Comprehensive Coverage:
Yes
Specific Systems Covered:
Engine, Fuel System, Lubrication System, Cooling System, Exhaust System, Transmission, Drive Train, Chassis, Suspension, Steering, Brakes, Electrical System, Ignition System, Lighting, Bodywork, Troubleshooting, Maintenance
Type:
Factory Service Repair Manual
Engine Mechanical:
Complete overhaul, disassembly, assembly, inspection, and repair of all engine components including cylinder head, pistons, crankshaft, camshaft, valves, timing components, seals, and gaskets.
Fuel System:
Carburetor adjustment, cleaning, and rebuilding; fuel pump operation; fuel filter replacement; fuel line inspection and repair.
Transmission Drivetrain:
Clutch operation, gear shifting mechanisms, chain drive maintenance and adjustment, differential inspection and service (if applicable).
Chassis Frame:
Frame integrity inspection, welding repairs (if applicable), sub-frame components, and mounting points.
Suspension System:
Front and rear shock absorber inspection, replacement, and adjustment; A-arm bushings; ball joints; steering linkage components.
Steering System:
Handlebar assembly, steering stem, tie rods, steering knuckle inspection, and wheel alignment procedures.
Brake System:
Hydraulic brake system diagnosis, caliper inspection, pad replacement, brake fluid bleeding and replacement, master cylinder service, brake line integrity.
Electrical System:
Battery testing and maintenance, charging system (stator, regulator/rectifier), starter motor operation, lighting circuits, wiring diagrams, fuse and relay identification.
Ignition System:
Spark plug specifications, ignition timing, CDI unit, ignition coil testing, and troubleshooting.
Bodywork Plastics:
Fender removal and installation, body panel fasteners, seat removal, and general cosmetic repairs.
Oil System:
Oil pump operation, oil filter replacement, oil change intervals, lubrication points, and oil pressure testing.
Liquid Cooling:
Radiator, coolant hoses, thermostat operation, water pump, fan operation, coolant replacement and bleeding procedures.
Emission Control:
Muffler inspection and replacement, exhaust pipe integrity, and potential emissions-related components.
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain lubrication and adjustment, brake fluid checks, tire pressure checks.
Diagnostic Troubleshooting:
Step-by-step guides for identifying and resolving common and uncommon mechanical and electrical issues based on symptoms.
Engine Repair Rebuild:
Complete procedures for engine disassembly, parts inspection, component replacement, and reassembly for full engine overhauls.
Transmission Service:
Clutch adjustment, gearbox inspection, and replacement of wear items within the transmission system.
Electrical Troubleshooting:
Detailed wiring diagrams, component testing procedures for electrical faults, and diagnostic flowcharts.
Brake System Repair:
Brake pad replacement, rotor inspection, brake fluid flushing and bleeding, and master cylinder seal replacement.
Suspension And Steering Adjustment:
Alignment procedures, shock absorber adjustments, and replacement of steering and suspension components.
Depth:
In-depth technical information suitable for professional mechanics and experienced DIY enthusiasts, covering everything from basic maintenance to complete engine and transmission rebuilds.
Engine Type:
Four-stroke, SOHC, air-cooled
Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
72.0 mm x 61.2 mm (approximate)
Compression Ratio:
9.2:1 (typical)
Horsepower:
Approx. 17-19 HP (at crankshaft, subject to tuning and regional variations)
Torque:
Approx. 14-16 lb-ft (at crankshaft, subject to tuning and regional variations)
Carburetion:
Mikuni BSR32, 32mm flat-slide carburetor
Fuel Tank Capacity:
Approx. 2.6 US gallons (9.8 Liters)
Ignition System:
Electronic ignition (CDI)
Oil Type:
Suzuki recommends Suzuki Genuine 4-stroke Engine Oil (e.g., 10W-40 API SG or higher)
Cooling Method:
Air-cooled with oil cooler
Oil Change Interval:
Refer to manual for specific mileage or hours, typically every 1000 miles or 6 months, but frequent use may require more often.
Air Filter Cleaning:
Inspect and clean every few rides or as per manual recommendations, depending on operating conditions.
Chain Adjustment:
Check and adjust tension regularly, especially after initial break-in and after riding in wet or muddy conditions.
Spark Plug Replacement:
Recommended replacement every 2000-3000 miles or annually, or as indicated by the manual.
Engine Oil Viscosity:
10W-40 (API SG or higher)
Brake Fluid Type:
DOT 3 or DOT 4 Hydraulic Brake Fluid
Coolant Type:
Permanent type antifreeze coolant (ethylene glycol based), typically a 50/50 mixture with distilled water.
Carburetor Clogging:
Can occur due to stale fuel or debris, requiring cleaning and proper fuel storage.
Chain Wear:
Regular lubrication and adjustment are critical to prevent premature wear.
Suspension Bushings:
Can wear over time, leading to play and reduced handling precision. Replacement is a common maintenance item.
