1982-1983 Suzuki Gn250 Workshop Repair Manual -German

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🏷️ Basic Information Identification Make: Suzuki Model: GN250 Model Code: GN250 Generation Generation Designation: First Generation Codes Chassis Code: DJ01 👋 Introduction Market Position Market Segment: Lightweight, versatile motorcycle popular...

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类型: Motorcycle

斯库: 604128

标签: 1982 1983 GN Series Gn250 Motorcycle Motorcycles Suzuki

产品多属性

Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GN250

Model Code:

GN250

Generation

Generation Designation:

First Generation

Codes

Chassis Code:

👋 Introduction

Market Position

Market Segment:

Lightweight, versatile motorcycle popular for commuting, general riding, and custom builds.

Target Audience:

New riders, experienced riders seeking a simple and reliable machine, customizers.

Competitive Analysis

Key Competitors:

Honda CB250, Yamaha SR250, Kawasaki EN500 (though slightly larger displacement).

Key Features

Engine Layout:

Single-cylinder, 4-stroke, SOHC, 2-valve.

Cooling Method:

Air-cooled, enhancing simplicity and reliability.

Transmission:

6-speed constant mesh.

Starter:

Electric start and kick start.

Suspension Type:

Telescopic front forks, Monoshock rear suspension.

Braking Type:

Front disc brake, rear drum brake.

Fuel Delivery:

Mikuni VM34 carburetor.

📋 Manual Details

Coverage Areas

Engine Coverage:

Transmission Coverage:

Electrical System Coverage:

Chassis And Suspension Coverage:

Braking System Coverage:

Fuel System Coverage:

Exhaust System Coverage:

Cooling System Coverage:

Bodywork And Trim Coverage:

Troubleshooting Coverage:

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Workshop Repair Manual

Language

Language:

German

Format

Format:

Digital (likely PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full disassembly, assembly, tuning, and specifications for the 249cc single-cylinder engine.

Engine Management:

Carburetor system (Mikuni VM34) tuning, cleaning, and component identification.

Transmission System:

Clutch operation, gearbox disassembly and reassembly, gear selection mechanisms, and lubrication.

Electrical System:

Wiring diagrams, ignition system, lighting system, charging system (stator, regulator/rectifier), starter motor, battery, and fuses.

Suspension System:

Front fork (telescopic) disassembly, seal replacement, fluid type and level, rear shock absorber (monoshock) overhaul and adjustment.

Braking System:

Front disc brake (caliper, master cylinder, disc) service and bleeding, rear drum brake adjustment and inspection.

Fuel And Exhaust:

Fuel tank maintenance, fuel lines, exhaust pipe inspection and mounting.

Cooling System:

Air-cooled engine specifications, airflow management.

Wheels And Tires:

Wheel bearing maintenance, tire pressure recommendations, spoke wheel truing.

Frame And Body:

Frame inspection, fairing and plastic component removal/installation, seat, and tank mounting.

Procedures Included

Routine Maintenance:

Oil changes, filter replacement, chain adjustment, brake pad inspection, spark plug replacement, air filter cleaning/replacement.

Major Repairs:

Engine rebuild, gearbox overhaul, fork seal replacement, clutch replacement.

Diagnostics:

Troubleshooting common starting, running, and electrical issues with step-by-step guides.

Adjustments:

Carburetor synchronization and mixture adjustment, valve clearance adjustment, clutch and brake lever free play adjustment, idle speed adjustment.

Component Removal Installation:

Detailed instructions for removing and reinstalling all major and minor components.

Technical Depth

Depth Level:

Comprehensive (from basic service to full engine and transmission rebuild).

Diagnostic Approach:

Systematic troubleshooting flows and symptom-based diagnosis.

Torque Specifications:

Precise torque values for all critical fasteners.

Clearances And Tolerances:

Specifications for valve clearances, piston-to-cylinder wall, bearing clearances, etc.

📊 Manual Specifications

File Format

Digital Format:

Likely PDF, optimized for viewing and printing.

Print Quality

Print Quality:

High-resolution scans with clear diagrams and text.

Binding Type

Binding Type:

N/A (Digital)

Paper Type

Paper Type:

N/A (Digital)

Searchability

Searchable Text:

Likely searchable text within the PDF for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 4-stroke, SOHC, single-cylinder

Displacement:

249 cc (249cc)

Bore X Stroke:

66.0 mm x 72.0 mm

Compression Ratio:

9.2:1

Valve Configuration:

SOHC, 2 valves

Performance

Horsepower:

Approx. 20 hp @ 7,000 rpm (varies slightly by market and tuning)

Torque:

Approx. 20 Nm (14.8 lb-ft) @ 5,500 rpm

Fuel System

Carburetor Model:

Mikuni VM34

Fuel Type:

Unleaded gasoline (91 octane or higher recommended)

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition)

Lubrication

Lubrication System:

Wet sump

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 6-speed sequential

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

Features

Gear Ratios:

Refer to manual for specific gear ratios.

Transmission Oil Type:

API SE, SF, or SG class SAE 10W-40 motorcycle oil.

📐 Dimensions

Exterior

Length:

2075 mm (81.7 in)

Width:

770 mm (30.3 in)

Height:

1070 mm (42.1 in)

Wheelbase:

1385 mm (54.5 in)

Ground Clearance:

150 mm (5.9 in)

Weights

Dry Weight:

132 kg (291 lbs)

Wet Weight:

Approx. 145 kg (320 lbs)

Fuel Tank Capacity:

14 L (3.7 US gal)

Oil Capacity:

1.8 L (1.9 US qt) for oil change, 2.1 L (2.2 US qt) for overhaul

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety ratings are generally not standardized like cars)

Active Features

Active Safety:

Responsive braking system, agile handling characteristics.

Passive Features

Passive Safety:

Sturdy frame construction, rider-assistive ergonomics.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Mechanical motorcycle)

Driver Assistance

Driver Assistance Features:

N/A (Mechanical motorcycle)

Connectivity

Connectivity Options:

N/A (Mechanical motorcycle)

🔧 Maintenance

Service Intervals

Engine Oil Change Interval:

Every 3,000 km (1,860 miles) or 6 months, whichever comes first.

Oil Filter Replacement:

Every 6,000 km (3,730 miles) or annually.

Air Filter Cleaning:

Every 3,000 km (1,860 miles), replace as needed.

Spark Plug Replacement:

Every 6,000 km (3,730 miles).

Valve Clearance Check:

Every 6,000 km (3,730 miles).

Chain Adjustment:

Check and adjust every 1,000 km (620 miles) or as needed.

Fluid Specifications

Engine Oil Specification:

API SE, SF, or SG class SAE 10W-40 motorcycle oil.

Front Fork Oil Type:

Show Motorcycle Fork Oil 10W (or equivalent, e.g., KYB 01-103).

Front Fork Oil Capacity:

160 ml (5.4 US oz) per fork leg.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, fork seals, and carburetors can be common wear items over time.

Electrical Gremlins:

Age-related issues with wiring connectors and the regulator/rectifier can occur.

Carburetor Cleaning:

The VM34 carburetor requires regular cleaning and tuning for optimal performance, especially if the bike sits unused.

📚 Vehicle History

Brand Heritage

Brand Philosophy:

Suzuki is known for its balance of performance, reliability, and value, particularly in its motorcycle division.

Model Evolution

Model Introduction:

The GN250 was introduced in 1982 as a stylish and practical all-rounder, aimed at filling a gap in Suzuki's lineup.

Design Inspiration:

It featured a classic motorcycle aesthetic with a single-cylinder engine that was known for its smooth operation and efficiency.

Development Focus:

Development focused on user-friendliness, low maintenance, and a comfortable riding experience.

Production

Production Years:

1982-2000 (globally, with variations in specific markets)

Manufacturing Locations:

Primarily Japan, with some production later in other Asian countries.

🏆 Awards & Recognition

Recognitions

Industry Awards:

N/A (Motorcycles of this era typically did not receive formal industry awards in the same vein as cars)

Ratings

Consumer Satisfaction:

Generally well-regarded for its reliability and ease of use, making it a popular choice for daily commuting and as a platform for customization.

Certifications

Manufacturing Standards:

Built to Suzuki's stringent Japanese manufacturing standards of the era.