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GW250
Suzuki GW250 User Manual
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COOLING AND LUBRICATION
SYSTEM 7-13
WATER PUMP
CONSTRUCTION
FWD
1
Wa
t
e
r
p
u
m
p
c
o
ve
r
7
O-r
ing
2
O-r
ing
8
Impeller shaft
ITEM
N·m
kgf-m
lbf-ft
3
Impeller
A
W
ater pump air bleeder bolt
A
60
.
6
4
.
5
4
Mechanical seal
B
Impe
ller secur
ing bolt
B
80
.
8
6
.
0
5
Oil seal
C
Water pump co
ver scre
w
C
5.5
0.55
4.0
6
W
ater pu
mp body
D
W
ater pump mounting bolt
D
10
1.0
7.0
275
277
Table of Contents
General Information 1
7
Fi System Diagnosis
2
General Information
2
Periodic Maintenance
2
Servicing Information
2
Wiring Diagram
2
How to Use this Manual
3
Abbreviations Used in this Manual
5
Table of Contents
7
Electrical System
2
Warning/Caution/Notice/Note
8
General Precautions
8
Suzuki Gw250L3 ('13-Model)
10
Serial Number Location
10
Fuel, Oil and Engine Coolant Recommendation
11
Fuel
11
Engine Oil
11
Brake Fluid
12
Front Fork Oil
12
Engine Coolant Recommendation
12
Break-In Procedures
13
Cylinder Identification
13
Information Labels
14
Specifications
15
Dimensions and Curb Mass
15
Engine
15
Drive Train
15
Chassis
16
Electrical
16
Capacities
16
Periodic Maintenance
17
Periodic Maintenance Schedule
18
Periodic Maintenance Chart
18
Lubrication Points
19
Maintenance and Tune-Up Procedures
20
Air Cleaner
20
Exhaust Pipe Bolts and Muffler Bolts
21
Spark Plugs
22
Valve Clearance
24
Engine Oil Replacement
27
Engine Oil and Oil Filter
27
Fuel Line
28
Oil Filter Replacement
28
Pair (Air Supply) System
29
Throttle Cable Play
29
Engine Idle Speed
29
Clutch Cable Play
30
Cooling System
31
Drive Chain
33
Brake
35
Tires
39
Tires Condition/Pressure
39
Steering
40
Front Forks
40
Rear Suspension
40
Chassis Bolts and Nuts
41
Compression Pressure Check
43
Compression Test Procedure
43
Oil Pressure Check
44
Sds Check
45
Data at the Time of Racing
46
Engine
49
Engine Components Removable with Engine in Place
50
Engine Removal and Installation
51
Engine Removal
51
Engine Installation
56
Engine Disassembly
60
Engine Components Inspection and Service
73
Cylinder Head Cover
73
Pair Reed Valve
73
Camshaht Housing
74
Cylinder Head
75
Camshaft
82
Camshaft Runout
83
Cam Chain Tension Adjuster
84
Cam Chain Tensioner and Cam Chain Guide
84
Cylinder
84
Piston
85
Piston Diameter
85
Piston Ring Groove Width
86
Piston Ring Thickness
86
Piston Ring End Gap
87
Clutch
88
Oil Pump
89
Starter Clutch
90
Generator
92
Water Pump
92
Gearshift System
93
Clutch Release Camshaft
94
Oil Pressure Regulator
95
Oil Strainer
95
Transmission
96
Crankcase
99
Crank Balancer
106
Crank Balancer Journal Bearing
107
Crankshaft and Conrod
109
Crankshaft Journal Bearing
113
Crankshaft Thrust Bearing
116
Engine Reassembly
118
Fi System Diagnosis
142
Precautions in Servicing
144
Electrical Parts
144
Fuse
145
Switch
145
Ecm/Various Sensors
146
Battery
146
Electrical Circuit Inspection Procedure
147
Using the Multi Circuit Tester
150
Fi System Technical Features
151
Injection Time (Injection Volume)
151
Compensation of Injection Time (Volume)
152
Injection Stop Control
152
Fi System Parts Location
153
Fi System Wiring Diagram
155
Ecm Terminal
156
Self-Diagnosis Function
157
User Mode
157
Dealer Mode
158
Tps Adjustment
160
Fail-Safe Function
161
Fi System Troubleshooting
162
Customer Complaint Analysis
162
Visual Inspection
163
Self-Diagnostic Procedures
164
Self-Diagnosis Reset Procedure
164
Use of Sds Diagnostic Procedures
165
Use of Sds Diagnosis Reset Procedure
166
Show Failure Data (Displaying Data at the Time of Dtc)
167
Malfunction Code and Defective Condition
168
Dtc "C12" (P0335): Ckp Sensor Circuit Malfunction
171
DTC "C13" (P1750-H/L) or "C17" (P0105-H/L): IAP SENSOR CIRCUIT MALFUNCTION
175
Dtc "C14" (P0120-H/L): Tp Sensor Circuit Malfunction
179
Dtc "C15" (P0115-H/L): Ect Sensor Circuit Malfunction
183
Dtc "C21" (P0110-H/L): Iat Sensor Circuit Malfunction
187
Dtc "C23" (P1651-H/L): to Sensor Circuit Malfunction
191
DTC "C24" (P0351) or "C25" (P0352): IGNITION SYSTEM MALFUNCTION
194
Dtc "C31" (P0705): Gp Switch Circuit Malfunction
195
DTC "C32" (P0201) or "C33" (P0202): FUEL INJECTOR CIRCUIT MALFUNCTION
198
Dtc "C40" (P0505): Isc Valve Circuit Malfunction
201
Dtc "C41" (P0230-H/L): Fp Relay Circuit Malfunction
207
Dtc "C41" (P2505): Ecm Power Input Signal Malfunction
210
Dtc "C42" (P1650): Ig Switch Circuit Malfunction
211
Dtc "C44" (P0130/P0135): Ho2 Sensor (Ho2S) Circuit Malfunction
212
Dtc "C49" (P1656)
222
Pair Control Solenoid Valve Circuit Malfunction
222
Dtc "C60" (P0480)
226
Cooling Fan Relay Circuit Malfunction
226
Dtc "C65" (P0506/P0507): Idle Speed Malfunction
230
Sensors
232
Ckp Sensor Inspection
232
Ckp Sensor Removal and Installation
232
Iap Sensor Inspection
232
Iap Sensor Removal and Installation
232
Tp Sensor Inspection
232
Tp Sensor Removal and Installation
232
Tps Adjustment
232
Ect Sensor Inspection
233
Ect Sensor Removal and Installation
233
Iat Sensor Inspection
233
Iat Sensor Removal and Installation
233
To Sensor Inspection
233
To Sensor Removal and Installation
233
Ho2 Sensor Inspection
234
Ho2 Sensor Removal and Installation
234
Fuel System and Throttle Body
236
Fuel System
237
Fuel Tank Removal
237
Fuel Tank Installation
238
Fuel Pressure Inspection
238
Fuel Pump Inspection
239
Fuel Discharge Amount Inspection
239
Fuel Pump Relay Inspection
240
Fuel Pump and Fuel Level Gauge Removal
241
Fuel Pump Disassembly
243
Fuel Mesh Filter Inspection and Cleaning
244
Fuel Pump and Fuel Level Gauge Reassembly and Installation
244
Throttle Body
246
Construction
246
Throttle Body Removal
247
Throttle Body Disassembly
248
Throttle Body Cleaning
250
Inspection
250
Throttle Body Reassembly
251
Throttle Body Installation
252
Fuel Injector Removal
253
Fuel Injector Inspection
253
Fuel Injector Installation
253
Isc Valve Removal
253
Isc Valve Inspection
255
Isc Valve Installation
255
Isc Valve Reset
256
Tp Reset
257
Throttle Valve Synchronization
258
Exhaust System
261
Exhaust System
262
Removal
262
Inspection
263
Installation
263
Engine Coolant
265
Cooling Circuit
267
Cooling Circuit Inspection
267
Radiator and Cooling Fan Motor
268
Radiator and Cooling Fan Motor Removal
268
Radiator and Cooling Fan Motor Installation
269
Water Hose Inspection
270
Radiator Cap Inspection
270
Radiator Inspection and Cleaning
271
Cooling Fan
271
Inspection
271
Cooling Fan Relay Inspection
272
Ect Sensor
272
Removal
272
Inspection
273
Installation
273
Thermostat
274
Removal
274
Inspection
274
Installation
275
Water Pump
276
Construction
276
Removal and Disassembly
277
Inspection
279
Reassembly and Installation
280
Lubrication System
283
Oil Pressure
283
Oil Filter
283
Oil Pressure Regulator
283
Oil Strainer
283
Oil Jet
283
Oil Pump
283
Oil Pressure Switch
283
Engine Lubrication System Chart
284
Chassis
285
Exterior Parts
287
Fastener
287
Frame Cover
288
Frame Front Cover
288
Fuel Tank Center Cover
288
Fuel Tank Cover
289
Seat
289
Frame Upper Cover
290
Pillion Rider Handle
290
Front Wheel
291
Construction
291
Removal
292
Inspection and Disassembly
292
Reassembly and Installation
295
Front Fork
299
Construction
299
Removal and Disassembly
300
Inspection
302
Reassembly and Installation
303
Steering
307
Construction
307
Removal
308
Inspection and Disassembly
309
Reassembly
310
Installation
310
Steering Tension Adjustment
311
Handlebars
312
Construction
312
Removal
313
Installation
314
Rear Wheel
316
Construction
316
Removal
317
Inspection and Disassembly
318
Reassembly and Installation
320
Rear Shock Absorber
324
Construction
324
Removal
325
Inspection
325
Bearing Replacement
326
Rear Shock Absorber Disposal
327
Insallation
328
Suspension Setting
328
Rear Suspension
329
Construction
329
Installation
334
Front Brake
335
Construction
335
Brake Pad Replacement
336
Brake Fluid Replacement
338
Caliper Removal
338
Caliper Disassembly
339
Caliper Inspection
340
Caliper Reassembly
341
Caliper Installation
342
Brake Disc Inspection
342
Master Cylinder Removal and Disassembly
343
Master Cylinder Inspection
344
Master Cylinder Reassembly and Installation
345
Rear Brake
347
Construction
347
Brake Pad Replacement
348
Brake Fluid Replacement
349
Caliper Removal
350
Caliper Disassembly
350
Caliper Inspection
351
Caliper Reassembly
352
Caliper Installation
353
Brake Disc Inspection
353
Master Cylinder Removal and Disassembly
353
Master Cylinder Inspection
355
Master Cylinder Reassembly and Installation
355
Tire and Wheel
357
Tire Removal
357
Inspection
357
Tire Installation
359
Balancer Weight Installation
360
Drive Chain
361
Drive Chain Cutting
361
Drive Chain Connecting
362
Electrical System
365
Cautions in Servicing
367
Connector
367
Coupler
367
Clamp
367
Fuse
367
Switch
368
Semi-Conductor Equipped Part
368
Battery
368
Connecting the Battery
368
Wiring Procedure
368
Using the Multi Circuit Tester
369
Location of Electrical Components
370
Charging System
372
Troubleshooting
372
Inspection
373
Starter System
376
Troubleshooting
376
Starter Motor Removal
377
Starter Motor Disassembly
378
Starter Motor Inspection
378
Starter Motor Reassembly
379
Starter Relay Inspection
381
Side-Stand/Ignition Interlock System Parts
382
Inspection
382
Ignition System
385
Troubleshooting
385
Inspection
387
Combination Meter
390
Description
390
Removal and Disassembly
391
Inspection
392
Lamps
399
Headlight and Position Light
399
License Plate Light
402
Brake/Tail Light
403
Turn Signal Light
404
Turn Signal Relay Inspection
406
Switches Inspection
407
Initial Charging
408
Recharging Operation
410
Servicing Information
411
Troubleshooting
413
Fi System Malfunction Code and Defective Condition
413
Engine
413
Radiator (Cooling System)
419
Chassis
420
Brakes
421
Electrical
422
Battery
423
Wiring Harness, Cable and Hose Routing
424
Wiring Harness Routing
424
Cable Routing
427
Intake System Hose Routing
428
Fuel Tank Drain Hose Routing
429
Cooling System Hose Routing
430
Ignition Coil Installation
432
Front Brake Hose Routing
433
Rear Brake Hose Routing
434
Pair (Air Supply) System Hose Routing
435
Fuel Tank Installation
436
Muffler & Exhaust Pipe Installation
437
Seat Lock Cable Routing
438
Front Fender Installation
439
FRONT LICENSE PLATE INSTALLATION (Only for P-12)
439
FRONT SIDE REFLEX REFLECTOR INSTALLATION (Only for P-24)
440
Frame Cover Installation
441
Frame Installation
442
Side-Stand Installation
442
CENTER STAND INSTALLATION (for P-12)
443
Rear Brake Pedal Installation
444
Handlebars Installation
445
Headlight Cover Installation
446
Headlight Installation
447
Front Turn Signal Light Installation
448
Rear Combination Light Installation
449
Regulator/Rectifier Installation
450
Special Tools
451
Tightening Torque
454
Engine
454
Fi System and Intake Air System
456
Cooling System
456
Chassis
456
Tightening Torque Chart
458
Service Data
459
Emission Control Systems
470
Noise Emission Control System
470
Ho2 Sensor Inspection
470
Ho2 Sensor Removal and Installation
470
Pair (Air Supply) System and Emission Control System Inspection
471
Pair Hoses
471
Pair Reed Valve
471
Pcv Hose
472
Pair Control Solenoid Valve
472
Pair (Air Supply) System Hose Routing
474
4
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Suzuki GW250 Specifications
General
Brand
Suzuki
Model
GW250
Category
Motorcycle
Language
English
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