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1991 – 1994 SUZUKI GSX250F GSX 250F GSX250 Workshop Service Manual – PDF DOWNLOAD
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1991 – 1994 SUZUKI GSX250F GSX 250F GSX250 Workshop Service Manual
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Description
1991 – 1994 SUZUKI GSX250F GSX 250F GSX250 Workshop Service Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:229
DOWNLOADABLE:YES
FILE TYPE:PDF
1991 – 1994 SUZUKI GSX250F GSX 250F GSX250 WORKSHOP SERVICE MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
1991 – 1994 SUZUKI GSX250F GSX 250F GSX250 Workshop Service Manual
FOREWORD:
The SUZUKI GSX250F has been developed as a new generation motorcycle to the (ES-models. it is packed with highly advanced design concepts including a new highly efficient combustion system, a fully transistorized ignition system and 3 improved link type rear suspension. Combined with precise cantroi and easy handling the GSX250F provides excellent performance and outstanding riding comfort. This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service SUZUKI motor cycles. Apprentice mechanics and daft-yourself mechanics, will also find this manual as an extremely useful repair guide. This manual contains the most up-to-da Is in formation at the time of publication. The rights are reserved to update or make corrections to this manual at any time.
TABLE OF CONTENTS:
1991 – 1994 SUZUKI GSX250F GSX 250F GSX250 Workshop Service Manual
Workshop Manual, SUZUKI GSX250F.............................. 1 Group Index.................................................. 1 1. General Information....................................... 2 Vin and Serial number lacations.......................... 3 Fuel, Oil and Cooling solution Recommendations........... 3 Fuel................................................. 3 Engine Oil........................................... 3 Front Fork Oil....................................... 3 Brake Fluid.......................................... 3 Cooling Solution..................................... 4 Breaking-in Procedures................................... 4 Cylinder Identification.................................. 4 Special Materials........................................ 5 Precations and General Instrutions....................... 7 Replacement Parts.................................... 7 Specifications........................................... 8 2. Periodic Maintenance and Tune-Up Procedures............... 9 Periodic Maintenance Schedule............................ 10 Periodic Maintenance Chart........................... 10 Lubrication Points................................... 11 Maintenance and Tune-Up Procedures....................... 12 Battery.............................................. 12 Air Cleaner.......................................... 13 Exhaust Pipe Bolts................................... 13 Tappet Clearance..................................... 14 Spark Plug........................................... 15 Engine Oil and Oil Filter............................ 15 Fuel Lines........................................... 15 Carburators.......................................... 16 Cooling System....................................... 16 Clutch............................................... 17 Drive Chain.......................................... 18 Brakes............................................... 20 Tires................................................ 22 Steering............................................. 23 Front Fork........................................... 23 Rear Suspension...................................... 23 Chassis Bolts and Nuts............................... 24 3. Engine.................................................... 26 Compression Pressure Check............................... 27 Compression Test Procedure........................... 27 Oil Pressure Check....................................... 28 Oil Pressure Test Procedure.......................... 28 Engine Componenta Removable with Engine in Place......... 29 Engine Removal and Remounting............................ 30 Engine Removal....................................... 30 Engine Remounting.................................... 34 Engine Disassembly....................................... 35 Engine Components Inspection and Servicing............... 44 Cylinder Head........................................ 44 Valve................................................ 45 Camshaft............................................. 49 Cam Chain Tensioner.................................. 51 Cylinder............................................. 51 Piston............................................... 52 Piston Ring.......................................... 53 Piston Pin........................................... 54 Conrod............................................... 54 Crankshaft........................................... 57 Clutch............................................... 61 Oil Pump............................................. 62 Transmission Gears................................... 62 Engine Reassembly........................................ 65 4. Fuel and Lubrication System............................... 80 Fuel Cock................................................ 81 Fuel Pump and Fuel Pump Relay............................ 81 Fuel Tank................................................ 83 Carburetor............................................... 85 Specifications....................................... 86 I.D. No. Location.................................... 86 Removal and Disassenbly.............................. 87 Inspection........................................... 89 Reassembly and Remounting............................ 89 Balance of Carburetors............................... 91 Lubrication System....................................... 93 5. Cooling System............................................ 94 Cooling System........................................... 95 Cooling Solution......................................... 96 Radiator and Reservoir Tank.............................. 96 Thermostat, Water Thermo-gauge and cooling fan switch.... 99 Water Pump...............................................103 6. Electrical System.........................................107 Ignition System..........................................108 Description..........................................108 Inspection...........................................108 Charging System..........................................112 Description..........................................112 Inspection...........................................114 Starter System...........................................116 Description..........................................116 Removal and Disassembly..............................116 Inspection...........................................117 Reassembly...........................................118 Starter Relay Inspection.............................119 Side-stand/ignition Interlock System.....................119 Description..........................................119 Inspection...........................................121 Front amd Rear Solenoid and Control Unit.................122 Inspection...........................................122 Water Temperature Meter..................................122 Combination Meter........................................123 Lambs....................................................124 Switches.................................................125 Battery..................................................127 Specifications.......................................127 Initial Charging.....................................127 Servicing............................................128 Recharging Operation.................................129 7. Chassis...................................................130 Fairing..................................................131 Removal..............................................131 Remounting...........................................132 Front wheel..............................................133 Removal..............................................133 Inspection and Disassembly...........................134 Reassembly and Remounting............................135 Tire and Wheel...........................................137 Tire Removal.........................................137 Inspection...........................................139 Tire Mountinig.......................................140 Front Brake..............................................142 Brake Pad Replacement................................143 Caliper Removal and Diassembly.......................143 Caliper and Disc Inspection..........................144 Caliper Reassembly and Remounting....................145 Disc Inspection......................................145 Master Cylinder Removal and Diassembly...............145 Master Cylinder Inspection...........................146 Master Cylinder Reassembly and Remounting............147 Front Fork...............................................148 Removal and Diassembly...............................148 Inspection...........................................150 Reassembly and Remounting............................151 Steering Stem............................................153 Removal and Diassembly...............................153 Inspection...........................................155 Reassembly and Remounting............................155 Iginition Switch.....................................156 Rear Wheel...............................................158 Removal..............................................158 Inspection and Diassembly............................159 Reassembly and Remounting............................160 Rear Brake...............................................161 Brake Pad Replacement................................161 Caliper Removal and Diassembly.......................162 Caliper and Disc Inspection..........................163 Caliper Reassembly and Remounting....................163 Master Cylinder Removal and Diassembly...............164 Master Cylinder Inspection...........................165 Master Cylinder Reassembly and Remounting............165 Rear Swingarm and Suspension.............................166 Removal..............................................166 Inspection and Diassembly............................168 Reassembly and Remounting............................169 Reassembling Information.............................170 8. Service Information.......................................171 Troubleshooting..........................................172 Wiring Diagram...........................................179 Wire, Cable and Hose Routing.............................180 Wire Routing.........................................180 Cable Routing........................................182 Hose Routing.........................................183 Special Tools............................................186 Tightening Torque........................................188 Service Data.............................................191 9. GSX250FN (`92-Model)......................................198 Specifications...........................................199 Service Data.............................................200 Wiring Diagram...........................................208 Wire Routing.............................................209 Speedometer Cable and Front Brake Hose Routing...........210 10. GSX250FP (`93-Model).....................................211 Specifications...........................................212 Service Data.............................................213 11. GSX250FR (`94-Model).....................................220 Specifications...........................................221 Service Data.............................................222
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]
