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1985-1990 Suzuki GS250 FWS Service Repair Manual

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The Suzuki GS250 FWS, produced between 1985 and 1990, is a classic sportbike renowned for its reliable parallel-twin engine and agile handling. This model represents Suzuki's commitment to engineering quality,...
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Type: Motorcycle
Vendor:
Sku: 130382
1985-1990 Suzuki GS250 FWS Service Repair Manual
The Suzuki GS250 FWS, produced between 1985 and 1990, is a classic sportbike renowned for its reliable parallel-twin engine and agile handling. This model represents Suzuki's commitment to engineering quality, offering a balanced blend of performance and everyday usability that made it a popular choice for riders seeking a versatile machine. Its design emphasizes straightforward mechanics and rider engagement, embodying the spirit of 1980s motorcycle innovation. This comprehensive Service and Repair Manual in English provides detailed guidance for maintaining and repairing the 1985-1990 Suzuki GS250 FWS motorcycle. It covers all essential systems, including engine, fuel, electrical, drivetrain, suspension, and brakes, with in-depth procedures for routine maintenance, adjustments, troubleshooting, and major repairs. Featuring high-quality diagrams and step-by-step instructions, this manual is an indispensable resource for DIY enthusiasts, home mechanics, and professional technicians.
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
GS250 FWS
Model Designation:
FWS
Model Code:
GS250FWS
Generation
Production Years:
1985-1990
👋 Introduction
Market Position
Target Audience:
DIY enthusiasts, home mechanics, and professional technicians working on the Suzuki GS250 FWS.
Competitive Analysis
Value Proposition:
Provides a highly complete and detailed resource for servicing and repairing the GS250 FWS, offering significant cost savings over dealership services.
Key Features
Completeness:
Described as the most complete service manual compiled, covering all aspects of the motorcycle's maintenance and repair.
Instruction Quality:
Features high-quality diagrams and step-by-step instructions.
Download Benefit:
Instant download saves time and money on shipping and packaging.
📋 Manual Details
Coverage Areas
Scope:
Comprehensive service, repair, and maintenance for the 1985-1990 Suzuki GS250 FWS motorcycle.
Page Count
Estimated Pages:
High-quality diagrams and instructions suggest a detailed manual, likely exceeding 300 pages.
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Disassembly, inspection, adjustment, and servicing of engine components, including cylinder head, pistons, crankshaft, lubrication system, and cooling system.
Fuel System:
Carburetor servicing and adjustment, fuel tank inspection, fuel pump operation, and fuel lines.
Electrical System:
Ignition system diagnostics and repair, lighting circuits, charging system (alternator, rectifier/regulator), starter motor, battery maintenance, and wiring diagrams.
Drivetrain:
Clutch inspection and adjustment, transmission disassembly and reassembly, gear shifting mechanisms, and final drive (chain and sprockets).
Suspension:
Front fork disassembly, servicing, and adjustment; rear shock absorber inspection and replacement.
Brakes:
Front and rear brake system inspection, adjustment, caliper servicing, master cylinder maintenance, and bleeding procedures.
Chassis And Bodywork:
Frame inspection, steering system maintenance, wheel bearing service, and body panel removal/installation.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug inspection/replacement, air filter cleaning, chain lubrication and adjustment, tire pressure checks.
Troubleshooting:
Diagnosis of common problems related to engine performance, electrical systems, and other motorcycle functions.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension overhauls, carburetor rebuilding, and electrical component replacement.
Adjustments:
Valve clearance adjustment, carburetor synchronization, clutch and brake lever adjustments, idle speed adjustment.
Technical Depth
Depth:
Comprehensive, covering everything from basic inspections and adjustments to complete disassembly, repair, and reassembly of all major motorcycle systems.
📊 Manual Specifications
File Format
Format:
PDF
Compatibility:
All versions of Windows & Mac
Requirements:
Adobe PDF Reader
Print Quality
Printability:
All pages are printable, allowing for physical reference.
Binding Type
Binding:
Not Applicable (Digital Download)
Paper Type
Paper:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, DOHC, parallel-twin
Displacement:
248 cc (approximate)
Bore X Stroke:
Specifications would be detailed in the manual (typical for this era, around 54mm x 54mm).
Compression Ratio:
Specifications would be detailed in the manual (typically around 9.2:1 to 9.5:1).
Cooling System:
Air-cooled
Performance
Horsepower:
Specifications would be detailed in the manual (typically in the 25-30 HP range).
Torque:
Specifications would be detailed in the manual (typically around 20-23 Nm).
Fuel System
Carburetion:
Dual Mikuni carburetors (likely VM series or similar), specific models detailed in manual.
Fuel Type:
Unleaded gasoline, octane rating as specified in the manual (likely 91 RON or higher).
Lubrication
Oil Type:
Engine oil specifications (e.g., 10W-40, API SG or higher) would be detailed.
Oil Capacity:
Oil capacity for engine oil change and with filter change would be specified in the manual.
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet, multi-plate
Final Drive:
Chain drive
Features
Gear Ratios:
Specific gear ratios for each speed would be detailed in the manual.
Transmission Oil:
Specifications for transmission oil (if separate) would be detailed in the manual.
📐 Dimensions
Exterior
Length:
Specifications not provided, detailed in manual.
Width:
Specifications not provided, detailed in manual.
Height:
Specifications not provided, detailed in manual.
Weights
Dry Weight:
Specifications not provided, detailed in manual (likely around 140-150 kg).
Wet Weight:
Specifications not provided, detailed in manual.
Fuel Tank Capacity:
Specifications not provided, detailed in manual (typical for this class, around 14-17 liters).
🛡️ Safety Features
Ratings
Safety Standards:
Adheres to applicable motorcycle safety standards of the era. Specific ratings not applicable in the same way as cars.
Active Features
Braking System:
Front disc brake, rear drum brake (common for the era). Specific caliper and rotor details in manual.
Lighting:
Headlight, tail light, brake light, turn signals. Wiring diagrams in manual.
Passive Features
Frame Construction:
Steel tube frame, details on inspection and repair in manual.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable. This is a 1980s motorcycle, focusing on mechanical and electrical systems.
Driver Assistance
Driver Assistance Systems:
Not applicable. Focus on fundamental mechanical and electrical systems.
Connectivity
Connectivity Features:
Not applicable.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Detailed in the manual (typically every 3,000-5,000 km or 6 months).
Valve Clearance Interval:
Detailed in the manual (often around 6,000-10,000 km).
Spark Plug Replacement:
Detailed in the manual (typically every 10,000-15,000 km).
Fluid Specifications
Engine Oil Viscosity:
Recommended viscosity grade (e.g., 10W-40) and API service classification will be specified.
Brake Fluid Type:
Specified brake fluid type (e.g., DOT 3 or DOT 4) will be detailed.
Coolant Type:
If liquid-cooled (which this model is not, it's air-cooled), the coolant type would be specified.
Known Issues
Carburetor Wear:
Common to older motorcycles, carburetor diaphragms and jets can wear, leading to rough idling or poor performance. Manual covers servicing.
Electrical Gremlins:
Age-related issues with wiring insulation, connectors, and charging system components can occur. Manual provides troubleshooting.
Suspension Seals:
Front fork seals can degrade over time, leading to leaks. Manual details fork seal replacement.
Exhaust System Corrosion:
Rust and corrosion can affect the exhaust system. Manual covers inspection and potential repair/replacement.
📚 Vehicle History
Brand Heritage
Suzuki Legacy:
Suzuki has a long-standing reputation for producing reliable and sporty motorcycles, known for their innovation in engine technology and design.
Model Evolution
Gs Series:
The GS series represented Suzuki's robust line of sporty street motorcycles, often featuring parallel-twin engines that offered a good balance of performance and refinement.
Gs250Fws Positioning:
The GS250 FWS was positioned as a versatile and approachable sportbike, suitable for commuting, touring, and spirited riding, appealing to a broad range of riders.
Production
Manufacturing Era:
Produced during the mid-to-late 1980s, a period of significant evolution in motorcycle design and technology.
🏆 Awards & Recognition
Recognitions
Model Awards:
Specific awards for the GS250 FWS are not readily available, but the GS series was generally well-regarded for its performance and value in its era.
Ratings
Consumer Reviews:
General consumer reception of the GS series was positive, highlighting reliability and sporty handling. Specific reviews would require historical automotive press research.
Certifications
Manufacturing Standards:
Manufactured to Suzuki's internal quality control and Japanese industry standards of the period.
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