Market Segment:
Entry-level to mid-range sportbike/naked bike segment, popular for its accessible performance and styling.
Competitors:
Kawasaki Ninja 250, Honda CBR250R, Suzuki GS500 (though 500cc, it competed for rider attention in the beginner sportbike class).
Vehicle Appeal:
Sporty styling, manageable power delivery for new riders, relatively affordable ownership costs.
Diy Support:
Empowers owners to perform routine maintenance and complex repairs, reducing reliance on expensive dealership services.
Covered Model Years:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Specific Models Covered:
GT250, GT250R (likely, as they share core components)
Estimated Page Count:
Likely 300-500+ pages based on typical factory service manuals for this complexity
Manual Type:
Factory Service Repair Manual / Workshop Manual
Language:
English (presumed, typical for official service documentation)
Engine Systems:
Engine overhaul, cylinder head, pistons, crankshaft, camshafts, valve train, lubrication system, cooling system, fuel system (carburetor or early EFI depending on exact variant), ignition system.
Drivetrain Systems:
Clutch operation and service, transmission disassembly and reassembly, gear inspection, final drive (chain and sprockets).
Chassis Systems:
Frame inspection, suspension (front forks, rear shock absorber), steering system, wheel bearings, brake system (front and rear disc brakes, master cylinders, calipers, hydraulic lines).
Electrical Systems:
Wiring diagrams, lighting system, ignition system, starting system, charging system (stator, regulator/rectifier, battery), instrument cluster, switches.
Bodywork And Fittings:
Fairing removal and installation, seat, fuel tank, fenders, handlebars, controls, exhaust system.
Routine Maintenance:
Oil change intervals and specifications, filter replacement, chain adjustment and lubrication, brake fluid checks, coolant checks, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnostic procedures for common performance issues, electrical faults, starting problems, braking issues.
Repair And Rebuild:
Complete step-by-step instructions for engine disassembly, component inspection, and reassembly; transmission rebuild; suspension overhaul; brake caliper servicing.
Technical Specifications:
Torque specifications for all fasteners, engine timing procedures, valve clearances, fluid capacities, electrical resistance values.
Depth Of Coverage:
Comprehensive factory-level detail, suitable for complete motorcycle rebuilds and advanced diagnostics. Includes specific measurements for worn parts.
Print Quality:
High resolution, clear text and illustrations. Printable pages.
Binding Type:
Digital (N/A for physical binding)
Paper Type:
Digital (N/A for physical paper type)
Searchability:
Likely searchable text content within the PDF for quick information retrieval.
Engine Type:
Four-stroke, V-twin (90-degree)
Engine Displacement:
249 cc (approximately)
Bore X Stroke:
Specification available in manual (typical around 57mm x 49mm)
Cooling System:
Liquid-cooled
Valve Train:
DOHC, 4 valves per cylinder
Horsepower Output:
Approx. 30-33 HP (at ~10,000 RPM, specific to year/tuning)
Torque Output:
Approx. 22-24 Nm (at ~8,000 RPM, specific to year/tuning)
Fuel Delivery:
Carbureted (typically dual Mikuni BS30 or similar) for most models in this range. Early or specific market versions might have had EFI.
Fuel Type:
Unleaded gasoline (Octane rating specified in manual)
Recommended Oil Viscosity:
Typically 10W-40 or 20W-50 (refer to manual for exact specification and API service classification)
Oil Capacity:
Approx. 1.8 - 2.0 Liters with filter change (refer to manual for exact specification)
Transmission Type:
Constant mesh, 6-speed sequential
Clutch Type:
Wet multi-plate
Final Drive:
Chain driven (DID 520 O-ring chain or equivalent, with specific pitch and roller type detailed in manual)
Transmission Oil Specification:
Gear oil (GL-4 or GL-5, specific viscosity like 75W-90, manual will specify)
Length:
Approx. 2070 mm (refer to manual for exact specification)
Width:
Approx. 740 mm (refer to manual for exact specification)
Height:
Approx. 1100 mm (refer to manual for exact specification)
Dry Weight:
Approx. 160-165 kg (refer to manual for exact specification)
Fuel Tank Capacity:
Approx. 17 Liters (refer to manual for exact specification)
Front Tire Size:
110/70-17 (Tubeless)
Rear Tire Size:
150/70-17 (Tubeless)
Wheel Bolt Pattern:
Not applicable (spoked wheels with axle nuts, not bolt-on wheels)
Frame Construction:
Steel diamond frame (provides structural integrity)
Braking System Front:
Dual piston caliper acting on a single disc (Hydraulic actuation). Disc diameter specified in manual.
Braking System Rear:
Single piston caliper acting on a single disc (Hydraulic actuation). Disc diameter specified in manual.
Lighting:
Halogen headlamp, LED taillight (model dependent), turn signals. Bulb types and wattages specified in manual.
Instrument Cluster:
Analog tachometer and speedometer, fuel gauge, indicator lights. Specific layout detailed in manual.
ABS Availability:
Generally not available on models within this specific year range (ABS became more common later).
Charging System:
AC generator (stator) with external regulator/rectifier.
Oil Change Interval:
Typically every 3,000-5,000 km or 6 months, whichever comes first (refer to manual for precise interval).
Valve Clearance Check Interval:
Often around 10,000-15,000 km, but crucial to follow manual's recommendation.
Chain Maintenance Interval:
Check and lubricate every 500-1000 km, adjust slack as needed (specific slack measurement in manual).
Coolant Type:
Ethylene glycol based antifreeze coolant, typically 50/50 mix with distilled water. Manual specifies type and capacity.
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid (refer to manual for specific recommendation).
Common Wear Items:
Clutch plates, brake pads, fork seals, chain and sprockets, spark plugs.
Potential Electrical Issues:
Regulator/rectifier failures, stator coil degradation (common in many liquid-cooled bikes of this era if not maintained).
Engine Tuning:
Carburetor synchronization and jetting can be sensitive; manual provides specifications for tuning.
