1982 1983 Suzuki GN250 Motorcycle Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Suzuki Model: GN250 Year: 1982, 1983 Vehicle Type: Motorcycle 👋 Introduction Market Position Model Positioning: The Suzuki GN250 was a popular entry-level to mid-range standard motorcycle, known for its reliability and ease of use. Competitive Analysis Competitors Era: Competed with other 250cc class motorcycles from manufacturers like Yamaha (e.g., XS250), Honda (e.g., CB250), and Kawasaki (e.g., KZ250) in the early to mid-1980s. Key Features Value Proposition: This manual offers comprehensive, professional-level repair and maintenance information, allowing owners to service their classic GN250 effectively. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: PDF (Digital Download) Downloadable: Yes Requirements: PDF Reader Compatibility: Windows, Mac, Linux 📖 Manual Coverage Systems Covered Engine Mechanical: Full coverage including disassembly, inspection, assembly, and tuning. Engine Lubrication System: Detailed procedures for oil pump, oil filter, oil passages, and oil change intervals. Engine Cooling System: Information on air-cooled systems (if applicable for GN250), heat dissipation, and related components. Engine Control System: Coverage of ignition system, carburetor settings, and timing. Fuel System: Comprehensive details on fuel tank, fuel lines, fuel filter, and carburetor(s). Exhaust System: Information on exhaust pipes, mufflers, and emissions control (if applicable). Clutch: Detailed procedures for clutch operation, adjustment, and replacement (e.g., clutch plates, springs). Manual Transaxle: Complete coverage of gearbox components, shifting mechanisms, and maintenance. Front Axle: Information on front forks, steering head bearings, and wheel assembly. Rear Axle: Coverage of swingarm, rear suspension linkage, and drive sprocket/chain maintenance. Front Suspension: Detailed fork disassembly, oil change, seal replacement, and spring information. Rear Suspension: Information on shock absorbers, linkages, and bushings. Road Wheels And Tyres: Wheel bearing maintenance, tire pressure recommendations, and rim specifications. Brake System: Detailed coverage of front and rear brakes (likely drum or single disc), including pad/shoe replacement, fluid bleeding, and caliper/cylinder service. Parking Brake System: If applicable, procedures for parking brake mechanism. Brake Control System: Lever and pedal adjustment, cable routing and maintenance. Steering System: Steering head bearing adjustment, handlebar removal, and related components. Body Lock And Security System: Information on seat locks, ignition switch, and minor body panel fasteners. Glasses Window System And Mirrors: Windshield (if equipped), mirrors, and associated mounting hardware. Roof: Not applicable to this motorcycle model. Exterior And Interior: Body panels, fenders, fuel tank, seat, and trim. Instrumental Panel: Speedometer, tachometer, indicator lights, and their servicing. Seat: Seat removal, installation, and latch mechanism. Air Conditioner System: Not applicable to this motorcycle model. Wiring Diagrams: Detailed electrical schematics for all systems. Starting And Charging System: Battery, starter motor, alternator/generator, and regulator/rectifier testing and repair. Lighting System: Headlight, taillight, brake lights, turn signals, and dashboard illumination. Driver Information System: Indicator lights, warning signals, and gauges. Wiper Washer And Horn: Horn operation and electrical circuit. Body Control System: Relates to electrical controls for body components. Lan System: Not applicable to this motorcycle model. Audio Visual Navigation And Telephone System: Not applicable to this motorcycle model. Auto Cruise Control System: Not applicable to this motorcycle model. Power Supply Ground And Circuit Elements: Fuses, relays, wiring harnesses, and grounding points. Procedures Included Maintenance: Scheduled maintenance, lubrication, inspections, and fluid changes. Troubleshooting: Diagnostic procedures for common and uncommon issues across all systems. Repair: Step-by-step instructions for component disassembly, repair, and reassembly. Rebuilding: Comprehensive procedures for major component overhauls, particularly the engine. Refurbishment: Guidance on restoring components and systems to optimal condition. Restoration: Information to assist in bringing a vintage motorcycle back to original specifications. Technical Depth Depth: Covers all diagnostic and repair procedures in great detail, equivalent to professional technician knowledge. 📊 Manual Specifications File Format File Type: PDF Print Quality Image Quality: High quality photos, illustrations, and diagrams. Binding Type Binding: Not applicable (Digital Download) Paper Type Paper Type: Not applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, SOHC, 2-valve, air-cooled Displacement: 249 cc (approximately) Bore X Stroke: Typical around 65.0 mm x 75.0 mm (specifics to be confirmed in manual) Performance Horsepower: Approximately 20-22 HP (specifics to be confirmed in manual) Torque: Approximately 18-20 Nm (specifics to be confirmed in manual) Fuel System Carburetor: Single Mikuni VM series (e.g., VM28SS or similar, specific model to be confirmed in manual) Fuel Delivery: Gravity feed from fuel tank. 🔧 Transmission Standard Transmission Type: 5-speed constant mesh manual Optional Optional Transmission: Not applicable (standard 5-speed manual only) Features Final Drive: Chain drive 📐 Dimensions Exterior Overall Length: Approx. 2100 mm (specifics to be confirmed in manual) Overall Width: Approx. 750 mm (specifics to be confirmed in manual) Overall Height: Approx. 1100 mm (specifics to be confirmed in manual) Weights Dry Weight: Approx. 143 kg (specifics to be confirmed in manual) Fuel Tank Capacity: Approx. 12 Liters (specifics to be confirmed in manual) 🛡️ Safety Features Ratings Safety Ratings: Not applicable (historical motorcycle model, no standardized ratings like modern cars) Active Features...
The Suzuki GN250 was a popular entry-level to mid-range standard motorcycle, known for its reliability and ease of use.
Competitive Analysis
Competitors Era:
Competed with other 250cc class motorcycles from manufacturers like Yamaha (e.g., XS250), Honda (e.g., CB250), and Kawasaki (e.g., KZ250) in the early to mid-1980s.
Key Features
Value Proposition:
This manual offers comprehensive, professional-level repair and maintenance information, allowing owners to service their classic GN250 effectively.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
PDF (Digital Download)
Downloadable:
Yes
Requirements:
PDF Reader
Compatibility:
Windows, Mac, Linux
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full coverage including disassembly, inspection, assembly, and tuning.
Engine Lubrication System:
Detailed procedures for oil pump, oil filter, oil passages, and oil change intervals.
Engine Cooling System:
Information on air-cooled systems (if applicable for GN250), heat dissipation, and related components.
Engine Control System:
Coverage of ignition system, carburetor settings, and timing.
Fuel System:
Comprehensive details on fuel tank, fuel lines, fuel filter, and carburetor(s).
Exhaust System:
Information on exhaust pipes, mufflers, and emissions control (if applicable).
Clutch:
Detailed procedures for clutch operation, adjustment, and replacement (e.g., clutch plates, springs).
Manual Transaxle:
Complete coverage of gearbox components, shifting mechanisms, and maintenance.
Front Axle:
Information on front forks, steering head bearings, and wheel assembly.
Rear Axle:
Coverage of swingarm, rear suspension linkage, and drive sprocket/chain maintenance.
Front Suspension:
Detailed fork disassembly, oil change, seal replacement, and spring information.
Rear Suspension:
Information on shock absorbers, linkages, and bushings.
Road Wheels And Tyres:
Wheel bearing maintenance, tire pressure recommendations, and rim specifications.
Brake System:
Detailed coverage of front and rear brakes (likely drum or single disc), including pad/shoe replacement, fluid bleeding, and caliper/cylinder service.
Parking Brake System:
If applicable, procedures for parking brake mechanism.
Brake Control System:
Lever and pedal adjustment, cable routing and maintenance.
Steering System:
Steering head bearing adjustment, handlebar removal, and related components.
Body Lock And Security System:
Information on seat locks, ignition switch, and minor body panel fasteners.
Glasses Window System And Mirrors:
Windshield (if equipped), mirrors, and associated mounting hardware.
Roof:
Not applicable to this motorcycle model.
Exterior And Interior:
Body panels, fenders, fuel tank, seat, and trim.
Instrumental Panel:
Speedometer, tachometer, indicator lights, and their servicing.
Seat:
Seat removal, installation, and latch mechanism.
Air Conditioner System:
Not applicable to this motorcycle model.
Wiring Diagrams:
Detailed electrical schematics for all systems.
Starting And Charging System:
Battery, starter motor, alternator/generator, and regulator/rectifier testing and repair.
Lighting System:
Headlight, taillight, brake lights, turn signals, and dashboard illumination.
Driver Information System:
Indicator lights, warning signals, and gauges.
Wiper Washer And Horn:
Horn operation and electrical circuit.
Body Control System:
Relates to electrical controls for body components.
Lan System:
Not applicable to this motorcycle model.
Audio Visual Navigation And Telephone System:
Not applicable to this motorcycle model.
Auto Cruise Control System:
Not applicable to this motorcycle model.
Power Supply Ground And Circuit Elements:
Fuses, relays, wiring harnesses, and grounding points.
Procedures Included
Maintenance:
Scheduled maintenance, lubrication, inspections, and fluid changes.
Troubleshooting:
Diagnostic procedures for common and uncommon issues across all systems.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly.
Rebuilding:
Comprehensive procedures for major component overhauls, particularly the engine.
Refurbishment:
Guidance on restoring components and systems to optimal condition.
Restoration:
Information to assist in bringing a vintage motorcycle back to original specifications.
Technical Depth
Depth:
Covers all diagnostic and repair procedures in great detail, equivalent to professional technician knowledge.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Image Quality:
High quality photos, illustrations, and diagrams.
Binding Type
Binding:
Not applicable (Digital Download)
Paper Type
Paper Type:
Not applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, SOHC, 2-valve, air-cooled
Displacement:
249 cc (approximately)
Bore X Stroke:
Typical around 65.0 mm x 75.0 mm (specifics to be confirmed in manual)
Performance
Horsepower:
Approximately 20-22 HP (specifics to be confirmed in manual)
Torque:
Approximately 18-20 Nm (specifics to be confirmed in manual)
Fuel System
Carburetor:
Single Mikuni VM series (e.g., VM28SS or similar, specific model to be confirmed in manual)
Fuel Delivery:
Gravity feed from fuel tank.
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh manual
Optional
Optional Transmission:
Not applicable (standard 5-speed manual only)
Features
Final Drive:
Chain drive
📐 Dimensions
Exterior
Overall Length:
Approx. 2100 mm (specifics to be confirmed in manual)
Overall Width:
Approx. 750 mm (specifics to be confirmed in manual)
Overall Height:
Approx. 1100 mm (specifics to be confirmed in manual)
Weights
Dry Weight:
Approx. 143 kg (specifics to be confirmed in manual)
Fuel Tank Capacity:
Approx. 12 Liters (specifics to be confirmed in manual)
🛡️ Safety Features
Ratings
Safety Ratings:
Not applicable (historical motorcycle model, no standardized ratings like modern cars)
Active Features
Active Safety:
Effective braking system (front disc, rear drum), responsive steering, and stable chassis design for its era.
Passive Features
Passive Safety:
Sturdy frame construction, rider ergonomics designed for control.
💡 Technology Features
Infotainment
Infotainment Features:
Not applicable (basic instrumentation only).
Driver Assistance
Driver Assistance Systems:
Not applicable (no electronic rider aids).
Connectivity
Connectivity Features:
Not applicable.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 3,000-5,000 km or 6 months (specifics to be confirmed in manual, refer to oil type).
Spark Plug Maintenance:
Recommended inspection/replacement every 5,000-10,000 km (specifics to be confirmed in manual).
Chain Lubrication Adjustment:
Frequent checks and lubrication recommended, adjustment as needed (typically every 1,000-1,500 km).
Fluid Specifications
Engine Oil Type:
SE or SF classification SAE 10W-40 motorcycle specific oil recommended (refer to manual for exact API and viscosity).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid for hydraulic systems (if front brake is disc, specific to be confirmed in manual).
Known Issues
Common Wear Items:
Typical issues for motorcycles of this age include carburetor gumming, aging electrical connections, worn suspension seals, and clutch wear.
Engine Reliability:
The GN250's engine is generally considered robust and reliable if properly maintained.
📚 Vehicle History
Brand Heritage
Suzuki Motorcycle Legacy:
Suzuki has a long history of producing reliable and performance-oriented motorcycles across various categories, from commuters to sportbikes and off-road machines.
Model Evolution
Gn Series Development:
The GN series represented Suzuki's offering in the popular lightweight to mid-displacement standard motorcycle segment, emphasizing practicality and longevity.
Production
Gn250 Production Years:
The GN250 model line generally ran from the early 1980s through the early 2000s in various forms and markets, with 1982-1983 being early production years.
🏆 Awards & Recognition
Recognitions
Model Awards:
While specific awards for the GN250 are not widely documented, it was recognized for its value and reliability in its class during its production run.
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