Suzuki GZ250 Marauder Manual de usuario

FOREWORD

Thismanualcontains an introductory description on

the SUZUKIGZ250 and procedures for its inspec-

tion/service and overhaulof itsmaincomponents.

Otherinformationconsideredas generally known is

not included.

Read the GENERAL INFORMATION section to fa-

miliarizeyourself with themotorcycle and its mainte-

nance.Usethis section as well as othersections as a

guide for proper inspection and service. This

manual will help you know the motorcycle better so

that you can assure your customers of fast and re-

liable service.

This manual has beenprepared on the basis

of the latestspecifications atthe time of pub-

lication. If modifications have been made

since then, differences may exist between

thecontentofthis manualand theactualmo-

torcycle.

Illustrations in this manual are usedtoshow

the basic principles of operation and work

procedures. They may notrepresent the ac-

tual motorcycle exactly in detail. This

manual is written for persons who have

enough knowledge, skills and tools, includ-

ing special tools, forservicing SUZUKI mo-

torcycles. If you do not have the proper

knowledge and tools, ask your authorized

SUZUKImotorcycle dealerto helpyou.

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FUEL AND LUBRICATION

SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

WARNING

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the

service described in this manual. Improp-

er repair may result in injury to the me-

chanic and mayrender the motorcycle un-

safe for the rider and passenger.

SUZUKIMOTORCORPORATION

MotorcycleServiceDepartment

©COPYRIGHTSUZUKI MOTORCORPORATION 1998

HOW TO USE THIS MANUAL

TOLOCATE WHAT YOU ARE

LOOKING FOR:

1. The text ofthis manualis divided intosections.

2. Thesection titles arelisted in the GROUP INDEX.

3. Holding themanual as shownattherightwill allow

you tofind the firstpage of thesection easily.

4. Thecontents arelistedonthefirstpageofeachsec-

tion tohelp you find the item andpage you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service

informationsuch as the tightening torque, lubricating points and locking agent points, are provided.

Example: Frontwheel

SYMBOL

Listed in the table below are thesymbols indicating instructions and otherinformation necessary for

servicing. The meaning of each symbol is also included in the table.

SYMBOL

DEFINITION

SYMBO

L DEFINITION

Torque control required.

Data beside it indicates specified

torque.

Apply THREAD LOCK "1360".

99000-32130

Apply oil. Use engine oil unless

otherwise specified.

Apply or use brake fluid.

Apply molybdenum oil solution (mix-

ture of engine oil and SUZUKI MOLY

PASTE in a ratio of 1 : 1).

Measure in voltage range.

Apply SUZUKI SUPER GREASE

"A".

99000-25010

Measure in resistance range.

Apply SUZUKI SILICONE GREASE.

99000-25100

Measure in current range.

Apply SUZUKI MOLY PASTE.

99000-25140

Measure in diode test range.

Apply SUZUKI BOND "1215".

99000-31110

Measure in continuity test range.

Apply THREAD LOCK SUPER

"1303".

99000-32030

Use special tool.

Apply THREAD LOCK "1342".

99000-32050

Use fork oil. 99000-

99001-SS8

GENERAL INFORMATION

--------------------------------------------CONTENTS-------------------------------------------------1

WARNING/CAUTION/NOTE....................................................................... 1- 1

GENERAL PRECAUTIONS......................................................................... 1- 1

SUZUKI GZ250X ('99-MODEL)................................................................. 1-3

SERIAL NUMBER LOCATION.................................................................. 1-3

FUEL AND OIL RECOMMENDATIONS.................................................... 1-3

FUEL......................................................................................................... 1-3

ENGINE OIL .......................................................................................... 1-4

BRAKE FLUID ....................................................................................... 1-4

FRONT FORK OIL................................................................................... 1-4

BREAK-IN PROCEDURES........................................................................ 1-4

INFORMATION LABELS............................................................................ 1-5

SPECIFICATIONS ..................................................................................... 1-6

COUNTRYAND AREA CODES ............................................................... 1-8

1-1 GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the

symbol and thewords WARNING, CAUTION and NOTE havespecialmeanings. Payspecial attention

to the messages highlighted by these signal words.

WARNING

Indicates a potential hazardthat could resultin deathor injury.

CAUTION

Indicates a potential hazardthat could result in motorcycle damage.

NOTE:

Indicates special information tomake maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manualcannot possiblycover

all potential hazards relating to theservicing, or lack ofservicing, of the motorcycle. In addition to the

WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety prin-

ciples. If you are unsure about how to perform a particular service operation, ask amore experienced

mechanic for advice.

GENERAL PRECAUTIONS

WARNING

Proper service and repair procedures are important for the safetyof the service me-

chanic and the safetyand reliabilityof the motorcycle.

When 2 or more persons work together, payattention to the safetyof each other.

When it is necessaryto run the engine indoors, make sure that exhaust gas isforced

outdoors.

When working with toxic or flammable materials, make sure thatthe area you workinis

well ventilated and that you follow all of the manufacturer's instructions. Never use

gasoline as a cleaning solvent.

To avoidgetting burned, donottouchthe engine,engine oil andexhaust systemuntil

theyhave cooled.

After servicing fuel, oil, exhaust or brake systems, check all of the lines and fittings

related to the systemfor leaks.

GENERAL INFORMATION 1-2

CAUTION

* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their

equivalent.

* When removing parts that are to be reused, keep them arranged in an orderly manner

so that they may be reinstalled in the proper order.

* Be sure to use special tools when instructed.

* Make sure that all parts used in reassembly are clean. Lubricate them when specified.

* Use the specified lubricant, bond, or sealant.

* When removing the battery, disconnect the negative cable first and then the positive

cable.

* When reconnecting the battery, connect the positive cable first and then the negative

cable, and cover the positive terminal with the terminal cover.

* When performing service to electrical parts, disconnect the battery negative cable unless

the service procedure requires the battery power.

* When tightening cylinder head and crankcase bolts and nuts, tighten the larger sizes

first. Always tighten the bolts and nuts from the inside working out, in a crisscross

pattern and to the specified tightening torque.

* Whenever you remove oil seals, gaskets, packing, O-rings, self-locking nuts, locking

washers,cotter pins, circlips, and certain other parts as specified, be sure to replace them

with new ones. Also, before installing these new parts, be sure to remove any left over

material from the mating surfaces.

* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap

larger than required to slip the circlip over the shaft. After installing a circlip, always ensure

that it is completely seated in its groove and securely fitted.

* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and

oil if a thread is smeared with them.

* After reassembling, check parts for tightness and proper operation.

CAUTION

* To protect the environment, do not unlawfully dispose of used motor oil and all other fluids,

batteries, and tires.

* To protect the earth's natural resouces, properly dispose of used motorcycles and parts.

1-3 GENERAL INFORMATION

SUZUKI GZ250X ('99-MODEL)

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number) isstamped on the rightside of the

steering head pipe. The engine serial number is located on the left side of the crankcase. These

numbers arerequired especially for registering the machine and ordering spare parts.

FUEL AND OIL RECOMMENDATIONS

FUEL

Use unleaded gasoline that is graded 91 octane or higher.

GENERAL INFORMATION 1-4

ENGINE OIL

Use only oils which are rated SF or SG under the APIclas-

sification. The recommended viscosity is SAE 10W/40. If

SAE 10W/40 engine oil is not available, select an alterna-

tive according to the chart.

BRAKE FLUID

Specificationandclassification:DOT 4

WARNING

This motorcycle uses a glycol-based brake fluid. Do not use or mix different types of

brake fluid such as silicone-based andpetroleum-based fluids for refilling the system,

otherwise serious damage will resultto the brake system.

Never use anybrake fluid taken fromold, used or unsealed containers.

Never re-use brake fluid left over froma last servicing or whichhasbeen storedfor a long

period of time.

FRONT FORK OIL

Use SUZUKIfork oil SS-08 (#10).

BREAK-IN PROCEDURES

Duringmanufacturing only the best possiblematerials are used and allmachined parts are finished to

a veryhighstandard. It is still necessary to allow themoving parts to "BREAK-IN" before subjecting the

engine to maximum stresses. The future performance and reliability of the engine depends on thecare

and restraint exercised during its early life. The general rules are as follows.

•Keep to this break-in throttle position.

Initial 800 km(500 miles) : Less than 1/2 throttle

Up to 1 600 km(1 000 miles): Less than 3/4 throttle

•Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle

operation for short periods of time.

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