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Suzuki GS250 1985-1990 Workshop Service Manual for Repair

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This manual covers the GS250 motorcycle, a model produced between 1985 and 1990. As part of the esteemed GS series, this first-generation model is recognized for its reliable performance and...
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Type: Motorcycle
Vendor:
Sku: 148735
Suzuki GS250 1985-1990 Workshop Service Manual for Repair
This manual covers the GS250 motorcycle, a model produced between 1985 and 1990. As part of the esteemed GS series, this first-generation model is recognized for its reliable performance and versatile application, often serving as an entry-level sport or standard motorcycle. Engineered during a period of significant innovation in motorcycle technology, the GS250 embodies a commitment to quality and performance in its class. Its design, featuring a vertical twin-cylinder, four-stroke engine with a displacement of approximately 249cc, DOHC valve train, and air cooling, contributed to its reputation for dependability and enjoyable riding. This comprehensive workshop service manual is designed to assist both mechanics and DIY enthusiasts in the maintenance and repair of the GS250. The manual provides in-depth coverage of all major systems, including the engine, transmission, fuel system, electrical system, suspension, brakes, and chassis. Within its over 120 pages, users will find detailed procedures for routine maintenance, troubleshooting common issues, component disassembly and assembly, adjustments, and complete overhauls. Technical specifications, wiring diagrams, and safety guidelines are also included, ensuring that all repair and maintenance tasks are performed correctly and efficiently, enabling owners to keep their GS250 in optimal condition.
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
GS250
Product Name:
Suzuki GS250 1985-1990 Workshop Service Manual for Repair PDF
Generation
Model Generation:
First Generation GS250
Codes
Engine Codes:
GS250 engine family (specific code not detailed in product info, but typical for this era)
👋 Introduction
Market Position
Target Audience:
Mechanics and DIY (Do-It-Yourself) enthusiasts for the Suzuki GS250.
Competitive Analysis
Value Proposition:
Provides comprehensive, detailed, and easy-to-understand repair information, enabling owners and technicians to maintain and repair the GS250 effectively and economically.
Key Features
Download Method:
Instant download upon completion of secure payment.
Payment Options:
All major credit/debit cards, PayPal.
📋 Manual Details
Coverage Areas
Model Years Covered:
1985, 1986, 1987, 1988, 1989, 1990
Page Count
Number Of Pages:
Over 120
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed coverage of engine disassembly, assembly, diagnostics, adjustments, and maintenance.
Transmission:
Includes procedures for transmission removal, installation, and internal component servicing.
Fuel System:
Carburetor tuning, fuel delivery system checks, and component overhaul.
Electrical System:
Wiring diagrams, ignition system troubleshooting, lighting, and charging system analysis.
Suspension And Steering:
Fork service, shock absorber adjustments, steering head bearing maintenance, and related components.
Brakes:
Brake system bleeding, pad replacement, caliper service, and master cylinder maintenance.
Cooling System:
Radiator, fan, and coolant circulation system maintenance.
Chassis And Frame:
Frame inspection, component mounting, and general chassis work.
Bodywork And Trim:
Fairing removal/installation, seat, tank, and other cosmetic component procedures.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug checks, and lubrication.
Troubleshooting:
Diagnostic guides for common problems, symptom-based fault finding.
Disassembly And Assembly:
Step-by-step instructions for component removal and reinstallation.
Adjustments:
Valve clearances, carburetor synchronization, brake lever adjustments, etc.
Repair And Rebuilding:
Comprehensive guides for overhauling key components like the engine and transmission.
Specifications:
Torque values, clearances, fluid capacities, and performance data.
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to complete engine rebuilds and complex system diagnostics.
Detail Level:
Detailed explanations, step-by-step procedures, pictorial diagrams, exploded views, and photographs.
Tool References:
Includes reference to specific special service tools and their usage.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Printability:
Yes, all pages are printable.
Resolution:
Assumed high resolution for clear viewing and printing of diagrams and text.
Binding Type
Binding:
N/A (Digital Download - PDF)
Paper Type
Paper Type:
N/A (Digital Download - PDF)
Compatibility
Operating Systems:
Windows, Mac, Linux OS
Requirements
Software Requirement:
Adobe Reader
⚙️ Engine Specifications
Primary Engine
Engine Type:
Vertical Twin Cylinder, Four-Stroke
Displacement:
249cc (approximate, standard for GS250 models)
Bore X Stroke:
Specific values would be detailed in the manual, but typically around 54.0 mm x 54.0 mm for this displacement.
Valve Train:
DOHC (Double Overhead Camshaft), 2 valves per cylinder (typical for GS250).
Cooling System:
Air-Cooled
Performance
Horsepower:
Approx. 25-30 HP (specific figures in manual).
Torque:
Specific Nm/lb-ft figures would be in the manual.
Fuel System
Carburetion:
Twin Mikuni VM series carburetors (typical, specific model number in manual).
Fuel Type:
Unleaded gasoline (as per era standards).
Lubrication
Oil Type:
Motorcycle specific 4-stroke engine oil, viscosity grade specified in manual (e.g., 10W-40).
🔧 Transmission
Standard
Type:
Constant Mesh, 6-speed Sequential
Clutch Type:
Wet Multi-Plate
Features
Drive Type:
Chain Drive
📐 Dimensions
Exterior
Length:
Specific dimensions not provided, but typical for a 250cc sport/standard motorcycle of the era.
Width:
Specific dimensions not provided.
Height:
Specific dimensions not provided.
Weights
Dry Weight:
Approximately 150-160 kg (specific weight in manual).
🛡️ Safety Features
Ratings
Safety Features Description:
Focus on rider safety through proper maintenance and adherence to repair procedures outlined in the manual. Highlights the importance of using correct tools and following safety precautions (DANGER, CAUTION, NOTE).
💡 Technology Features
Infotainment
Infotainment System:
N/A (This era of motorcycle did not feature electronic infotainment systems).
Driver Assistance
Electronic Aids:
N/A (Basic motorcycle design, no electronic rider aids like ABS or traction control).
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Periodic Maintenance:
The manual provides a periodic maintenance chart outlining recommended service intervals for various components and systems.
Fluid Specifications
Engine Oil Capacity:
Specific capacity will be detailed in the manual (typically around 2-2.5 liters).
Coolant Type:
For liquid-cooled variants, but the GS250 is air-cooled. If any ancillaries require coolant, it would be specified.
Brake Fluid:
DOT 3 or DOT 4 (typical for the era, specific type in manual).
Known Issues
Common Wear Items:
Carburetor synchronization drift, potential wear in valve guides/seals, chain and sprockets, brake pad wear.
Diagnostic Focus:
The manual's troubleshooting section is designed to address these common issues and more.
📚 Vehicle History
Brand Heritage
Manufacturer Focus:
Suzuki has a long history of producing reliable and performance-oriented motorcycles, particularly in the 250cc to 750cc range with its GS series.
Model Evolution
Gs Series Context:
The GS250 was part of Suzuki's successful GS series, known for its versatile performance, often serving as an entry-level sport or standard motorcycle.
Production
Production Era:
Mid to late 1980s, a period of significant innovation in motorcycle design and technology.
🏆 Awards & Recognition
Recognitions
Model Achievements:
While specific awards for the GS250 may not be widely documented, the model was part of Suzuki's successful GS lineup which garnered a reputation for reliability and performance within its class during the 1980s.
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