
20
Carburetor
21
Idle Speed Adjustment
21
Throttle Cable Adjustment
21
Fuel Hose
21
Clutch Adjustment
22
Drive Chain
22
Inspecting the Drive Chain
22
Drive Chain Cleaning and Oiling
22
Brakes
23
Brake Fluid
23
Drive Chain Adjustment
23
Brake Pads
24
Rear Brake Pedal Adjustment
24
Rear Brake Light Switch
25
Spoke Nipple Tightness
25
Brake Lining Wear Limit
25
Tires
26
Tire Pressure and Loading
26
Tire Condition and Type
26
Side Standing/Ignition Interlock System
27
Front Wheel Removal
27
Rear Wheel Removal
28
Light Bulb Replacement
29
Headlight Beam Adjustment
29
Turn Signal Light
29
Troubleshooting
30
Fuse
30
Brake Light/Taillight
30
Engine Is Hard to Start or Does Not Start at All
30
Storage Procedure
31
If Engine Stalls
31
Appearance Care
32
Corrosion Prevention
32
Procedures for Returning the Motorcycle to Service after Storage
32
Motorcycle Cleaning
33
Inspection after Cleaning
33
Waxing the Motorcycle
33
Serial Number Location
34
Tampering with Noise Control System
34
Specifications
35

Suzuki GZ250 Marauder Owner's Manual (35 pages)

Brand: Suzuki | Category: Motorcycle | Size: 5.21 MB

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Suzuki GZ250 Marauder Manuals

Suzuki GZ250 Marauder Service Manual (230 pages)

Table of Contents

General Information

Periodic Maintenance

Engine

Engine Components Removable with the Engine in Place

Engine Removal and Reinstallation

Engine Reinstallation

Engine Disassembly

Engine Components Inspection and Service

Engine Reassembly

Fuel and Lubrication System

Chassis

Electrical System

Servicing Information

Suzuki GZ250 Marauder Service Manual (230 pages)

Table of Contents

General Information

Periodic Maintenance

Engine

Fuel and Lubrication System

Chassis

Electrical System

Servicing Information

Suzuki GZ250 Marauder Owner's Manual (36 pages)

Table of Contents

Suzuki GZ250 Marauder Owner's Manual (35 pages)

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