Suzuki GZ250 Marauder User manual

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.