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Suzuki GSX250F 1990 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: GSX250F Year: 1990 Codes Chassis Code: GJ73A Engine Code Designation: G704 👋 Introduction Market Position Bike Segment: Entry-level to mid-range sportbike / naked...

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类型: Motorcycle

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斯库: 370275

标签: 1990 GSX250F Katana Models Motorcycle Motorcycles Suzuki

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Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GSX250F

Year:

1990

Codes

Chassis Code:

GJ73A

Engine Code Designation:

G704

👋 Introduction

Market Position

Bike Segment:

Entry-level to mid-range sportbike / naked bike category

Target Audience:

New riders, commuting, light sport touring

Competitive Analysis

Competitors:

Kawasaki GPZ250R, Yamaha FZR250R, Honda CB-1

Key Features

Engine Configuration:

Compact inline-four cylinder, liquid-cooled, DOHC

Styling:

Sporty yet accessible, often available in faired or unfaired variants

Manual Value Proposition:

Essential tool for owners and independent mechanics to maintain peak performance and longevity

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service, repair, and maintenance for the 1990 Suzuki GSX250F

Secondary Coverage:

Includes troubleshooting, adjustments, specifications, and diagnostic procedures

Page Count

Estimated Pages:

Approx. 300-400 (typical for a full factory service manual of this era)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Likely digital (PDF) given modern sales, originally printed

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, overhaul, valve clearance, timing chain, piston, rings, crankshaft, connecting rods, lubrication system

Fuel System:

Carburetor (Mikuni VM series typical), fuel pump, fuel tank, fuel lines, fuel filter

Ignition System:

CDI ignition, spark plugs, ignition coils, stator, pickup coils

Cooling System:

Liquid cooling, radiator, fan, thermostat, water pump, coolant specifications

Transmission Drivetrain:

Gearbox, clutch operation, gear shifting mechanism, drive chain adjustment and maintenance

Brakes:

Front and rear brake systems (likely hydraulic disc), brake caliper overhaul, master cylinder, brake fluid specifications

Suspension:

Front telescopic forks, rear monoshock or twin shocks, fork oil specifications, rear suspension adjustments

Wheels Tires:

Wheel bearing maintenance, tire pressure specifications, wheel balancing

Electrical System:

Wiring diagrams, battery specifications, lighting system, charging system (alternator/stator), starter motor, fuses, relays, horn

Frame Bodywork:

Frame inspection, fairing removal and installation, seat, fuel tank mounting, handlebars, footpegs

Diagnostics Troubleshooting:

Common problems and solutions, fault finding charts, diagnostic procedures for electrical and mechanical issues

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, spark plug replacement, air filter cleaning/replacement

Major Overhauls:

Engine rebuilds, transmission overhauls, carburetor tuning and rebuilding, suspension rebuilds

Adjustments:

Carburetor synchronization, idle speed adjustment, clutch and throttle cable free play, brake lever adjustment

Component Replacement:

Replacement procedures for all major components including engine parts, electrical components, and body panels

Electrical Diagnostics:

Wiring harness tracing, testing of electrical components (coils, CDI, stator), troubleshooting electrical faults

Technical Depth

Depth:

Comprehensive factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts

Detail Level:

Includes torque specifications, clearances, measurements, and precise assembly sequences

📊 Manual Specifications

File Format

Digital Format:

PDF (Portable Document Format)

Searchability:

Likely includes searchable text for efficient information retrieval

Print Quality

Original Quality:

High-quality technical illustrations, schematics, and diagrams

Binding Type

Original Binding:

Staple-bound or perfect-bound (for printed versions)

Paper Type

Original Paper:

Durable paper stock suitable for workshop environments

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-four cylinder, 4-stroke, DOHC, 16-valve

Displacement:

249 cc (Cubic Centimeters)

Bore X Stroke:

Approx. 49.0 mm x 64.4 mm (typical for GSX-R/F series of this era)

Compression Ratio:

Approx. 11.5:1 to 12.0:1

Performance

Horsepower Rating:

Typically around 35-40 PS (Pferdestärke) / HP at ~11,000-12,000 RPM (JDM spec, may vary by market)

Torque Rating:

Around 2.4 - 2.6 kgf·m / 23-25 Nm at ~9,000-10,000 RPM

Fuel System

Carburetor Type:

Dual Mikuni VM30SS or similar CV (Constant Velocity) carburetors

Fuel Tank Capacity:

Approx. 13 Liters (2.86 US gal)

Cooling System Details

Coolant Type:

Ethylene glycol-based coolant (e.g., Suzuki's specific blend or equivalent 50/50 mix with distilled water)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-plate

Features

Drive System:

Chain drive

Transmission Fluid Type:

SAE 10W-40 API SE or SF classification motorcycle oil (refer to manual for exact spec)

📐 Dimensions

Exterior

Length:

Approx. 2010 mm

Width:

Approx. 700-750 mm (depending on fairing)

Height:

Approx. 1050-1100 mm

Weights

Dry Weight:

Approx. 145 kg

Wet Weight:

Approx. 155 kg (with fluids)

Weight Distribution:

Refer to manual for specific load distribution guidelines

🛡️ Safety Features

Ratings

Crash Test Ratings:

Not applicable for motorcycles of this era in standardized crash testing formats.

Active Features

Braking System:

Hydraulic disc brakes front and rear, offering good stopping power for its class

Tires:

Tubeless sport-biased tires for enhanced grip and safety

Passive Features

Lighting:

Halogen headlamp, tail light, and turn signals for visibility

Frame Construction:

Robust steel frame (likely twin-spar or cradle type) for stability

💡 Technology Features

Infotainment

Infotainment System:

Not applicable (analog instrumentation typical for the era)

Driver Assistance

Assistance Features:

None (ABS was extremely rare in this class at this time)

Instrumentation

Instrument Cluster:

Analog speedometer, tachometer, coolant temperature gauge, fuel gauge, warning lights (oil pressure, neutral, turn signals, high beam)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 km or 6-12 months (refer to manual for precise recommendation)

Air Filter Service:

Check every 3,000 km, clean/replace as needed (more frequently in dusty conditions)

Spark Plug Replacement:

Every 10,000-15,000 km (refer to manual for specific plug type and gap)

Valve Clearance Check:

Every 6,000-12,000 km (critical for engine health)

Fluid Specifications

Engine Oil Capacity:

Approx. 2.0 - 2.3 Liters with filter change (refer to manual)

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for specific recommendation)

Fork Oil Type:

SAE 10W (or equivalent) - capacity specified per fork leg

Known Issues

Carburetor Issues:

Clogged jets, vacuum leaks, sticky slides due to age and fuel deposits.

Electrical Issues:

Corroded connectors, faulty rectifiers/regulators, weak charging systems.

Cooling System Issues:

Leaking hoses, failing water pump seals, clogged radiators.

Clutch Wear:

Fading clutch performance or slipping due to worn friction plates.

📚 Vehicle History

Brand Heritage

Suzuki Legacy:

Suzuki has a long history in motorcycle manufacturing, known for innovative designs and performance-oriented machines across various categories.

Model Evolution

Gsx Lineage:

The GSX designation has historically represented Suzuki's range of sporty four-stroke motorcycles, evolving from earlier models like the GS series.

Gsx250F Context:

The GSX250F was part of Suzuki's strategy to offer capable and stylish 250cc sportbikes, catering to riders seeking a balance of performance and affordability.

Production

Production Years:

Likely produced from the late 1980s into the early 1990s.

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Model Awards:

Specific awards for the GSX250F are not widely documented, but the GSX line generally received positive reviews for its performance and value in its class.