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Introduction
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Market Position
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Vehicle Segment:
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Entry-level to mid-range dual-sport motorcycle, popular for commuting, light trail riding, and general utility.
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Competitive Analysis
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Key Competitors:
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Honda XR250L, Kawasaki KLX250S, Yamaha XT250.
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Key Features
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Engine Type:
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Reliable, air-cooled, single-cylinder engine known for its longevity and ease of maintenance.
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Drivetrain:
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Chain drive, suitable for varied terrain.
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Suspension Setup:
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Versatile suspension capable of handling both pavement and off-road conditions.
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Manual Value Proposition
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Target Audience:
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Owners seeking to perform their own maintenance and repairs, DIY enthusiasts, independent repair shops.
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Dealership Equivalence:
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Provides the same level of detail and accuracy as manuals used by official Suzuki dealerships.
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Manual Coverage
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Systems Covered
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Engine:
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Detailed overhaul, internal components, combustion system, valve timing, cooling system (air-cooled).
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Fuel And Lubrication:
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Carburetor assembly, fuel delivery, oil pump, oil filter, oil capacities, lubrication points.
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Chassis:
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Frame, suspension (front forks, rear shock absorber), steering system, wheels, brakes (front disc, rear drum), final drive (chain).
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Electrical System:
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Ignition system, lighting, starting system, charging system (alternator, battery), wiring diagrams, component testing.
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Emission Control:
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Information on emission control systems as applicable to the 2004 model year, potential adjustments or checks.
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Procedures Included
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General Information:
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Vehicle identification, safety precautions, basic tools, torque specifications, measurement units.
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Periodic Maintenance:
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Scheduled service intervals, oil changes, filter replacements, chain adjustment, brake inspection, valve clearance checks.
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Engine Repair:
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Engine disassembly, reassembly, piston, rings, cylinder, crankshaft, camshaft, timing chain replacement, cylinder head service.
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Fuel System Repair:
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Carburetor cleaning, adjustment, jetting, fuel line inspection, fuel tank maintenance.
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Chassis Repair:
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Front fork seal replacement, rear shock absorber servicing, steering bearing replacement, wheel bearing replacement, brake pad/shoe replacement, chain and sprocket replacement.
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Electrical Troubleshooting:
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Fault diagnosis using wiring diagrams, testing of ignition coil, stator, rectifier/regulator, battery, starter motor.
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Technical Depth
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Depth Of Coverage:
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Comprehensive; covers all aspects from routine maintenance and minor adjustments to complete engine and chassis overhauls, including detailed diagnostics.
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Engine Specifications
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Primary Engine
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Engine Type:
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4-stroke, OHC, air-cooled
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Displacement:
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199 cc
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Bore X Stroke:
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66.0 mm x 57.0 mm
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Compression Ratio:
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9.4:1
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Carburetion:
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Mikuni VM26 (or similar specification for 2004 model)
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Performance
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Horsepower:
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Approximately 16-18 HP (estimated, as specific figures are often not published for this model).
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Torque:
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Approximately 11-13 lb-ft (estimated).
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Fuel System
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Fuel Type:
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Unleaded gasoline
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Fuel Tank Capacity:
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Approximately 3.4 US gallons (13 Liters)
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Lubrication
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Oil Type:
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SAE 10W-40 API SE, SF, SG or higher (specific recommendations in manual)
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Oil Capacity With Filter Change:
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Approximately 1.6 US quarts (1.5 Liters)
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Ignition
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Ignition System:
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Electronic ignition (CDI)
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Dimensions
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Exterior
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Overall Length:
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Approximately 80.5 inches (2045 mm)
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Overall Width:
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Approximately 32.1 inches (815 mm)
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Overall Height:
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Approximately 44.3 inches (1125 mm)
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Wheelbase:
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Approximately 53.0 inches (1345 mm)
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Ground Clearance:
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Approximately 10.4 inches (265 mm)
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Weights
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Dry Weight:
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Approximately 256 lbs (116 kg)
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Wet Weight:
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Approximately 276 lbs (125 kg) (estimated with fluids)
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Wheels And Tires
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Front Tire Size:
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80/100-21 51P
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Rear Tire Size:
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100/90-17 55P
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Front Brake:
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Disc brake
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Rear Brake:
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Drum brake
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Suspension
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Front Suspension Type:
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Telescopic, coil spring, oil damped
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Rear Suspension Type:
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Swingarm type, coil spring, oil damped (linkage type often on larger models)
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Maintenance
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Service Intervals
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Engine Oil Change Interval:
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Typically every 2,000-3,000 miles or 6 months, refer to manual for precise interval.
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Air Filter Cleaning Interval:
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Frequent checks recommended, cleaning/replacement every 4,000-6,000 miles or as needed based on riding conditions.
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Spark Plug Replacement Interval:
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Typically every 6,000-10,000 miles, refer to manual for specific spark plug type and gap.
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Chain Lubrication And Adjustment:
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Recommended every 500-1,000 miles or after riding in wet conditions.
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Fluid Specifications
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Engine Oil Specification:
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SAE 10W-40 API SE, SF, SG or higher (refer to manual for exact API service classification and viscosity grade).
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Brake Fluid Specification:
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DOT 3 or DOT 4 brake fluid (refer to manual for specific type and replacement interval).
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Known Issues
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Common Wear Items:
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Chain and sprockets, brake pads/shoes, tires, clutch plates, fork seals.
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Carburetor Cleaning:
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Carburetors can sometimes become gummed up if the motorcycle sits for extended periods without fuel stabilizer, requiring cleaning and re-jetting.
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Electrical Connections:
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Corrosion in electrical connectors can lead to intermittent issues, particularly in humid or salty environments.
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Troubleshooting Guidance
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Manual Diagnostic Assistance:
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The manual provides step-by-step troubleshooting guides for common starting, running, and electrical problems.
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