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1991-1995 Suzuki GSX250F Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: GSX250F Model Nickname: Katana (sometimes referred to by this styling) Years Covered By Manual: 1991, 1992, 1993, 1994, 1995 👋 Introduction Market Position...
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Type: Motorcycle
Vendor:
Sku: 355165
1991-1995 Suzuki GSX250F Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
GSX250F
Model Nickname:
Katana (sometimes referred to by this styling)
Years Covered By Manual:
1991, 1992, 1993, 1994, 1995
👋 Introduction
Market Position
Category:
Sportbike / Sport-tourer
Target Audience:
Owners and technicians maintaining the Suzuki GSX250F motorcycle
Competitive Analysis
Competitors Era:
Competed with other entry-level to mid-displacement sportbikes of the early to mid-90s, offering a balance of performance and affordability
Key Features
Styling:
Often featured faired bodywork and a sporty aesthetic, sometimes drawing comparisons to the larger Katana models
Engine Configuration:
Known for its inline-four engine, providing smooth power delivery
📋 Manual Details
Coverage Areas
Manual Type:
Service Repair Manual
Language:
English
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnosis, troubleshooting, internal components, lubrication system, cooling system
Fuel System:
Carburetor systems (synchronization, adjustment, rebuild), fuel delivery, fuel tank, petcock
Ignition System:
CDI system, spark plugs, ignition coils, timing
Transmission:
Gearbox disassembly and reassembly, clutch operation, shift mechanism, lubrication
Chassis:
Frame inspection, suspension (front forks, rear shock), steering system
Brakes:
Front and rear brake systems, hydraulic lines, calipers, master cylinders, disc pads, bleeding procedures
Electrical System:
Wiring diagrams, lighting system, charging system (stator, regulator/rectifier), starting system (starter motor, battery), instrumentation
Bodywork And Fittings:
Body panel removal and installation, seat, fairings, handlebars
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug checks, air filter cleaning/replacement, brake fluid replacement
Troubleshooting:
Diagnostic charts for common problems, electrical fault finding, engine performance issues
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment
Rebuilds:
Detailed instructions for major component overhauls, e.g., engine internal rebuilds, carburetor rebuilds
Technical Depth
Diagnostic Capabilities:
Includes specific diagnostic procedures and troubleshooting flowcharts
Repair Scope:
Comprehensive coverage for both routine maintenance and complex repairs
Specification Detail:
Provides torque values, clearances, fluid types, and electrical specifications
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Likely searchable text, enabling quick access to information
Printability:
Printable pages for convenient on-the-go referencing
Print Quality
Image Clarity:
Diagrams and illustrations are typically clear and easy to follow in digital service manuals
Binding Type
Physical Format:
N/A (assumed digital)
Paper Type
Physical Format:
N/A (assumed digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, DOHC, inline-four cylinder
Displacement:
249 cc
Bore X Stroke:
Approximately 49.0 mm x 33.0 mm
Cooling System:
Liquid-cooled
Performance
Horsepower Approximate:
35-40 HP (at crankshaft, depending on tuning and region)
Torque Approximate:
20-24 Nm (at crankshaft, depending on tuning and region)
Fuel System
Fuel Delivery:
Carburetor
Carburetor Type:
Mikuni VM Series (likely twin carburetors)
Fuel Tank Capacity Approximate:
15 Liters
Ignition System
Ignition Type:
CDI (Capacitor Discharge Ignition)
🔧 Transmission
Standard
Transmission Type:
Constant mesh 6-speed sequential
Clutch Type:
Wet, multi-plate
Features
Final Drive:
Chain drive
Transmission Fluid Type:
API GL-4, SAE 75W/90 or similar (check manual for exact spec)
Transmission Fluid Capacity:
Approximately 1.8 Liters (check manual for exact spec)
📐 Dimensions
Exterior
Overall Length Approximate:
2000 mm
Overall Width Approximate:
750 mm
Overall Height Approximate:
1150 mm
Wheelbase Approximate:
1375 mm
Weights
Dry Weight Approximate:
150 kg
Wet Weight Approximate:
165 kg
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles of this era typically did not have formal crash test ratings like cars; safety relied on design and rider skill.
Active Features
Braking System Front:
Disc brake (likely dual discs on some models)
Braking System Rear:
Disc brake
Passive Features
Frame Construction:
Steel diamond frame
Lighting:
Headlight, taillight, turn signals
💡 Technology Features
Infotainment
Infotainment System:
N/A (Motorcycle of this era, focus is on basic functionality)
Driver Assistance
ABS:
N/A (ABS was not common on 250cc bikes of this period)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 4,000-6,000 km or 6 months (refer to manual for precise interval)
Spark Plug Check:
Every 6,000-8,000 km
Valve Clearance Check:
Every 12,000-16,000 km
Chain Lubrication And Adjustment:
Regularly, or every 1,000 km
Fluid Specifications
Engine Oil Type:
SAE 10W-40 API SG or SH (check manual for exact viscosity and API rating)
Engine Oil Capacity With Filter:
Approximately 2.4 Liters (check manual for exact capacity)
Coolant Type:
Ethylene glycol-based antifreeze (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for exact specification)
Known Issues
Carburetor Issues:
Carburetors can be prone to clogging or synchronization issues over time, requiring regular cleaning and adjustment.
Electrical Connections:
As with many bikes of this age, corrosion on electrical connectors can lead to intermittent issues.
Suspension Wear:
Fork seals and rear shock absorbers may require rebuilding or replacement due to age and mileage.
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation
Reputation:
Suzuki has a long history of producing reliable and performance-oriented motorcycles across various segments.
Model Evolution
Model Lineage:
The GSX250F was part of Suzuki's range of sport-oriented motorcycles in the 250cc class, often utilizing inline-four engines for smooth performance.
Design Influences:
Shares design cues and engineering principles with other Suzuki sportbikes of its time, including the larger GSX series.
Production
Production Years:
Approximately 1989-1995 (exact debut may vary by region)
Manufacturing Locations:
Japan (typical for Suzuki motorcycles of this era)
🏆 Awards & Recognition
Recognitions
Industry Awards:
Specific industry awards for the GSX250F are not widely documented; however, Suzuki motorcycles of this period were generally well-regarded for their performance and reliability in their class.
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