Suzuki GSX25 Owner's manual

Brand: Suzuki

Model: GSX25

Type: Owner's manual

$ SUZUKI

OWNER'SMANUAL

GSX250

IMPORTANT

BREAK-IN INFORMATIONFOR

YOUR MOTORCYCLE

The first 1600km(1000miles)are the

most important in the life of your

motorcycle. Proper break-in opera-

tion during this time will help en-

sure maximum life and performance

from your new' motorcycle. Suzuki

parts are manufactured of high qual-

ity materials, and machined parts are

finished to close tolerances. Proper

break-in operation allows the ma-

chined surfaces to polish each other

and mate smoothly.

Motorcycle reliability and perform-

ance depend on special care and re-

straint exercised during the break-in

period. It is especially important that

you avoid operating the engine in a

manner which could expose the en-

gine parts to excessive heat.

Please refer to the BREAK-IN sec-

tion for specific break-in recommen-

dations.

WARNING/CAUTION/NOTE

Please read this manual and follow

its instructions carefully. To empha-

size special information the words

FOREWORD

THANK YOU for choosing Suzuki.

We at Suzuki have designed, tested

and produced this motorcycle using

the most modern technology availa-

ble to provide you with many hap-

py, enjoyable, safe riding. Motorcy-

cling is one of the most exhilarating

sports and to ensure your riding en-

joyment, you should become thor-

oughly familiar with the information

presented in this Owner's Manual

before riding the motorcycle.

WAImING, CAUTION and NOTE

carry special meanings and should

be carefully reviewed.

WARNING

The personal siuety of the rider

may be involved.Disregarding this

information could result in injury

to the rider.

CAUTION

The proper care and maintenance

that your motorcycle requires is out-

lined in this manual. By following

these instructions explicitly you will

ensure a long troublefree operating

life for your motorcycle. Your Suzu-

ki dealer has experienced technicians

that are trained to provide your ma-

chine with the best possible service

with the right tools and equipment.

These instructions point out spe-

cial service procedures or precau-

tions that must be followed to a-

void damaging the machine.

NOTE, This provides special infor-

mation to make maintenance easier

or important instructions clearer.

All information', illustrations, photo-

graphs and specifications contained

in this manual are based on the lat-

est product information available at

the time of publication. Due to im-

provements or other changes, there

may be some discrepancies in this

manual. Suzuki reserves the right to

make changes at any time.

Please note that this manual applies

to all specifications or all respective

destinations and explains all equip-

ment. Therefore, your model may

have different standard features than

shown in this manual.

CORPORATION

TABLEOFCONTENTS

CONSUMER

INFORMATION 3

LOCATION OF PARTS 8

CONTROLS 11

FUEL AND OIL

RECOMMENDATION 21

BREAK- IN 22

INSPECTION REFORE

RIDING 23

RIDING TIPS 24

INSPECTION AND

MAINTENANCE 27

TROUBLESHOOTING 52

STORAGE PROCEDURE 54

SPECIFICATIONS 56

CONSUMER

INFORMATION

ACCESSORYINSTALLATIONAND

PRECAUTIONSAFETYTIPS

There are a great variety of accesso-

ries available to Suzuki owners' Su-

zuki can not have direct control over

the quality or suitability of accesso-

ries you may wish to purchase. The

addition of unsuitable accessories

can lead to unsafe operating condi-

tions. It is not possible for Suzuki to

test each accessory on the market or

combinations of all the available ac-

cess-ories; however, your authorized

dealer can assist you in selecting

quality accessories and installing

them correctly.

Use extreme caution when selecting

and installing the accessories for

your Suzuki. We have developed

some general guidelines which will

aid you when deciding whether, and

how to equip your motorcycle.

(1) Any time that additional weight

or aerodynamic affecting access-

ories are installed, they should

be mounted as low as possible,

as close to the motorcycle and as

near the center of gravity as is

feasible. The mounting brackets

and other attachment hardware

should be carefully checked to

ensure that it provides for a rig-

id, nonmovable mount. Weak

mounts can allow the shifting of

the weight and create a dangero-

us, unstable condition.

(2) Inspect for proper ground clear-

ance and bank angle. An im-

properly mounted load could

critically reduce these two safe-

ty factors. Also determine that

the" load" does not interfere

with the operation of the sus-

pension, steering or other con-

trol operations.

(3) Accessories fitted to the handle-

bars or the front fork area can

create serious stability prob-

lems. This extra weight will

cause the motorcycle to be less

responsive to your steering con-

trol. The weight may also cause

oscillations in the front end and

lead to instability problems. Ac-

cessories added to the handle-

bars or front fork should be as

light as possible and kept to a

minimum.

(4) The motorcycle may be affected

by a lifting condition or by an

instability in cross winds or

when being passed or passing

large vehicles. Improperly moun

ted or poorly designed accesso-

ries can result in an unsafe rid-

ing condition, therefore caution

should be used when selecting

and installing all accessories.

(5) Certain accessories displace the

rider from his or her normal rid-

ing position. This limits the

freedom of movement 6f the rid-

er and may limit his or her con-

trol ability.

( 6) Additional electrical accessories

may overload the existing elec-

trical system. Severe overloads

may damage the wiring harness

or create a dangerous situation

due to the loss of electrical

power during the operation of

the motorcycle.

When carrying a load on the motor-

cycle. mount it as low as possible

and as close as possible to the ma-

chine. An improperly mounted load

can create a high center of gravity

which is very dangerous and makes

the motorcycle difficult to handle.

The size of the "load" can also affect

the aerodynamics and handling of

the motorcycle. Balance the load be-

tween the right and left side of the

motorcycle and fasten it securely.

MODIFICATION

Modification of the motorcycle. or

removal of original equipment may

render the motorcycle unsafe or ille-

gal.

SAFERIDINGRECOMMENDATION

FOR MOTORCYCLE RIDERS

Motorcycle riding is great fun and

an exciting sport. Motorcycle riding

also requires that some extra pre-

cautions be taken to ensure the safe-

ty of the rider and passenger.

These precautions are:

WEAR A HELMET

Motorcycle safety equipment starts

with a quality safety helmet. One of

the most serious injuries that can

happen is a head injury. ALWAYS

wear a properly approved helmet.

You should also wear suitable eye

protection.

RIDING APPAREL

Loose.fancy clothing can be uncom-

fortable and unsafe when riding your

motorcycle. Choose good quality

motorcycle riding apparel when rid-

ing your motorcycle.

INSPECTION BEFORE RIDING

Review thoroughly the instructions

in the INSPECTION BEFORE RID-

ING section of this manual. Do not

forget to perform an entire safety in-

spection to ensure the safety of the

rider and its passenger.

FAMILIARIZE YOURSELF WITH

THE MOTORCYCLE

Your riding skill and your mechani-

cal knowledge form the foundation

for safe riding practices. We suggest

that you practice riding your motor-

cycle in a non-traffic situation until

you are thoroughly familiar with

your machine and its controls. Re-

member practice makes perfect.

KNOW YOUR LIMITS

Ride within the boundaries of your

own skill at all times. Knowing

these limits and staying within them

will help you to avoid accidents.

BE EXTRA SAFETY CONSCIOUS

ON BAD WEATHER DAYS

Riding on bad weather days. espe-

cially wet ones. requires extra cau-

tion. Braking distances double on a

rainy day. Stay off the painted sur-

face marks. manhole covers and

greasy appearing areas as they can

be especially slippery. Use extreme

caution at railway crossings and on

metal gratings and bridges. Whenev-

er in doubt about road condition.

slow down!

SERIAL NUMBER LOCATION

The frame and/or engine serial

numbers are used to register the

motorcycle. They are also used to

assist your dealer when ordering

parts or referring to special service

information. The frame number <D is

stamped on the steering head tube.

The engine serial number (2) is

stamped on the left side of the

crankcase assembly.

Please write down the numbers in

the box provided below for your fu-

ture reference.

Frame number:

Engine number:

LOCATION OF PARTS

<DClutch lever

(IDCarburetor choke lever

<IDSpeedometer

@Fuelmeter

<IDTachometer

<IDFront brake fluid reservoir

<!>Front brake lever

<IDLeft hadlebarswitch

<IDIndicator light

@Fuel tank cap

@Ignition switch

@Right handlebar switch

@Throttle grip

III

I1I

I g

@Battery

@Fuse

@Tools

@Fuel cock

@Throttle stop screw

@Center stand

@Side stand

@Gear shift lever

@Passenger footrests

@Seat lock and Helmet holder

@Rear brake fluid reservoir

@Air cleaner

@Kick start lever

@Engine oil filler cap

@Rerar brake pedal

@Engine oil inspection window

~ Engine oil drain plug

@Engine oil filter

illI

CONTROLS

11'

KEY

1II11

1I11

SUJ<q~

"UIt~

This motorcycle comes equipped wi-

th a main ignition key and a spare

one. Keep the spare key in a safe

place.

I1II1

1111

The ignition keys are stamped with

an indentifying number. This num-

ber is used when making replace-

ment keys.

III

Please write your key number in the

box provided for your future refer-

ence.

I Keynumber: I

III

IGNITION SWITCH

The ignition switch has three posi-

tions:

"OFF" POSITION

I1I

All electrical circuits are cut off.

"ON" POSITION

The ignition circuit is completed and

the engine can now be started. The

key connot be removed from the ig-

nition switch in this position.

CAUTION

Start the engine promptly after

turning the ignition key to the"

ON"position. The reason for this

is that the headlight and taillight

comeon at the same time the igni-

tion is turned on and will cause

battery to losepower.

"LOCK"POSITION

To lock the steering, turn the han-

dlebar all the way to the left. Push

down and turn the key to the 11

. LOCK11 position and remove the

key. All electrical circuits are cut

off.

WARNING

. BeforeTurningthe ignition

switchto the

11LOCK" posi-

tion, stop the motorcycle and

place the motorcycle on th~

side stand or the center stand.

.Never attempt to move the mo-

torcycle when the steering is

locked, or you may lose bal-

ance.

INSTRUMENT PANEL

CD @ <ID

@ @ (l)@ @ @) @

SPEEDOMETERU)

The speedometer indicates the road

speed in kilometers per hour.

ODOMETER~

The odometer registers the total dis-

tance that the motorcycle has been

ridden.

FUEL METER<ID

Even if the ignition switch is cut

off, fuel meter still indicate the a-

mount of the fuel.

TACHOMETER@

the tachometer indicates the engine

speed in revolutions per minute (r/

min).

KNOB<ID

Turning counterclockwise will re-

turn the meter to zero.

TRIP METER<ID

The trip meter is a resettable odom-

eter located in the speedometer as-

sembly. It can be used to indicate the

distance traveled on short trips or

between fuel stops.

OIL PRESSURE INDICATOR

LlGHT!1>

With the ignition switch in the 11

ON11 position but the engine not

started, the oil pressure indicator

light should be lit

.As soon as the

engine is started ,the light should go

out.

CONTROLS

KEY

This motorcycle comes equipped wi-

th a main ignition key and a spare

one. Keep the spare key in a safe

place.

The ignition keys are stamped with

an indentifying number. This num-

ber is used when making replace-

ment keys.

Please write your key number in the

box provided for your future refer-

ence.

Key number:

IGNITION SWITCH

The ignition switch has three posi-

tions:

"OFF" POSmON

All electrical circuits are cut off.

"ON" POSmON

The ignition circuit is completed and

the engine can now be started. The

key connot be removed from the ig-

nition switch in this position.

CAUTION

Start the engine promptly after

turning the ignition key to the"

ON"position. The reason for this

is that the headlight and taillight

comeon at the same time the igni-

tion is turned on and will cause

battery to lose power.

"LOCK"POSITION

To lock the steering, turn the han-

dlebar all the way to the left. Push

down and turn the key to the"

LOCK" position and remove the

key. All electrical circuits are cut

off.

WARNING

. Before Turning the ignition

switchto the 11LOCK11 posi-

tion, stop the motorcycle and

place the motorcycle on the

side stand or the center stand.

.Never attempt to move the ID;0-

torcycle when the steering is

locked, or you may lose bal-

ance.

INSTRUMENT PANEL

@ @ CV@

SPEEDOMETERW

The speedometer indicates the road

speed in kilometers per hour.

ODOMETER(2)

The odometer registers the total dis-

tance that the motorcycle has been

ridden.

FUEL METER<ID

Even if the ignition switch is cut

off, fuel meter still indicate the a-

mount of the fuel.

TACHOMETER@

the tachometer indicat~s the engine

speed in revolutions per minute (r/

min).

KNOB<ID

. ,

Turning counterclockwise will 're-

turn the meter to zero.

TRIP METER@)

The trip meter is a resettable odom-

eter located hi the speedometer as-

sembly. It can be used to indicate the

distance traveled on short trips or

between fuel stops.

OIL PRESSURE INDICATOR

LlGHT<V

With the ignition switch in the

ON" position but the engine not

started, the oil pressure indicator

light should be lit .As soon as the

engine is started, the light should go

out.

,11

CAUTION

Whenever the oil pressure indica-

tor lights up, indicating no oiJ

pressure stop the engine immedi-

ately. First check the oil level and

determine if the proper amount of

oil is in the engine. If the light still

does not go out, then have your au-

thorized suzuki dealer inspect your

motorcycle to determine the diffi-

culty. Do not operate the motorcy-

cle when the light is lit as it may

causeserious damage to the inter-

nal parts of the engine or trans-

mission.

NEUTRAL INDICATOR LIGHT@

The green light will come on when

the transmission is in neutral. The

light will go out when you shift into

any gear other than neutral.

GEAR POSmON INDICATOR

LIGHT@

The numeral in the indicator shows

the gear position

TURN SIGNALINDICATORLIGHT

When the turn signals are being op-

erated either to the right or to the

left, the indicator will flash at the

same time.

NOTE: if tum signal light is not

operating properly due to bulb fila-

ment or circuit failure, the indicator

light flickers more quickly to notify

the rider of the existence of trouble.

IDGH BEAM INDICATOR LIGHT

The blue indicator light will be lit

when the headlight high beam is

turned on.

LEFT HANDLEBAR

DIMMER SWITCH<D

When the switch is in "HI"position,

the high beam will be lit. At the

same time that the high beam is lit,

the high beam indicator will also

light in the instrument panel. When

the switch is in" La" position, the

low beam will be lit.

TRUN SIGNAL LIGHT SWITCH(2)

Moving the switch to the" L" posi-

tion will flash the left turn signals.

Moving the switch to .the "R" posi-

tion will flash the right turn signals.

The indicator light will also. flash in-

termittendy. To cancel turn signal

operation, push the switch on.

WARNING

Always use the turn signals when

you intend to change lanes or

make a turn. Be sure to turn off

the turn signals after completing

the tum or lane change.

HORN SWITCH(ID

Press the switch to operate the

horn.

CLUTCH LEVER@)

The clutch lever is used to disengage

the drive to the rear wheel when

starting the engine or shifting the

transmission gear. Squeezing the le-

ver disengages the clutch.

RIGHT HANDLEBAR

ENGINE STOP SWITCH <D

The engine stop switch is located on

the top of the ;ight handleJ)~r grip

switch housing. This is a "rocker"

style switch which pivots in the cen-

ter. In the" RUN" position the igni-

tion circuit is on and.the engine will

operate. The switch is intended pri-

marilyasanemergencyswitch. When

the switch is in the" OFF" position

neither the starter motor nor the ig-

nition circuit will be energized.

ELECnIC STARTERBUTTON(2)

This button is used to turn the star-

ter motor. With the ignition switch

in the" ON" position, the transmis-

sion in neutral, and push the electric

starter button to engage the starter

motor and start the engine.

NOTE: This motorcycle is equipped

with interlock switches for the igni-

tion circuit and the starter circuit.

The engine can only be started if:

(1) The transmission is in neutral

and the clutch is disengaged,or

(2) The transmission is in gear the

side stand is fully up and the clutch

is disengaged.

CAUTION

Do not engage the starter motor

for more than flve seconds at a

time as it may overheat the wiring

harness and starter motor. If the

engine does not start after several

attempts, check the fuel supply

and Ignition systems. (Refer to the

"TROUBLESHOOTING"section)

FRONT BRAKE LEVER<ID

The front brake is applied by squee-

zing the brake lever gendy toward

the throttlegrip. This motorcycle is

equipped with disc brake system and

excessive pressure is not required to

slow the machine down properly.

The brake light will be lit when the

lever is squeezed inward.

THROTTLE GRIP@)

Engine speed is controlled by the

position of throttle grip. Twist it to-

ward you to increase engine speed.

Turn it away from you to decrease

the engine speed.

LIGHTING SWITCH<ID

The headlight and taillight turn on.

OFF

The headlight and taillight turn off.

FUEL TANK CAP

To open the fuel tank cap,insert the

ignition key into the lock and turn it

clockwise, with the key still held in

position, lift up with the key and

open the fuel tank cap. To replace

the fuel tank cap, push the cap down

firmly with the key in the cap lock.

<DFuellevel

(2)Fuel inlet

WARNING

8Do not overfill the fuel tank. A-

void spUIIngfuel on the hot en-

gine. Do not fill the fuel tank a-

bove the bottom of the fuellnJet

as shown In the Illustration or it

may overflow when the fuel

heats up later and expands.

.When refuellng,always shut the

engine off and tum the ignition

key to the" OFF"position.Never

refuel near an open flame.

FUELCOCK

This motorcycle is equipped with an

automatic type, diaphragm style fu-

elcock. There are three positions :

"ON, ""RESERVE"and"PRIME. "

"ON"POSmON

The normal position for the fuelcock

lever is in the "ON"position. In this

position, no fuel will flow from the

fuelcock to the carburetor unless the

engines is running or being started.

"RESERVE"POSITION

RES

If the fuel level in the tank is too

low, turn the lever to the" RE-

SERVE",position to use the reserve

fuel supply:4. 5L. In this position,no

fueJ will flow from the fuelcock to

the carbl,lretor unless the engine is

running or being started.

"PRIME" POSITION

PRI

If the motorcycle has run out of fuel

or has been stored for an extended

period, there may not be any gaso-

line in the carburetor. In this in-

stance the fuelcock lever should be

moved to tne "PRIME" position.

This will allow the- fuel to flow di-

rectly into the carburetor even

though the engine is not operating.

Upon starting. the engine, be sure to

return the lever to the "ON"position

or if necessary, to the "RESERVE"

position.

~II

CAUTION

Leaving the fuelcock in the

"PRIME" position may cause the

carburetor to overflow and fuel to

run into the engine. It is possible

that this may cause severe me-

chanical damage when the engine

is started.

NOTE:After switching the fuelcock

lever to the "RESERVE"position,it

is advisable that the tank be refilled

at the closest gas station. After refu-

eling, be sure to move the fuelcock

to the "ON"position.

CARBURETOR CHOKE LE-

VER

The carburetor of this mot<;>rcycles

is equipped with a ctloke system to

provide easy starting. When starting

a cold en~ine, turn the choke lever

toward you. Immediately after the

engine starts, return the choke lever

halfway and let the engine run until

the engine sufficiently warm up,

thereafter the choke lever back to its

normal disengaged position. The

choke system will operate only when

the throttle is in the closed position

as opening the throttle will bypass

the choke system. When the engine

is warm, the choke system does not

need to be used for starting.

GEARSHIFT LEVER

This motorcycle is equipped with a 6

speed constant mesh transmission

which operates as shown in the fig-

ure. The shift lever is attached to a

ratchet type mechanism in the trans-

mission. Each time that a gear is se-

lected, the gearshift lever will return

to its normal position ready to select

the next gear. Neutral is located be-

tween low and 2nd gear. Low gear is

engaged by depressing the lever

downward from the neutral posi-

tion. Shifting into the higher gears is

accomplished by lifting up on the

shift lever once for each gear. It is

not possible to upshift or downshift

more than one gear at a time due to

the ratchet mechanism being used.

When shifting from low to 2nd gear

or 2nd gear to low, neutral will be

automatically skipped. When neutral

is desired, depress or lift the lever to

a position halfway between low and

2nd gear.

CAUTION

When the transmission Is In neu-

tral the green Indicator light on

the instrument panel will be lit.

However,even though the light is

illuminated, cautiously release the

clutch lever slowly to determine

whether the transmission is posi-

tively in neutral.

Reduce the motorcycle speed before

down

- shifting. When down- shift-

ing, the engine speed should be in-

creased before the clutch is en-

gaged. This will prevent unnecessary

wear on the drive train components

and the rear tire.

REAR BRAKE PEDAL

Depressing the rear brake pedal will

apply the rear disc brake. The brake

light will be illuminated when the

rear brake is operated.

FRONT BRAKE LEVER AD-

JUSTMENT

The distance between the throttle

grip and the front brake lever is ad-

.justable in four positions. To change

the position, push the brake lever

forward and turn the !idjuster to the

desired position. When changing the

brake lever position, always be sure

the adjuster stops in the proper po-

sition; a projection of the brake lever

holder should fit into the depression

of the adjuster. This motorcycle de-

livered from the factory with its ad-

juster set on position 2.

WARNING

Never attempt to change the front

brake lever position while riding,

or you may loss control.

KICK STARTLEVER

The engine can also be started with

the kick start lever.

SEAT LOCK AND HELMET

HOLDER

To unlock the seat lock, insert the

ignition key into the lock and turn it

clockwise. To lock the seat, slide the

seat hook into the seat hook retainer

and push down firmly.

WARNING

.Do not operate the motorcycle

with a helmet fastened to the

helmet holder. The helmet may

be caught in the wheel causing

loss of control, or interfere with

the safe operation of the motor-

cycle.

.Make sure to properly position

and securely attach the seat

when you install it. Failure to

install the seat properly could

allow the seat to moveand cause

loss of rider control.

SIDE STAND

An interlock switch is provided to

cut off the ignition circuit when the

side stand is down and the transmis-

sion is in any gear other than neu-

tral.

The side stand/ignition interlock

switch works as follows:

(l)If the side stand is down and the

transmission is in gear. the en-

gine can not be started.

(2) If the engine is running and the

transmission is shifted into gear

with the side stand down. the

engine will stop running.

(3) If the engine is running and the

side stand is put down with the

transmission in gear, the engine

will stop turning.

WARNING

Be sure to check the side standi ig-

nition interlock switch for proper

operation before riding. according

to the instructions in the SIDE

STAND/IGNITION INTERLOCK

SWITCH section. If the switch is

not working and the side stand is

left down, it may interfere with

rider control during a left turn.

FUEL AND OIL

RECOMMENDATION

FUEL

Use unleaded gasoline with an oc-

tane rating of 91 or higher (Re-

search method). Unleaded gasoline

can extend spark plug life and ex-

haust components life.

If pinking or knocking is experi-

enced, substitute higher octane grade

gasoline or another brand. because

there are differences between brand.

ENGINE OIL

Using a premium quality four stroke

motor oil will increase the service

life of your motorcycle. Use only oils

which are rated SE or SD under the

API classification system. The vis-

cosity rating shoul~ be SAE 10W-

40. If an SAE IOW-40 motor oil is

not available select an alternative ac-

cording to the chart below.

BREAK - IN

The opening explains how important

proper break - in is to achieving

maximum life and performance from

your new Suzuki. The following

guidelines explain proper break

- in

procedures.

MAXIMUMENGI~E SPEED

RECOMMENDATION

This table shows the maximum rec-

ommended engine speed during tJ:e

break-in period.

VARY THE ENGINE SPEED

The engine speed should be varied

and not held at a constant speed.

This allows the parts to be "loaded"

with pressure. and then unloaded.

allowing the parts to cool. This aids

the mating process of the parts. It is

essential that some stress be placed

on the engine components during

breakin to ensure this mating

process. Do not, though, apply ex-

cessive load on the engine.

AVOID CONSTANT LOW SPEED

Operating the engine at constant low

speed (light load) can cause parts to

glaze and not seat in. Allow the en-

gine to accelerate freely through the

gears, without exceeding the recom-

mended maximum limits. Do not,

however, use full throttle for the

first 1600km .

ALLOW THE ENGINE OIL TO

CIRCULATE BEFORE RIDING

Allow suficient idling time after

warm or cold engine start up before

applying load or revving the engine.

This allows time for the lubricating

oil to reach all critical engine com-

ponents.

OBSERVE YOUR FIRST, AND

MOST CRITICAL,SERVECE

The 1000km service is the most im-

portant service your motorcycle will

receive. During breakin all of the en-

gine components will have worn in

and all of the other parts will have

seated in. All adjustments will be re-

stored, all fasteners will be tight-

ened. and the dirty oil and oil filter

will be replaced. Timely perform-

I I I

. .

oil

. .

, . I

I I I I

-10 -20-10 0 10 20 JO 40

-22.... 14 22 10 .. .. 104

Below

Initial 800 km

5000rpm

Below

Up to 1600km

8000rpm

Below

Overl600km

I 10000rpm

ance of the 1000 km service will en-

sure optimum service life and per-

formance from the engine.

CAUTION

The 1000 km service should be

performed as outlined in the IN-

SPECflON AND MAINTE-

NANCE section of this Owner' s

ManuaJ. Pay particular attention

to the CAUTIN and WARNING in

that section.

INSPECTION

FORE RIDING

BE-

Before riding the motorcycle. be sure

to check the following items. Never

underestimate the importance of

these checks. Perform all of them

before riding the motorcycle.

WHAT

CHECK

Steering

Throttle

Clutch

Brakes

Fuel

CHECKFOR,

1)Smoothness

2) No restriction 0

movement

3)No lay or looseness

1) Correct play in th

throttle cable

2) Smooth operatio

and positive return 0

the throttle grip to the

closed position

DCorrect play in the ca-

ble

2) Smooth and progres-

sive action

1)Fluid level in the res-

ervoir to be abov

"LOWER"line .

2) Correct pedal and le-

ver play

3)No"sponginess"

4)No fluid leakage

Enough fuel for th

planned distance of op-

eration

RIDING TIPS

WARNING

.H this is the first time that YOUI

have ridden a machine of this

type. we suggest that you practice

on a non

- public road to become

thoroughly familiar with the con-

trols and operation of the motor-

cycle.

.One - hand riding is extremely

dangerous.Keep both hands firm-

lyon the handlebars and both feet

securely on the footrests. Under no

circumstances should both hands

be removed from the handlebars.

.Do not down shift in the midst of

cornering. Slow down to a safe

speed before negotiating a corner.

.When the road surface is wet or

slushy.there Is a reduction in tire

traction. You should reduce speed

whenever these condltious exist as

braking and cornering abUity are

reduced.

.At side winds which may be expe-

rienced at the exists of tunnels.

when passing by the cut of a hUl.

or when being overtaken by largerl

vehicles, you should reduce speed

and ride aJertly.

.Obey the speed limit and traffic

regulations at aJl times.

HAT TO

CHECK FOR:

CHECK

1) Correct

tension or

Drive chain

slack

2)Adequate lubrication

1) Correct pressure

Tires

2)Adequate tread depth

3) No cracks or cuts

Engine oil

Correct level

Lighting

Operation of all lights

and indicators

Horn Correct function

t;ngme

stop

correct function

,.with

Side standi

ignition

Proper operation

interlock

switch

WARNING

Do not run the engine indoors

where there is little or no ventila-

tion available. Carbon monoxide

fumes are extremely poisonous.

Never leave the engine running

while unattended, even for a mo-

ment.

CAUTION

II1

Do not let the engine run too long

without riding, or will overheat

and may damage internal engine

components.

ENGINE STARTING

(1) Check that the fuelcock is in the

"ON" position and that the en-

gine stop switch is in the

"RUN" position.

(2) Insert the ignition key into the

ignition switch and turn it to the

"ON" position.

( 3) Set the transmission into neu-

tral.

NOTE, This motorcycle is equipped

with interlock switches for the igni-

tion circuit and the starter circuit.

The engine can only be started if,

(1) The transmission is in neutral, or

(2) The transmission is in gear and

the side stand is fully up.

When the engine is cold;

(1) Turn the carburetor choke lever

all the way toward you.

(2)Close the throttle grip and push

the electric starter switch.

( 3) Immediately after the engine

starts, return the choke lever

halfway and warm up the en-

gine.

(4) Return the choke lever all the

way back to its disengaged posi-

tion.

When the engine is warm:

(1) Open the throttle grip 1/8 - 1/

(2)Push the electric starter switch.

NOTE, Operation of the carburetor

choke system is not necessary when

the engine is warm.

STARTING OFF

Pull the clutch lever in and pause

momentarily. Engage first gear by

depressing the gear shift lever

downward. Twist the throttle grip

toward you and at the same time re-

lease the clutch lever gently and

smoothly. As the clutch engages, the

motorcycle will start moving for-

ward. To shift to the next higher

gear, accelerate gently, then close

the throttle and pull the clutch lever

in simultaneously. Lift the gear shift

lever upward to select the next

gear, release the clutch lever and

open the throttle again. Select the

gears in this manner until top gear is

reached.

WARNING

Before starting off, check that the

side stand is returned to its full up

position and is not hanging down.

USING THE TRANSMISSION

The transmission is provided to

keep the engine operating smoothly

in its normal operating speed range.

The gear rations have been carefully

chosen to meet the characteristics of

the engine. The rider should always

select the most suitable gear for the

prevailing conditions. Never slip the

clutch to control road speed, but

rather downshift to allow the engine

to run within its normal operational

range.

CAUTION

Never allow the engineto rev up to

red zone in the tachometer in any

gear.

RIDING ON HILLS

- When climbing steep hills, the

motorcycle may begin to slow

down and show lack of power. At

this point you should shift to a

lower gear so that the engine will

again be operating in its normal

power range. Shift rapidly to pre-

vent the motorcycle from losing

momentum.

- When descending a long, steep

slope, use engine compression to

assist the brakes by shifting to a

lower gear. Continuous brake ap-

plication can overheat the brakes

and reduce their effectiveness.

- Be careful, however, not to allow

the engine to over rev.

STOPPING AND PARKING

- Twist the throttle grip away

from yourself to close the throt-

tle completely.

- Apply the front and rear brakes

evenly and at the same time.

- Downshift through the gears as

road speed decreases.

- Select neutral with the clutch le-

ver squeezed toward the grip

(disengaged position) just before

the motorcycle stops. Neutral po-

sition can be confirmed by ob-

serving the neutral indicator

light.

NOTE, Inexperienced riders tend to

use the rear brake only. This can

lead to premature brake wear and

excessive stopping distances.

II1

Ilr

I11

WARNING

III

Ill/

Using only the front or rear brake

is dangerous and can cause skid-

ding and loss of control. Apply the

brakes lightly and with great care

on a wet highway pavement or

other slippery surfaces and at all

corners. Any abrupt braking on

slippery or irregular roads can

cause loss of rider control.

lifi

- When the motorcycle is to be

parked on the side stand on a

slight slope, the front end of the

motorcycle should face" up" the

incline to avoid rolling forward

of the side stand. You may leave

the motorcycle in 1st gear to

help prevent it from rolling off

the side stand. Return to neutral

before starting engine.

- Turn the ignition key to the"

OFF" position to stop the en-

gine.

- Lock the steerinig for security.

- Remove the ignition key from the

switch.

- Turn the fuelcock lever to the

"OFF"position.

WARNING

As motorcycle speed increases,

stopping distance increases pro-

gressively.Be sure you have a safe

stopping distance between you and

the vehicleor object ahead of you.

INSPECTION AND

MAINTENANCE

MAINTENANCE SCHEDULE

The chart indicates the intervals be-

tween periodic services in miles, kil-

ometers and months. At the end of

each interval, be sure to inspect,

check, lubricate and service as in-

structed. If your motorcycle is used

under high stress conditions such as

continuous full throttle operation, or

is operated in a dusty climate, cer-

tain services should be performed

more often to ensure reliability of

the machine as explained in the ma-

intenance section. Your Suzuki deal-

er can provide you with further

guidelines. Steering components,

suspensions and wheel components

are key items and require very spe-

cial and careful servicing. For maxi-

mum safety we suggest that you

have these items inspected and serv-

iced by your authorized Suzuki deal-

er or a qualified service mechanic.

WARNING

Proper break - in maintenance

(1000 km)is a MANDATORYi-

tem for making certain that your

motorcycle is reliable and gives

full performance at all times. Be

sure that this periodic mainte-

nance is performed thoroughly and

in accordancewith the instructions

in this manual.

CAUTION

Periodical inspections may reveal

one or more parts that may need

replacement. Whenever replacing

parts on your motorcycle,it is rec-

ommended that you use genuine

Suzuki replacement parts or their

equivalent. Whether you are an

expert or do - it - yourself me-

chanic, Suzuki recommends that

those items on the" MAINTE-

NANCE CHART"marked with an

asterisk (* ), be performed by

your authorized Suzuki dealer or

qualified service mechanic. You

may perform the unmarked items

easily by referring to the instruc-

tions in this section.

MAINTENANCE CHART

This interval should be judged by odometer reading or months, whichever

comes first.

NOTE, 1= Inspect and c1ean.adjust.replace or lubricate as necessary,

T= Tighten.R=Replace

.I'

TOOLS

To assist you in the performance of

periodic maintenance, a tool kit is

supplied and located behind the

seat.

FRAME COVER REMOVAL

The frame covers can be removed

when servicing your motorcycle. Re-

move the frame covers is the follow-

ing procedure:

( 1) Place the motorcycle on the cen-

ter stand or the side stand.

(2) Remove the seat.

(3) Remove the two screws and re-

move the connector of the tail

light.

(4) Unhook the six frame cover

hooks and expand to remove

the right and left frame covers.

screw

LUBRICATION POINTS

Proper lubrication is important for

smooth operation and long life of

each working part of your motorcy-

cle and also for safe riding. It is a

good practice to lubricate the motor-

cycle after a long rOl{ghride and af-

ter getting it wet in the rain or after

washing it. Major lubrication points

are indicated below.

<DClutch cable

@Clutch lever holder

CIDSidestand pivot and spring hook

@ Center stand pivot and spring

hook

<IDGear shift lever holder and foot-

rest pin

<IDDrivechain

<VThrottle cable

<IDFrontbrake lever holder

@Brake pedal pivot and footrest pin

11: Motor oil

tB:Grease

km 1000

6000

12000

18000 24000

Item

months

1 6

18 24

Battery

I I I

* Valve clearance

I I

* Spark plugs

I R

Air cleaner element

Clean every 3000 Km and

replace every 12000 km

Engine idle speed

I I I

I I

Fuel line

* Replace every 4 years

Clutch I

I I

Engine oil and oil filter

R R R

I I I

I I

Drive chain

Clean and lubncate

everv 1000km

* Brake

I I

Brakehose

I I

* Replace every 4 years

I I

Brake fluid

* Replace every 2 years

* Steering

I I

* Front forks

* Rear suspension

Tires

I I

* Cylinder head nuts and exhaust

pipe bolts

* Chassis bolts and nuts

@m @1!1 @1!1@(;]

(1)(;] @1!1

BATTERY

The battery is located under the

seat. The solution level must be kept

between the UPPER and LOWER

level lines at all times. If the solution

level is below the LOWER limit

line,add ONLY distilled water up to

the UPPER limit line. NEVER use

tap water.

CAUTION

. Once the battery has been ini-

tially serviced,NEVER add di-

luted sulphuric acid.

. Do not bend, obstruct or

change the routing of the air

vent tube from the battery.

Make certain that the vent

tube is firmly attached to the

battery vent fitting and that

the opposite end is always

open. Route the battery vent

tube and located the battery

properly.

. When attaching the wiring

harness battery leads to the

battery terminals, observe the

correct polarity. The red lead

must go to the (+) positive

terminal and the black Cor

black with white tracer) lead

must go to the (-) negative

terminal. Reversingthese con-

nections will damage the char-

gingsystemandthe battery. .

NOTE: Initial 1000 km and every

5000 km have your dealer check the

specific gravity of the battery's cells

with a battery hydrometer. This will

determine the exact condition of each

of the six cells.

AIR CLEANER

The air cleaner is located under the

fuel tank. If the element has become

clogged with dust, intake resistance

will increase with a resultant de-

crease in output and an increase in

fuel consumption. Check and clean

the air cleaner element periodically

according to the following proce-

dure.

CAUTION

If driving under dusty conditions,

the air cleaner element must be

cleaned or replaced more fre-

quently than it is with periodic

maintenance.

(1) Remove the seat and frame cov-

ers.

(2) Remove the BATTERY.

(3) Loosen the four bolts and re-

move the air cleaner element.

screw

WARNING

After reinstalling the fuel tank.

make sure that the fuel tank is

correctly positioned. If the fuel

tank is not installed properly. it

may come looseand interfere with

the rider's control.

CAUTION

Take care not to damage the fuel

tank hoses when raising the fuel

tank.

Cleaning the Element

(1) Carefully use an air hose to blow

the dust from the air cleaner ele-

ment.

CAUTION

Always apply air pressure to the

outside of the air cleaner element

only. If air pressure is used on the

inside. dirt will be forced into the

pores of the cleaner element re-

stricting the air flow through the

cleaner element.

(2) Reinstall the cleaned element or

new air cleaner element in re-

verse order of removal. Be abso-

lutely sure that the element is

securely in position and is seal-

ing properly. Replace the air

cleaner element with a new one

every 1200 km.

CAUTION

Before and during the cleaning op-

eration. carefully examine the ele-

ment for any tears in the materi-

al. A torn element must be re-

placed with a new noe.

CAUTION

. If driving under dusty condi-

tions. the air cleaner element

must be cleaned or replaced

more frequently than it is with

periodic maintenance.

.Never operate the engine with-

out the element in position.

Operating the engine without

the air cleaner element will in-

crease engine wear. Always be

sure that the air cleaner ele-

ment is in excellentoperational

condition. The life of the en-

gine depends largely on this

single component.

SPARK PLUGS

Remove the carbon deposits periodi-

cally from the spark plug with a

piece of hard wire or pin. Readjust

the spark plug gap to O.6-0. 7 mm

by using a spark plug gap thickness

gauge.

,';---'

I/; .

Whenever removing the carbon de-

posits. be sure to observe the opera-

tional color of each spark plug' s

porcelain tip. This color tells you

whether or not the standard spark

plug is suitable for your type of us-

age. A normal operating spark plug

should be very light brown in color.

If the spark plug is very white or

glazed appearing. it has been operat-

ing much too hot. This spark plug

should be replaced with the colder

plug.

Plug replacement guide

REMARKS

If thestandardplug

isaptto wet.replace

withthisplug.

Standard

If the standardplug

is very white or

glazedin appearance

replace with this

plug.

CAUTION

.Do not overtorque or cross

thread the spark plugs or the

aluminum threads of the cyl-

inder head will be damaged.

Do not allow contaminants to

enter the engine through the

spark plug holes when the

plugs are removed.

.The standard spark plug for

this motorcycle has been care-

fully selected to meet the vast

majority of all operational

ranges.If the spark plug color

indicates that other than a

standard spark plug be used,it

is best to consult your Suzuki

dealer before selecting an al-

ternate plug or heat range.The

selection of an improper spark

plug can lead to sever engine

damage.

FUEL LINE

Replace the fuel lines every 4 years.

fuel line

ENGINE OIL

Long engine life depends much on

the selection of a quality oil and the

. periodic changing of the oil. Daily oil

level checks and periodic changes are

two of the most important mainte-

nance to be performed.

ENGINE OIL LEVEL CHECK

Follow the procedure below to in-

spect the engine oil level

Cl) Start the engine and run it for a

few minutes.

(2)Stop the engine and wait one mi-

nute.

(3) Keep the motorcycle vertical and

inspect the engine oil. level

through the engine oil level in-

spection window.

CAUTION

Never !lperate the motorcycle if

the ~ngin~oil level is below the"

L" (Iow)line. Never fill the engine I,

oil level above the" F" (fuIlHine.

ENGINE OIL AND OIL FILTER

REPLACE.

(1) Place the motorcycle on the cen-

ter stand.

(2) Remove the oil filler cap CD.

(3) After removing the drain plug

~ from the bottom of the en-

gine,drain the engine oil.

WARNING

. The engineoil temperature may

be high enough to bum you

when the drain plug is loos-

ened. Wait until the drain plug

is cool enough to touch with

bare hand.

.Be careful not to touch the ex-

haust pipe when it is hot;a hot

exhaust pipe can burn you.

CAUTION

When reassembling the oil filter,

make sure to check the oil filter

installed as shown above. The fil-

ter installed with a wrong way will

cause the serious engine damage.

(4)Loosen the oil filterQ)with suit-

able or suzuki special tool.

(5) Clean the engine and the surface

@ of the new oil filter with

cleaning cloth.

(6) Apply the oil to the new oil fil-

ter rubber washer(5).

(7) Tighter the new oil filter until

the filter rubber washer close to

the install surface closely.

NGK

NIPPON

DENSO

CR7EAU22ESR-U

CR8EAU24ESR-N

CR9EA U27ESR-N

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Suzuki GSX25 Owner's manual

Suzuki GSX25 Owner's manual

Suzuki GSX25 Owner's manual

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