Suzuki GW250 Bedienungsanleitung

K Dic128

GW250 L3 99500-32170-01E Cover14 (18 mm) 2012.06.12

Printed in Japan

SERVICE MANUAL

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.



* 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

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

BBDC : Before Bottom Dead Center

BTDC : Before Top Dead Center

B+ : Battery Positive Voltage

CKP Sensor : Crankshaft Position Sensor

(CKPS)

CKT : Circuit

CLP Switch : Clutch Lever Position Switch

(Clutch Switch)

CO : Carbon Monoxide

CPU : Central Processing Unit

DC : Direct Current

DRL : Daytime Running Light

DTC : Diagnostic Trouble Code

ECM : Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp.

Sensor (WTS)

FI : Fuel Injection, Fuel Injector

FP : Fuel Pump

FPR : Fuel Pressure Regulator

FP Relay : Fuel Pump Relay

FWD : Forward

GEN : Generator

GND : Ground

GP Switch : Gear Position Switch

HC : Hydrocarbons

HO2 Sensor : Heated Oxygen Sensor (HO2S)

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)

JASO : Japanese Automobile

Standards Organization

LCD : Liquid Crystal Display

LED : Light Emitting Diode

(Malfunction Indicator Lamp)

LH : Left Hand

MAL-Code : Malfunction Code

(Diagnostic Code)

Max : Maximum

MIL : Malfunction Indicator Lamp

(LED)

Min : Minimum

NOX : Nitrogen Oxides

OHC : Over Head Camshaft

OPS : Oil Pressure Switch

PAIR : Pulsed Secondary Air Injection

PCM : Power control module

PCV : Positive Crankcase

Ventilation (Crankcase Breather)

RH : Right Hand

ROM : Read Only Memory

SAE : Society of Automotive Engineers

SDS : Suzuki Diagnosis System

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

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

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