Product Type:
Service Manual, Repair Manual, Owner's Manual
Set Name:
1999-2009 Suzuki GZ250 Marauder Service Manual Repair Manuals -And- Owner‘s Manual Ultimate Set
Covered Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Motorcycle Segment:
Cruiser/Classic Style Motorcycle
Target Audience:
Entry-level riders, commuters, owners seeking a reliable and stylish, low-displacement cruiser.
Key Competitors Era:
Honda Rebel 250, Yamaha Virago 250, Kawasaki Eliminator 125 (for lower displacement comparison).
Bike Key Features:
Low seat height, relaxed riding position, classic styling, fuel efficiency, ease of use, torquey low-end power delivery.
Manual Set Value:
Comprehensive coverage for maintenance, repair, and ownership of the GZ250 Marauder across its primary production run, providing significant value for owners and independent repair shops.
Service Manual Coverage:
Engine, Chassis, Electrical System, Fuel System, Transmission, Suspension, Brakes, Cooling System, Lubrication System, Frame, Bodywork, Troubleshooting, Maintenance, Specifications, Wiring Diagrams.
Owner Manual Coverage:
Operation, Maintenance, Controls, Features, Specifications, Safety Information, Storage, Troubleshooting.
Service Manual Page Count:
Estimated 300-400 pages (typical for this era and bike type)
Owner Manual Page Count:
Estimated 50-100 pages (typical for this era and bike type)
Primary Manual Type:
Factory Service Manual (FSM)
Secondary Manual Type:
Owner's Manual
Engine System:
Top-end overhaul, bottom-end overhaul, valve clearance adjustment, camshaft timing, piston and ring replacement, crankshaft and connecting rod service, oil pump, cylinder head, cylinder block, cooling system (air-cooled specific). Specific procedures for carburetor removal, cleaning, and adjustment.
Fuel System:
Carburetor (VM28SS typically) disassembly, cleaning, inspection, and adjustment. Fuel tank maintenance, fuel petcock operation and service, fuel filter replacement.
Transmission System:
Clutch operation and adjustment, gear shift mechanism, transmission disassembly and reassembly, gear inspection, shift drum and forks, clutch plates and springs inspection and replacement.
Electrical System:
Ignition system (CDI), starter motor, charging system (alternator, rectifier/regulator), battery service, lighting system (headlight, taillight, turn signals), fuse box, wiring diagrams for all models and variations.
Chassis System:
Frame inspection, front fork assembly (disassembly, seal replacement, oil level/viscosity), rear shock absorber service/replacement, swingarm bearing service, steering head bearing service.
Brake System:
Front and rear brake caliper overhaul, brake pad replacement, brake fluid flush and bleeding, brake master cylinder inspection, brake line inspection and replacement, brake disc inspection.
Wheels And Tires:
Tire inspection and replacement, tube replacement, wheel bearing service, spoke tension adjustment (if applicable to spoked wheels), wheel balancing.
Bodywork And Trim:
Fender removal and installation, fuel tank removal and installation, seat removal and installation, side cover removal and installation, handlebar replacement, exhaust system removal and installation.
Preventive Maintenance:
Regularly scheduled checks, oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment and lubrication, brake system checks, tire pressure checks.
Troubleshooting:
Diagnostic charts for common problems related to starting, running, electrical issues, braking, and suspension. Step-by-step guidance for identifying and resolving faults.
Repair And Rebuild:
Complete instructions for engine teardown and rebuild, transmission overhaul, carburetor rebuilding, suspension component replacement, brake system overhauls, and electrical component diagnostics and repair.
Assembly And Disassembly:
Detailed procedures for removing and installing major components, including torque specifications for all fasteners.
Diagnostic Capabilities:
Advanced diagnostics, including electrical system troubleshooting with wiring diagrams and component testing procedures.
Rebuild Scope:
Complete engine, transmission, and carburetor rebuild procedures.
Detail Level:
Factory-level detail, including specific measurements, tolerances, and torque values.
Engine Type:
Four-stroke, air-cooled, SOHC, 2-valve
Engine Displacement:
249 cc (Cubic Centimeters)
Bore X Stroke:
66.0 mm x 72.0 mm
Carburetor Type:
Mikuni VM28SS (likely, specification may vary slightly by market)
Ignition System:
CDI (Capacitor Discharge Ignition)
Starter System:
Electric Starter
Lubrication System:
Forced lubrication (wet sump)
Horsepower Approx:
Approximately 16-20 HP (at specified RPM)
Torque Approx:
Approximately 14-16 Nm (at specified RPM)
Fuel Type:
Unleaded gasoline
Fuel Tank Capacity:
Approx. 13 Liters (3.4 US gal)
Oil Change Interval:
Every 3,000 km (1,800 miles) or 6 months
Oil Filter Replacement:
Every 6,000 km (3,600 miles) or 12 months (or with oil changes if integrated)
Spark Plug Check Replace:
Check every 6,000 km (3,600 miles), replace as needed. Specific gap: 0.7-0.8 mm.
Air Filter Maintenance:
Clean every 6,000 km (3,600 miles), replace as needed.
Chain Maintenance:
Lubricate every 1,000 km (600 miles) or after riding in wet conditions. Adjust chain slack to 20-30 mm.
Valve Clearance Check:
Every 12,000 km (7,200 miles)
Engine Oil Type:
SAE 10W-40 API SE, SF or SG
Engine Oil Capacity:
Approx. 1.4 L (1.5 US qt) without filter change; Approx. 1.6 L (1.7 US qt) with filter change
Brake Fluid Type:
DOT 3 or DOT 4
Fork Oil Type:
SAE 10W (Suzuki's recommended fork oil or equivalent)
Fork Oil Quantity:
Approx. 155 mm (6.1 in) from top of inner tube with spring removed
Common Wear Items:
Clutch plates, brake pads/shoes, tires, chain and sprockets, swingarm bushings, steering head bearings.
Carburetor Performance:
Carburetor can be sensitive to dirt and require periodic cleaning/adjustment to maintain smooth running and prevent stalling.
Electrical Connections:
Corrosion on electrical connectors can lead to intermittent issues, especially on bikes used in damp environments.
Suspension Feel:
Stock suspension may be considered basic; owners may upgrade for improved comfort and handling.
Suzuki Motorcycle Division:
Suzuki Motor Corporation has a long history in motorcycle manufacturing, known for innovation and a wide range of models from small commuters to superbikes and off-road machines.
Gz250 Introduction:
The GZ250 Marauder was introduced to offer a stylish, accessible, and affordable cruiser option within Suzuki's lineup, targeting riders new to the cruiser segment or those seeking a relaxed riding experience.
Gz250 Updates 1999 2009:
While the core design remained consistent, minor updates likely included cosmetic changes, emissions control adjustments, and potentially minor carburetor tuning for different markets and model years within this period.
Production Period Covered:
1999-2009
Manufacturing Location:
Likely manufactured in Japan or other Suzuki assembly plants.
