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Suzuki ACROSS GSX250F Service Repair Manual 1991-1995

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🏷️ Basic Information Identification Make: Suzuki Model: GSX250F ACROSS Model Alias: Across 250 Product Type: Service Repair Manual Codes Chassis Codes: GJ75A 👋 Introduction Market Position Segment: Sport Motorcycle Competitive...
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Type: Motorcycle
Vendor:
Sku: 273917
Suzuki ACROSS GSX250F Service Repair Manual 1991-1995
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
GSX250F ACROSS
Model Alias:
Across 250
Product Type:
Service Repair Manual
Codes
Chassis Codes:
GJ75A
👋 Introduction
Market Position
Segment:
Sport Motorcycle
Competitive Analysis
Competitors:
Competed against other 250cc sportbikes and naked bikes of its era, offering a blend of performance and usability. Specific competitors would include models from Yamaha, Kawasaki, and Honda in the same displacement class.
Key Features
Engine Type:
Liquid-cooled, DOHC, 4-stroke, V-twin engine.
Styling:
Sporty naked bike styling, often described as a 'streetfighter' or 'sport-standard'.
Handling:
Known for agile handling and a comfortable riding position suitable for both commuting and spirited riding.
📋 Manual Details
Coverage Areas
Years Covered:
1991, 1992, 1993, 1994, 1995
Page Count
Estimated Pages:
Hundreds (Specific count not provided in product description, assume comprehensive)
Manual Type
Type:
Service and Repair Manual
Language
Language:
English (Assumed based on product description context)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, including cylinder head, piston, crankshaft, camshafts, valve timing, lubrication system, cooling system, and all related components.
Fuel System:
Carburetor assembly and tuning, fuel pump, fuel lines, fuel tank maintenance and cleaning, air filter replacement.
Transmission:
Gearbox operation, clutch system, gear selection mechanisms, transmission fluid checks and changes, internal component inspection and repair.
Electrical System:
Ignition system, charging system (stator, rectifier/regulator), lighting circuits, starter motor, battery maintenance, wiring diagrams, troubleshooting electrical faults.
Chassis And Suspension:
Front fork servicing (oil changes, seal replacement), rear shock absorber maintenance, swingarm lubrication and inspection, steering head bearing adjustment.
Brakes:
Front and rear brake systems, brake caliper overhaul, brake pad replacement, brake fluid bleeding and replacement, brake line inspection.
Wheels And Tires:
Tire pressure checks, wheel bearing inspection and lubrication, tire replacement, wheel balancing.
Frame And Body:
Frame inspection, fairing removal and installation, seat maintenance, fuel tank mounting, general bodywork repairs.
Procedures Included
Routine Maintenance:
Scheduled maintenance tasks, oil and filter changes, spark plug replacement, chain adjustment and lubrication, brake fluid checks.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, fault code interpretation (if applicable).
Engine Repair:
Detailed step-by-step instructions for engine disassembly, component replacement, and reassembly.
Carburetor Rebuild:
Comprehensive guide to disassembling, cleaning, rebuilding, and synchronizing the carburetors.
Electrical Diagnostics:
Guidance on using multimeters, tracing electrical faults, and repairing wiring issues.
Suspension Overhaul:
Detailed procedures for servicing front forks and rear shock absorbers.
Brake System Maintenance:
Instructions for bleeding brakes, replacing pads, and overhauling calipers.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Quality:
High-resolution scans suitable for clear viewing and printing.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
90° V-twin, 4-stroke, DOHC, 8-valve, TSCC (Twin Swirl Combustion Chamber)
Displacement:
249 cc (249 cm³)
Bore X Stroke:
54.0 mm x 54.0 mm
Compression Ratio:
11.0:1 (Typical, consult manual for exact spec)
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 30-35 HP (Consult manual for exact factory spec)
Torque:
Approx. 23-26 Nm (Consult manual for exact factory spec)
Fuel System
Carburetors:
Twin Mikuni VM26SS (Slide valve carburetors)
Fuel Type:
Unleaded gasoline
Ignition
Ignition System:
Electronic ignition (CDI)
Lubrication
Oil Type:
API SE, SF or SG classification, SAE 10W-40 or 20W-50 motorcycle oil (Consult manual for specific recommendations)
Oil Capacity:
Approx. 1.9 L (with filter change) (Consult manual for exact capacity)
🔧 Transmission
Standard
Type:
Constant mesh 6-speed sequential gearbox
Clutch:
Wet multi-plate
Final Drive:
Chain drive
Features
Gear Ratios:
Specific gear ratios are detailed within the service manual, crucial for performance tuning and troubleshooting.
Fluid Specifications
Transmission Oil:
API GL-4 SAE 80W or 90 hypoid gear oil (Consult manual for specific Suzuki recommendations)
📐 Dimensions
Exterior
Overall Length:
Approx. 2055 mm (Consult manual for exact spec)
Overall Width:
Approx. 760 mm (Consult manual for exact spec)
Overall Height:
Approx. 1055 mm (Consult manual for exact spec)
Wheelbase:
Approx. 1420 mm (Consult manual for exact spec)
Weights
Dry Weight:
Approx. 139 kg (Consult manual for exact spec)
Wet Weight:
Approx. 152 kg (fully fueled, curb weight) (Consult manual for exact spec)
Fuel Tank Capacity:
15 Liters (including reserve)
🛡️ Safety Features
Ratings
Safety Features:
Reflective materials on bodywork, standard lighting. Motorcycle safety is primarily rider-dependent and based on mechanical integrity.
Active Features
Braking System:
Dual hydraulic disc brakes front, single hydraulic disc brake rear. ABS was not a common feature on this model.
Passive Features
Lighting:
Halogen headlamp, taillight, brake lights, turn signals.
💡 Technology Features
Infotainment
Features:
N/A (This era of motorcycle technology focused on mechanical systems and basic electrical functions, not infotainment.)
Driver Assistance
Features:
N/A (No electronic rider aids like traction control or ABS were standard on this model).
Connectivity
Features:
N/A (Basic electrical systems only, no onboard computers or connectivity.)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-4,000 km or 4-6 months, whichever comes first (Consult manual for precise Suzuki recommendation).
Spark Plug Replacement:
Every 6,000-8,000 km (Consult manual for specific spark plug type and gap).
Chain Maintenance:
Lubricate every 500 km, adjust tension as needed (refer to manual for correct slack).
Valve Clearance Check:
First check at 12,000 km, then every 18,000 km thereafter (Consult manual for exact intervals and procedures).
Fluid Specifications
Coolant Type:
Ethylene glycol-based antifreeze coolant, mixed with distilled water (50:50 ratio) (Consult manual for specific Suzuki coolant P/N or type).
Brake Fluid Type:
DOT 4 or DOT 5.1 (Consult manual for specific Suzuki recommendation, typically DOT 4).
Known Issues
Common Problems:
Carburetor synchronization issues due to wear or clogging, potential for stator or rectifier failure (common in older bikes), fork seal leaks, cam chain tensioner wear.
Common Issues
Troubleshooting Tips:
The manual provides detailed diagnostic trees for common starting, running, and electrical issues, essential for addressing these points.
📚 Vehicle History
Brand Heritage
Suzuki Legacy:
Suzuki has a long and storied history in motorcycle manufacturing, known for innovative engines and reliable performance across various categories, from sportbikes to off-road machines.
Model Evolution
Gsx250F Lineage:
The GSX250F 'Across' represented Suzuki's entry into the popular 250cc naked sportbike segment, offering a V-twin engine configuration which was less common in this class, providing a distinctive character and torque delivery compared to inline-fours.
Production
Production Period:
1991-1997 (Primary production range, with the manual covering the initial years).
🏆 Awards & Recognition
Recognitions
Awards Received:
Specific industry awards for the GSX250F ACROSS are not widely documented. Its success was more measured by its market acceptance and rider satisfaction for its class.
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