Suzuki GW250 User manual

K Dic128
GW250 L3 99500-32170-01E Cover14 (18 mm) 2012.06.12
Printed in Japan
L3
L3
SERVICE MANUAL
SERVICE MANUAL
GW250
GW250
9 9 5 0 0 - 3 2 1 7 0 - 0 1 E
CHANGZHOU HAOJUE SUZUKI MOTORCYCLE CO.,LTD.

GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE 3
FI SYSTEM DIAGNOSIS 4
FUEL SYSTEM AND THROTTLE
BODY 5
EXHAUST SYSTEM 6
COOLING AND LUBRICATION
SYSTEM 7
CHASSIS 8
ELECTRICAL SYSTEM 9
SERVICING INFORMATION 10
EMISSION CONTROL
INFORMATION 11
WIRING DIAGRAM 12
FOREWORD
This manual contains an introductory description on
the SUZUKI GW250 and procedures for its inspec-
tion/service and overhaul of its main components.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the motorcycle and its main-
tenance. Use this section as well as other sections
to use as a guide for proper inspection and service.
This manual will help you know the motorcycle bet-
ter so that you can assure your customers of fast
and reliable service.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2012
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual motorcycle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual motorcycle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI motorcy-
cles. If you do not have the proper knowledge
and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the motorcycle
unsafe for the rider and passenger.

HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find
the first page of the section easily.
4. The contents are listed on the first page of each section to
help you find the item and page 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 information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front wheel
1Brake disc
2Collar
3Dust seal
4Bearing
5Spacer
6Front wheel
AFront axle
BBrake disc bolt

ITEM N·m
kgf-m lbf-ft
A18 1.8 13.0
B65 6.5 47.0
FWD

SYMBOL MARKS AND MATERIALS
Listed in the table below are the symbols indicating instructions and other information. The meaning of each
symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Use SUZUKI SUPER LONG LIFE
COOLANT (BLUE).
99000-99032-20X
Use SUZUKI LONG LIFE COOLANT
(GREEN) or equivalent.
99000-99032-12X
Apply oil. Use engine oil or transmis-
sion oil unless otherwise specified.
Use SUZUKI FORK OIL G10
or equivalent.
99000-99001-G10
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKI
MOLY PASTE in a ratio of 1:1)
Apply or use brake fluid.
Apply SUZUKI SUPER GREASE “A”
or equivalent.
99000-25010
Measure in voltage range.
Apply SUZUKI SILICONE GREASE
or equivalent.
99000-25100
Measure in current range.
Apply SUZUKI MOLY PASTE
or equivalent.
99000-25140
Measure in resistance range.
Apply SUZUKI BOND “1207B”
or equivalent.
99000-31140
Measure in diode test range.
Apply THREAD LOCK CEMENT
SUPER “1303” or equivalent.
99000-32030
Measure in continuity test range.
Apply THREAD LOCK CEMENT
SUPER “1322” or equivalent.
99000-32110
Use special tool.
Apply THREAD LOCK CEMENT
SUPER “1360” or equivalent.
99000-32130
Indication of service data.
Apply THREAD LOCK CEMENT
SUPER“1342” or equivalent.
99000-32050

ABBREVIATIONS USED IN THIS
MANUAL
A
ABDC : After Bottom Dead Center
AC : Alternating Current
ACL : Air Cleaner, Air Cleaner Box
API : American Petroleum Institute
ATDC : After Top Dead Center
A/F : Air Fuel Mixture
B
BBDC : Before Bottom Dead Center
BTDC : Before Top Dead Center
B+ : Battery Positive Voltage
C
CKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT : Circuit
CLP Switch : Clutch Lever Position Switch
(Clutch Switch)
CO : Carbon Monoxide
CPU : Central Processing Unit
D
DC : Direct Current
DRL : Daytime Running Light
DTC : Diagnostic Trouble Code
E
ECM : Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
ECT Sensor : Engine Coolant Temperature
Sensor (ECTS), Water Temp.
Sensor (WTS)
F
FI : Fuel Injection, Fuel Injector
FP : Fuel Pump
FPR : Fuel Pressure Regulator
FP Relay : Fuel Pump Relay
FWD : Forward
G
GEN : Generator
GND : Ground
GP Switch : Gear Position Switch
H
HC : Hydrocarbons
HO2 Sensor : Heated Oxygen Sensor (HO2S)
I
IAP Sensor : Intake Air Pressure Sensor (IAPS)
(MAP Sensor)
IAT Sensor : Intake Air Temperature Sensor
(IATS)
IG : Ignition
ISC Valve : Idle Speed Control Valve (ISCV)
J
JASO : Japanese Automobile
Standards Organization
L
LCD : Liquid Crystal Display
LED : Light Emitting Diode
(Malfunction Indicator Lamp)
LH : Left Hand
M
MAL-Code : Malfunction Code
(Diagnostic Code)
Max : Maximum
MIL : Malfunction Indicator Lamp
(LED)
Min : Minimum
N
NOX : Nitrogen Oxides
O
OHC : Over Head Camshaft
OPS : Oil Pressure Switch

P
PAIR : Pulsed Secondary Air Injection
PCM : Power control module
PCV : Positive Crankcase
Ventilation (Crankcase Breather)
R
RH : Right Hand
ROM : Read Only Memory
S
SAE : Society of Automotive Engineers
SDS : Suzuki Diagnosis System
T
TO Sensor : Tip-Over Sensor (TOS)
TP Sensor : Throttle Position Sensor (TPS)
WIRE COLOR
B : Black Gr : Gray R : Red
Bl : Blue Lbl : Light blue V : Violet
Br : Brown Lg : Light green W : White
Dg : Dark green O : Orange Y : Yellow
G : Green P : Pink
B/Bl : Black with Blue tracer O/BI : Orange with Blue tracer
B/Br : Black with Brown tracer O/R : Orange with Red tracer
B/G : Black with Green tracer O/W : Orange with White tracer
B/R : Black with Red tracer O/Y : Orange with Yellow tracer
B/W : Black with White tracer R/B : Red with Black tracer
B/Y : Black with Yellow tracer R/Y : Red with Yellow tracer
Bl/G : Blue with Green tracer W/B : White with Black tracer
Bl/W : Blue with White tracer W/R : White with Red tracer
Bl/Y : Blue with Yellow tracer Y/G : Yellow with Green tracer
Br/Y : Brown with Yellow tracer Y/R : Yellow with Red tracer
G/Y : Green with Yellow tracer Y/W : Yellow with White tracer
O/B : Orange with Black tracer

GENERAL INFORMATION 1-1
1
GENERAL INFORMATION
CONTENTS
WARNING/CAUTION/NOTICE/NOTE ......................................................... 1- 2
GENERAL PRECAUTIONS ......................................................................... 1- 2
SUZUKI GW250L3 (’13-MODEL) ................................................................ 1- 4
SERIAL NUMBER LOCATION .................................................................... 1- 4
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION...................... 1- 5
FUEL...................................................................................................... 1- 5
ENGINE OIL .......................................................................................... 1- 5
BRAKE FLUID....................................................................................... 1- 6
FRONT FORK OIL................................................................................. 1- 6
ENGINE COOLANT RECOMMENDATION .......................................... 1- 6
BREAK-IN PROCEDURES.......................................................................... 1- 7
CYLINDER IDENTIFICATION...................................................................... 1- 7
INFORMATION LABELS............................................................................. 1- 8
SPECIFICATIONS........................................................................................ 1- 9
DIMENSIONS AND CURB MASS......................................................... 1- 9
ENGINE ................................................................................................. 1- 9
DRIVE TRAIN ........................................................................................ 1- 9
CHASSIS ............................................................................................... 1-10
ELECTRICAL ........................................................................................ 1-10
CAPACITIES ......................................................................................... 1-10
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
CODE COUNTRY or AREA EFFECTIVE FRAME NO.
P-12 Indonesia LC6GJ55B0C1 100001 –
P-21 E.U. LC6DC111101 100001 –
P-24 Australia LC6DC111201 100001 –
P-71 Mexico LC6GJ55E D1 100001 –

1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTICE/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION, NOTICE and NOTE have special meanings. Pay special attention to
the messages highlighted by these signal words.

Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in motorcycle damage.
Indicates a potential hazard that could result in motorcycle or equipment damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-
INGS, CAUTIONS and NOTICES stated, you must use good judgement and basic mechanical safety princi-
ples. If you are unsure about how to perform a particular service operation, ask a more experienced
mechanic for advice.
GENERAL PRECAUTIONS

* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the motorcycle.
* When 2 or more persons work together, pay attention to the safety of each other.
* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-
doors.
* When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer’s instructions.
* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system
until they have cooled.

GENERAL INFORMATION 1-3
* Never use gasoline as a cleaning solvent.
* After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings
related to the system for leaks.
* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-
lent.
* 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 and orientation.
* 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 replace the terminal cover on the positive terminal.
* When performing service to electrical parts, if the service procedures do not require use of
battery power, disconnect the negative cable from the battery.
* When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first.
Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci-
fied tightening torque.
* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking
nuts, 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.
* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and
other fluids: batteries and tires.
* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

1-4 GENERAL INFORMATION
SUZUKI GW250L3 (’13-MODEL)
NOTE:
Difference between illustration and actual motorcycle may exist depending on the markets.
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) 1is stamped on the right side of the
steering head pipe. The engine serial number 2is located on the left side of the crankcase. These numbers
are required especially for registering the machine and ordering spare parts.
RIGHT SIDE
LEFT SIDE