Suzuki gz250 User Manual

FOREWORD

This manual contains an introductory description on
the SUZUKI GZ250 and procedures for its inspec­tion/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 mainte­nance. Use this section as well as other sections 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 re­liable service.

This manual has been prepared on the basis
of the latest specifications at the time of pub­lication. If modifications have been made
since then, differences may exist between
the content 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 mo­torcycles. If you do not have the proper
knowledge and tools, ask your authorized
SUZUKI motorcycle dealer to help you.

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. Improp­er repair may result in injury to the me­chanic and may render the motorcycle un­safe for the rider and passenger.

SUZUKI MOTOR CORPORATION

Motorcycle Service Department

© COPYRIGHT SUZUKI MOTOR CORPORATION 1998

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

SYMBOL

Listed in the table below are the symbols indicating instructions and other information 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".

Apply oil. Use engine oil unless
otherwise specified.

Apply or use brake fluid.

Apply molybdenum oil solution (mix­ture 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.

Measure in current range.

Apply SUZUKI MOLY PASTE.

Measure in diode test range.

Apply SUZUKI BOND "1215".

Measure in continuity test range.

Apply THREAD LOCK SUPER
"1303".
99000-32030

Use special tool.

Apply THREAD LOCK "1342".

Use fork oil. 99000-

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

COUNTRY AND 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 the words WARNING, CAUTION and NOTE have special meanings. Pay special attention
to the messages highlighted by these signal words.

WARNING

Indicates a potential hazard that could result in death or injury.

CAUTION

Indicates a potential hazard that could result in motorcycle 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
WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety prin­ciples. If you are unsure about how to perform a particular service operation, ask a more experienced
mechanic for advice.

GENERAL PRECAUTIONS

WARNING

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
outdoors.
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 manufacturer's instructions. Never use
gasoline as a cleaning solvent.
To avoid getting burned, do not touch the engine, engine oil and exhaust system until
they have cooled.
After servicing fuel, oil, exhaust or brake systems, check all of the lines and fittings
related to the system for 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) is stamped on the right side of the
steering head pipe. The engine serial number is located on the left side of the crankcase. These
numbers are required 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 API clas­sification. The recommended viscosity is SAE 10W/40. If
SAE 10W/40 engine oil is not available, select an alterna­tive according to the chart.

BRAKE FLUID

Specification and classification: 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 and petroleum-based fluids for refilling the system,
otherwise serious damage will result to the brake system.
Never use any brake fluid taken from old, used or unsealed containers.

Never re-use brake fluid left over from a last servicing or which has been stored for a long

period of time.

FRONT FORK OIL

Use SUZUKI fork oil SS-08 (#10).

BREAK-IN PROCEDURES

During manufacturing only the best possible materials are used and all machined parts are finished to
a very high standard. It is still necessary to allow the moving parts to "BREAK-IN" before subjecting the
engine to maximum stresses. The future performance and reliability of the engine depends on the care
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.

GENERAL INFORMATION 1-6

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length .............................................

Overall width ................................................

Overall height ..............................................

Wheelbase ....................................................

Ground clearance .........................................

Seat height ....................................................

Dry mass .....................................................

ENGINE

Type ..............................................................

Number of cylinder ........................................

Bore ...............................................................

Stroke ...........................................................

Displacement ................................................

Compression ratio .........................................

Carburetor ...................................................

Air cleaner .....................................................

Starter system ...............................................

Lubrication system .......................................

TRANSMISSION

Clutch ...........................................................

Transmission ...............................................

Gearshift pattern ............................................

Primary reduction ratio ...............................

Final reduction ratio ......................................

Gear ratios, Low .........................................

2nd ........................................

3rd ..........................................

4th ..........................................

Top .......................................

Drive chain ...................................................

2 160 mm (85.0 in)

815 mm (32.1 in)

1 090 mm (42.9 in)
1 450 mm (57.1 in)

125 mm ( 4.9 in)
680 mm (27.8 in)
137 kg (302 lbs)

Four-stroke, air-cooled, OHC

1

72.0 mm (2.835 in)

61.2 mm (2.409 in)
249 cm3 (15.2 cu. in)

9.0 : 1

MIKUNI BSR32SS, single
Non-woven fabric element
Electric
Wet sump

Wet multi-plate type
5-speed constant mesh
1-down, 4-up

3.238 (68/21)

2.733 (41/15)

2.636 (29/11)

1.687 (27/16)

1.263 (24/19)

1.000 (20/20)

0.818 (18/22)
DID 520VC5, 110 links

1-7 GENERAL INFORMATION

ELECTRICAL

Ignition type .............................................................. Electronic ignition (Transistorized)

Ignition timing ........................................................ 10° B.T.D.C. at 1 300 r/min

Spark plug .............................................................. NGK DR8EA or DENSO X24ESR-U

Battery ...................................................................... 12V 21.6 kC (6 Ah)/10 HR

Generator ................................................................. Three-phase A.C. generator

Fuse ......................................................................... 20/15/15/15/10/10A

Headlight .................................................................. 12V 60/55W

Position light .......................................................... 12V 4W ....... Except for E-03, -24, -28, -33

Brake light/Taillight .................................................. 12V 21/5W

Front turn signal light/Running light .......................... 12V 21/5W ....... E-03, -28, -33

Turn signal light ..................................................... 12V 21W

Speedometer light .................................................... 12V 1.7W

Neutral indicator light ................................................ 12V 3.4W

Turn signal indicator light ......................................... 12V 3.4W

High beam indicator light ........................................ 12V 1.7W

CHASSIS

Front suspension ................................................... Telescopic, coil spring, oil damped

Rear suspension ...................................................... Swingarm type, coil spring, oil damped, spring

preload 5-way adjustable

Front fork stroke ....................................................... 120 mm (4.7 in)

Rear wheel travel ..................................................... 90 mm (3.5 in)

Steering angle .......................................................... 40° (right and left)

Caster ...................................................................... 32° 30'

Trail ......................................................................... 140 mm (5.5 in)

Turning radius .......................................................... 2.6 m (8.5 ft)

Front brake ............................................................... Disc brake

Rear brake ................................................................ Internal expanding

Front tire size .......................................................... 110/90-16 59P

Rear tire size ............................................................ 130/90-15M/C 66P

CAPACITIES

Fuel tank, including reserve ..................................... 14 L (3.7/3.1 US/Imp gal)

reserve ................................................ 2.9 L (0.8/0.6 US/Imp gal)

Engine oil, oil change ........................................... 1 300 ml (1.4/1.1 US/Imp qt)

with filter change ................................ 1 400 ml (1.5/1.2 US/Imp qt)

overhaul ............................................. 1 700 ml (1.8/1.5 US/Imp qt)

Front fork oil (each leg) ......................................... 369 ml (12.5/13.0 US/Imp oz)

Specifications are subject to change without notice.

GENERAL INFORMATION 1-8

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

CODE

COUNTRY OR AREA

E-01

General

E-02

UK

E-03

U.S.A. (Except for California)

E-04

France

E-17

Sweden, Finland (E-15), Norway (E-16), Denmark (E-26)

E-22

Germany

E-24

Australia

E-25

Netherlands

E-28

Canada

E-33

California (U.S.A.)

E-34

Italy, Belgium (E-21), Spain (E-53)

PERIODIC MAINTENANCE

----------------------------------------- CONTENTS ------------------------------------------

PERIODIC MAINTENANCE SCHEDULE ............................................. 2- 1

PERIODIC MAINTENANCE CHART ................................................ 2- 1

LUBRICATION POINTS ................................................................. 2-2

MAINTENANCE AND TUNE-UP PROCEDURES .............................. 2-3

EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS ......... 2-3

AIR CLEANER ................................................................................ 2- 3

VALVE CLEARANCE ..................................................................... 2-4

SPARK PLUG ................................................................................. 2- 6

FUEL HOSE .................................................................................... 2- 7

ENGINE IDLE SPEED ..................................................................... 2- 7

THROTTLE CABLE PLAY ............................................................... 2- 7

STARTER PLUNGER CABLE PLAY ............................................... 2-9

CLUTCH .......................................................................................... 2-9

ENGINE OIL AND OIL FILTER ........................................................ 2- 9

DRIVE CHAIN .................................................................................. 2-70

BRAKES .......................................................................................... 2-12

TIRE ............................................................................................... 2-15

STEERING ....................................................................................... 2-15

FRONT FORK ................................................................................. 2-16

REAR SUSPENSION ....................................................................... 2-16

CHASSIS BOLTS AND NUTS ......................................................... 2-16

COMPRESSION PRESSURE CHECK ............................................... 2-18

OIL PRESSURE CHECK .................................................................... 2-19

2-1 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating at peak performance and economy. Maintenance intervals are ex­pressed in terms of kilometers and months, and are dependant on whichever comes first.

NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.

PERIODIC MAINTENANCE CHART

Interval
Item

km

1 000

5 000

10 000

15 000

miles

600

3 000

6 000

9 500

months 3 15

30

45

Exhaust pipe bolts and muffler mounting

bolts - T T T

Air cleaner element

Clean every 3 000 km (2 000 miles).

Valve clearance

I I I

I

Spark plug

- I R

I

Fuel hose

- I I

I

Replace every 4 years.

Engine idle speed

I I I

I

Throttle cable play

I I I

I

Clutch - I I I

Engine oil

R R R

R

Engine oil filter

R - R

-

Drive chain

I I I

I

Clean and lubricate every 1 000 km (600 miles).

Brakes

I I I

I

Brake hose

- I I

I

Replace every 4 years.

Brake fluid

- I I

I

Replace every 2 years.

Tires - I I I

Steering

I - I

-

Front fork

- - I

-

Rear suspension

- - I

-

Chassis bolts and nuts

T T T

T

NOTE:
I: Inspection and adjust, clean, lubricate or replace as necessary
C: Clean R: Replace T: Tighten

PERIODIC MAINTENANCE 2-2

LUBRICATION POINTS

Proper lubrication is important for smooth operation and long life of each working part of the motor­cycle. Major lubrication points are indicated below.

Side-stand pivot Drive chain

and spring hook

Brake pedal pivot

NOTE:

* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
* Lubricate exposed parts which are subject to rust, with a rust preventative spray especially whenever

the motorcycle has been operated under wet or rainy condition.

Clutch lever holder

Brake lever holder

2-3 PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each
item in the Periodic Maintenance chart.

EXHAUST PIPE BOLTS AND MUFFLER
MOUNTING BOLTS

Tighten every 5 000 km (3 000 miles, 15 months).

• Tighten the exhaust pipe bolts and muffler mounting
bolt to the specified torque.

Exhaust pipe bolt : 14 N ■ m (1.4 kg-m, 10.0 Ib-ft)

Muffler mounting bolt : 29 N ■ m (2.9 kg-m, 21.0 Ib-ft)

AIR CLEANER

Clean every 3 000 km (2 000 miles).

If the air cleaner is clogged with dust, intake resistance will
increase, resulting in a decrease in engine output and an
increase in fuel consumption. Check and clean the air
cleaner element in the following manner.

• Remove the front seat. (See p. 5-1.)

• Remove the left frame cover. (See p. 5-1.)

• Remove the air cleaner element .

PERIODIC MAINTENANCE 2-4

• Carefully use compressed air to clean the air cleaner
element.

CAUTION ________________________________

Always apply compressed air to the
outside of the air cleaner element. If compressed
air is applied to the inside, dirt will be forced into
the pores of the air cleaner element, restricting
air flow through the air cleaner element.

• Reinstall the cleaned or new air cleaner element in the
reverse order of removal.

• When installing the air cleaner element into the air clean­er case, align the triangle marks on the air cleaner ele­ment and the air cleaner case.

CAUTION

If driving under dusty conditions, clean the air
cleaner element more frequently. The surest way
to accelerate engine wear is to operate the engine
without the element or to use a torn element.
Make sure that the air cleaner is in good condition
at all times. The life of the engine depends largely
on this component!

NOTE:
When cleaning the air cleaner element, remove the plug
and drain any water from the air cleaner drain hose.

VALVE CLEARANCE

Inspect initially at 1 000 km (600 miles, 3 months)
and every 5 000 km (3 000 miles, 15 months) there­after.

INSPECTION

• Remove the front seat. (See p. 5-1.)

• Remove the fuel tank. (See p. 4-1.)

• Remove the cylinder head cover left cap

• Disconnect the spark plug cap and remove the spark
plug.

09930-10121: Spark plug socket wrench set

CAUTION

2-5 PERIODIC MAINTENANCE

Remove the valve inspection caps

The valve clearance specification is different for intake and
exhaust valves.

Valve clearance adjustment must be checked and adjusted,

1) at the time of periodic inspection, 2) when the valve
mechanism is serviced, and 3) when the camshaft is re­moved for servicing.

Valve clearance (when cold):
IN. : 0.03-0.08 mm (0.001-0.003 in)
EX.: 0.08-0.13 mm (0.003-0.005 in)

NOTE:
* The piston must be at top dead center (TDC) on the

compression stroke in order to check or adjust the valve
clearance.

* The valve clearance should only be checked when the

engine is cold.

* Remove the valve timing inspection plug and

generator cover cap

Rotate the crankshaft with a box wrench to set the piston
at top dead center (TDC) on the compression stroke.
(Rotate the crankshaft until the "T" line on the
generator rotor is aligned with the triangle mark on
the generator cover.)

Insert a thickness gauge into the clearance between the
valve stem end and the adjusting screw on the rocker
arm.

09900-20803: Thickness gauge

If the clearance is out of specification, adjust it to specifica­tion as follows.

PERIODIC MAINTENANCE 2-6

ADJUSTMENT

The clearance is adjusted using the special tool and offset
wrench.

• Loosen the locknuts

• Insert a thickness gauge between the valve stem end
and the adjusting screw on the rocker arm.

• Adjust the valve clearance by turning the adjusting screw

using the special tool while holding the locknuts

09917-14920: Valve adjuster wrench

CAUTION

Both the right and left valve clearances should be as
closely as possible.

• After the adjustment is completed, tighten the locknut se­curely.

• Rotate the crankshaft 720° with a box wrench and check
that the clearance is within specification.

SPARK PLUG

Inspect every 5 000 km (3 000 miles, 15 months).
Replace every 10 000 km (6 000 miles, 30 months).

Neglecting the spark plug eventually leads to difficult start­ing and poor engine performance. If the spark plug is used
for a long period, the electrode gradually bums away and
carbon builds up along the inside part of the spark plug. In
accordance with the Periodic Maintenance chart, the spark
plug should be inspected, cleaned and regapped at the rec­ommended intervals.

• Remove the cylinder head cover left cap.

• Disconnect the spark plug cap and remove the spark
plug.

09930-10121: Spark plug socket wrench set

• Carbon deposits on the spark plug will prevent
good
sparking and may cause the engine to misfire. Be sure to
clean the carbon deposits off periodically.

If the center electrode is fairly worn down, the spark plug
should be replaced and the spark plug gap set to the speci­fication using a thickness gauge.

09900-20803: Thickness gauge

Spark plug gap: 0.6-0.7 mm (0.024-0.028 in)

2-7 PERIODIC MAINTENANCE

Check the spark plug for burns. If any abnormalities are
found, replace the spark plug as indicated below.

NGK

DENSO

Remarks

DR7EA

X22ESR-U

If the standard spark plug is

apt to get wet, replace with

this plug.

DR8EA

X24ESR-U

Standard

DR9EA

X27ESR-U

If the standard spark plug is

apt to overheat, replace with

this plug.

CAUTION

Confirm the thread size and reach when replacing
the spark plug. If the reach is too short, carbon
will be deposited on the screw portion of the plug
hole and engine damage may result.

CAUTION

Before using a spark plug wrench, carefully turn
the spark plug by finger into the threads of the
cylinder head to prevent damage.

• Tighten the spark plug to the specified torque using the
special tool.

Spark plug: 18 N-m (1.8 kg-m, 13.0 Ib-ft)

09930-10121: Spark plug socket wrench set

FUEL HOSE

Inspect every 5 000 km (3 000 miles, 15 months).
Replace every 4 years.

ENGINE IDLE SPEED

Inspect initially at 1 000 km (600 miles, 3 months)
and every 5 000 km (3 000 miles, 15 months) there­after.

• Adjust the throttle cable play. (See p. 2-8.)

• Warm up the engine.

NOTE:
Make this adjustment when the engine is hot.

• Connect an electric tachometer to the high tension cord.

PERIODIC MAINTENANCE 2-8

• Start the engine, turn the throttle stop screw and set
the engine idle speed as follows.

Engine idle speed:

1 300 ± 50 r/min .... For E-03, -28, -33

1 300 ±100 r/min ..... For the others

09900-26006: Tachometer

THROTTLE CABLE PLAY

Inspect initially at 1 000 km (600 miles, 3 months)
and every 5 000 km (3 000 miles, 15 months) there­after.

Adjust the throttle cable play
steps.

First step:

• Loosen the lock nut of the throttle returning cable
and turn in the adjuster fully into the threads.

Second step:

• Loosen the lock nut of the throttle pulling cable

• Turn the adjuster in or out until the throttle cable play

should be 2.0-4.0 mm (0.08-0.16 in) at the throttle

grip.

• Tighten the lock nut while holding the adjuster

Third step:

• While holding the throttle grip at the fully closed position,
slowly turn out the adjuster of the throttle returning
cable to feel resistance.

• Tighten the lock nut while holding the adjuster

Throttle cable play : 2.0-4.0 mm (0.08-0.16 in)

WARNING

After the adjustment is completed, check that
handlebar movement does not raise the engine
idle speed and that the throttle grip returns
smoothly and automatically.

NOTE:
Major adjustment can be made by the carburetor side ad­juster.

with the following three

2-9 PERIODIC MAINTENANCE

STARTER PLUNGER CABLE PLAY

Starter plunger cable play

should be 0.5-1.0 mm
(0.02-0.04 in) as shown. If the play is incorrect, adjust
it as follows:

• Loosen the lock nut and turn the adjuster in or out

until the specified play is obtained.

• Tighten the lock nut while holding the adjuster

Starter plunger cable play

CLUTCH

Inspect every 5 000 km (3 000 miles, 15 months).

• Loosen the lock nut and turn the adjuster fully in.

• Loosen the lock nut and turn the adjuster until the
clutch lever play is within specification.

Clutch lever play : 10-15 mm (0.4-0.6 in)

• Tighten the lock nuts

ENGINE OIL AND OIL FILTER

(ENGINE OIL)
Replace initially at 1 000 km (600 miles, 3 months)
and every 5 000 km (3 000 miles, 15 months) there­after.

(OIL FILTER)
Replace initially at 1 000 km (600 miles, 3 months)
and every 10 000 km (6 000 miles, 30 months)
thereafter.

The engine oil should be changed while the engine is
warm. Oil filter replacement at the above intervals should
be done together with the engine oil change.

ENGINE OIL REPLACEMENT

• Keep the motorcycle upright.

• Place an oil pan below the engine, and drain the engine

oil by removing the engine oil drain plug and oil filler
cap .

• Tighten the oil drain plug to the specified torque, and

pour new oil through the oil filler. When performing an oil
change (without oil filter replacement), the engine will
hold about 1 300 ml (1.4/1.1 US/Imp qt) of oil. Use SF or
SG classified (API) engine oil with a viscosity rating of
10W-40 (SAE).

Oil drain plug: 28 N-m (2.8 kg-m, 20.0 Ib-ft)

• Install the oil filler cap

0.5-1.0 mm
(0.02-0.04 in)

PERIODIC MAINTENANCE 2-10

• Start up the engine and allow it to run for a few minutes
at idling speed.

• Turn off the engine and wait about one minute, then
check the oil level through the inspection window . If
the level is below the "F" mark, add oil to the proper
level.

OIL FILTER REPLACEMENT

• Drain the engine oil as described in the engine oil re­placement procedure.

• Remove the oil filter cap by removing the nuts.

• Remove the oil filter and install a new one.

• Install the oil filter cap and tighten the nuts securely.

NOTE:
Before installing the new oil filter and oil filter cap, make
sure that the spring and new O-rings

are

installed correctly.

• Add new engine oil and check the oil level as described

in the engine oil replacement procedure.

Oil viscosity and classification:

10W/40 (SAE)/SF or SG (API)

NECESSARY AMOUNT OF ENGINE OIL
Oil change : 1 300 ml (1.4/1.1 US/Imp qt)
Oil and filter change: 1 400 ml (1.5/1.2 US/Imp qt)
Engine overhaul : 1 700 ml (1.8/1.5 US/Imp qt)

DRIVE CHAIN

Inspect initially at 1 000 km (600 miles, 3 months)
and every 5 000 km (3 000 miles, 15 months) there­after. Clean and lubricate every 1 000 km (600
miles).

Visually inspect the drive chain for the possible defects
listed below. (Support the motorcycle by a jack and a
wooden block, turn the rear wheel slowly by hand with the
transmission shifted to Neutral.)

• Loose pins * Excessive wear

• Damaged rollers * Kinked or binding links

• Dry or rusted links * Missing O-ring seals

• Twisted or seized links

If any defects are found, the drive chain must be replaced.

CAUTION __________________________________

The standard drive chain is DID520VC5. SUZUKI
recommends to use this standard drive chain as a
replacement.

replacement.

2-11 PERIODIC MAINTENANCE

CHECKING AND ADJUSTING

• Remove the rear axle cotter pin. (For E-28 model)

• Loosen the rear axle nut

• Tense the drive chain fully by turning chain adjuster nuts

• Count out 21 pins (20-pitch) on the chain measure the
distance between the two points. If the distance exceeds
the service limit, the chain must be replaced.

Drive chain 20-pitch length: 319.4 mm (12.57 in)

NOTE:

When replacing the drive chain, replace the drive chain and

sprockets as a set.

• Place the motorcycle on the side-stand.

• Loosen both chain adjuster nuts until the chain has 5-15
mm (0.2-0.6 in) of slack at the middle of the chain between
the engine and rear sprockets as shown. The reference
marks must be at the same position on the scale to
ensure that the front and rear wheels are correctly aligned.

Drive chain slack: 5-15 mm (0.2-0.6 in)

• After adjusting the drive chain, tighten the rear axle nut

to the specified torque.

Rear axle nut:

65 N-m (6.5 kg-m, 47.0 Ib-ft) ........ For E-03, -28, -33

78 N-m (7.8 kg-m, 56.5 Ib-ft) ........ For the others

• Recheck the chain slack after tightening the axle nut and

readjust if necessary.

* Tighten both chain adjuster nuts securely.

• Install the new cotter pin. (For E-03, -28, -33 models)

CLEANING AND LUBRICATING

• Clean the drive chain with kerosine. If the drive chain

tends to rust quickly, the intervals must be shortened.

CAUTION

Do not use trichloroethylene, gasoline or any sim­ilar solvent.
These fluids have too great a dissolving power for
this chain and they can damage the O-rings. Use
only kerosine to clean the drive chain.

PERIODIC MAINTENANCE 2-12

• After cleaning and drying the chain, oil it with a heavy­weight engine oil.

CAUTION

Do not use any oil sold commercially as "drive
chain oil", this type of oil can such oil can damage
the "0"-rings (or seals).

BRAKES

(BRAKE)
Inspect initially at 1 000 km (600 miles, 3 months)
and every 5 000 km (3 000 miles, 15 months) there­after.

(BRAKE HOSE AND BRAKE FLUID)
Inspect every 5 000 km (3 000 miles, 15 months).
Replace hose every 4 years. Replace fluid every 2
years.

BRAKE FLUID LEVEL

• Keep the motorcycle upright and place the handlebars
straight.

• Check the brake fluid level by observing the lower limit
line on the front brake fluid reservoir.

• When the brake fluid level is below the lower limit line
replenish with brake fluid that meets the following specifi­cation.

Specification and classification: DOT 4

WARNING

The brake system of this motorcycle is filled
with a glycol-based brake fluid. Do not use or
mix different types of fluid such as silicone­based and petroleum-based fluids. Do not use
any brake fluid taken from old, used or un­sealed containers. Never re-use brake fluid left
over from the last servicing or stored for a long

period of time.
Brake fluid, if it leaks, will interfere with safe
running and immediately discolor painted sur­faces. Check the brake hose and hose joints for
cracks and oil leakage.

2-13 PERIODIC MAINTENANCE

FRONT BRAKE PADS
The extent of brake pad wear can be checked by observing
the limit line on the pad. When the wear exceeds the
limit line, replace the pads with new ones. (See p. 5-8.)

A CAUTION

Replace the brake pad as a set, otherwise braking
performance will be adversely affected.

AIR BLEEDING THE BRAKE FLUID CIRCUIT

Air trapped in the brake fluid circuit acts like a cushion to
absorb a large proportion of the pressure developed by the
master cylinder and thus interferes with the full braking per­formance of the brake caliper. The presence of air is indi­cated by "sponginess" of the brake lever and also by lack
of braking force. Considering the danger to which such
trapped air exposes the machine and rider, it is essential
that, after remounting the brake and restoring the brake
system to the normal condition, the brake fluid circuit be
purged of air in the following manner:

• Fill the master cylinder reservoir to top of the inspection
window. Replace the reservoir cap to prevent dirt from
entering.

• Attach a hose to the air bleeder valve, and insert the free
end of the hose into a receptacle.

• Bleed air from the brake system.

• Squeeze and release the brake lever several times in
rapid succession and squeeze the lever fully without re­leasing it. Loosen the bleeder valve by turning it a quar­ter of a turn so that the brake fluid runs into the recep­tacle, this will remove the tension of the brake lever
causing it to touch the handlebar grip. Then, close the air
bleeder valve, pump and squeeze the brake lever, and
open the valve. Repeat this process until the fluid flowing
into the receptacle no longer contains air bubbles.

NOTE:
While bleeding the brake system, replenish the brake fluid
in the reservoir as necessary. Make sure that there is al­ways some fluid visible in the reservoir.

• Close the air bleeder valve, and disconnect the hose. Fill
the reservoir with brake fluid to the top of the inspection
window.

Air bleeder valve: 7.5 N ■ m (0.75 kg-m, 5.5 Ib-ft)

A CAUTION

Handle brake fluid with care: the fluid reacts
chemically with paint, plastics, rubber materials,
etc.

PERIODIC MAINTENANCE 2-14

REAR BRAKE PEDAL HEIGHT

• Loosen the lock nut

• Adjust the brake pedal height by turning the adjuster
to locate the pedal 50 mm (2.0 in) above the top face

of the footrest.

REAR BRAKE ADJUSTING

• Adjust the free travel to 20-30 mm (0.8-1.2 in) by

turning the adjusting nut

REAR BRAKE SHOE WEAR

This motorcycle is equipped with brake lining wear limit

indicator on the rear brake.

To check brake lining wear, perform the following steps.

• Make sure that the rear brake is properly adjusted.

• Depress the rear brake pedal. Make sure that the index
mark is within the range embossed on the brake
panel.

• If the index mark goes beyond the range, the brake shoe
assembly should be replaced with a new set of shoes.

The extension line of the index mark is within
the range.

The extension line of the index mark is out of
the ranae.

BRAKE LIGHT SWITCH

Adjust the rear brake light switch so that the brake light will
come on just before pressure is felt when the brake pedal
is depressed.