SUZUKI Bandit250 GSF250.Service Data

SUZUKI Bandit250 (GSF250) GJ74A SERVICEDATABandit Maintenance MENU(Japanese) >SERVICE DATA

SPECIFICATIONS & DATA / SERVICE DATA

INDEX

The following data is the one of "GSF250/45H.P/Separate handle type" as long as there is especiallyno annotation.

VALVE + GUIDECAMSHAFT + CYLINDER HEADCYLINDER + PISTON + PISTON RINGCONROD + CRANKSHAFTOIL PUMPCLUTCHTRANSMISSION + DRIVE CHAINCARBURETORELECTRICALWATTAGEBRAKE + WHEELTIRE PRESSURESUSPENTIONFUEL + OILTHERMOSTAT + RADIATOR + COOLANT

VALVE + GUIDE

ITEM STANDARD LIMIT 40H.P. STANDARD LIMIT

Valve diam.IN. 18.9-19.1 mm * = =EX. 15.9-16.1 mm * = =

Valve LiftIN. 6.8 mm * IN. 6.0 mm *EX. 6.2 mm * EX. 5.5 mm *

Valve clearance(when cold)IN. 0.17-0.27 mm * = =EX. 0.20-0.30 mm * = =

Valve stem deflection IN. & EX.* 0.35 mm = =Valve guide I.D. IN. & EX. 3.700-3.712 mm * = =Valve stem O.D. IN. 3.66-3.68 mm * = =

SUZUKI Bandit250 (GSF250) GJ74A SERVICE DATA http://www1.synapse.ne.jp/s-hara/bandit/ban-sdatae.html

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EX. 3.65-3.66 mm * = =Valve stem runout IN. & EX. * 0.05 mm = =

Valve seat widthIN. 0.7-1.1 mm * = =EX. 0.9-1.3 mm * = =

Valve head radial runout IN. & EX. * 0.03 mm = =Valve spring free length IN. & EX. 39.64 mm 38.1 mm = =

Valve spring tension IN. & EX. 37.2 kg(at length 27.9 mm) * = =

[RETURN INDEX]

CAMSHAFT + CYLINDER HEAD

ITEM STANDARD LIMIT 40H.P.STANDARD LIMIT

Cam heightIN. 32.77-32.83 mm 32.47

mm IN. 32.27-32.33 mm 31.97mm

EX. 32.17-32.23 mm 31.87mm

EX. 31.77-31.83mm

31.47mm

Camshaft journal oilclearance IN. & EX. 0.032-0.066 mm 0.15 mm = =

Camshaft journal holder I.D. IN. & EX. 22.012-22.025mm * = =

Camshaft journal O.D. IN. & EX. 21.959-21.98 mm * = =Camshaft runout IN. & EX. 0-0.02 mm 0.10 mm = =Camshaft 20-pitch length (NO DATA) * = =Cam chain pin 16th pin * = =Cylinder head distortion 0-0.05 mm 0.20 mm = =

[RETURN INDEX]

CYLINDER + PISTON + PISTON RING

ITEM STANDARD LIMITCompression pressure 11.5-13.5 kg/cm2(450r/min.) 8.05 kg/cm2

Compression pressure difference * 2 kg/cm2

Piston to cylinder clearance 0.04-0.06 mm 0.12 mmCylinder bore 49.0-49.015 mm 49.09 mm

Piston diam. 48.955-48.97 mm(Measures on 10 mm from the bottom end of a piston.) 48.88 mm

Cylinder distortion * 0.2 mmPiston ring free end gap 1st. R Approx. 7.0 mm 5.6 mm


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2nd. RN Approx. 5.2 mm 4.16 mm

Piston ring end gap1st. 0.1-0.25 mm 0.7 mm2nd. 0.25-0.45 mm 0.7 mm

Piston ring to groove clearance1st. * 0.18 mm2nd. * 0.15 mm

Piston ring groove width1st. & 2nd. 0.81-0.83 mm *Oil 2.01-2.03 mm *

Piston ring thickness 1st. & 2nd. 0.77-0.79 mm *Piston pin bore 14.002-14.008 mm 14.035 mmPiston pin O.D. 13.995-14.0 mm 13.98 mm

[RETURN INDEX]

CONROD + CRANKSHAFT

ITEM STANDARD LIMITConrod small end I.D. 14.01-14.018 mm 14.054 mmConrod big end side clearance 0.1-0.2 mm 0.3 mmConrod big end width 15.9-16.0 mm *Crank pin width 16.1-16.15 mm *Conrod big end oil clearance 0.024-0.048 mm *Crank pin O.D. 26.976-27.0 mm *Crankshaft journal oil clearance 0.020-0.044 mm *Crankshaft journal O.D. 27.976-28.0 mm *

Crankshaft thrust bearing thicknessRight side 2.425-2.45 mm(green) *Left side 2.420-2.575 mm *

Crankshaft thrust clearance 0.045-0.1 mm *Crankshaft runout * 0.08 mm

[RETURN INDEX]

OIL PUMP

ITEM STANDARD LIMIT

Oil pump reduction ratio 2.878(34T/27T x 80T/35T) *

Oil pressure (at 60 degree Centigrade) Above 2.0 kg/cm2

(at 3,000r/min.)*

[RETURN INDEX]


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CLUTCH

ITEM STANDARD LIMITClutch cable play 10-15 mm *Drive plate (No.1) thickness 2.9-3.1 mm 2.6 mmDriven plate distortion 0-0.1 mm 0.2 mmClutch spring free length 38.2 mm 36.29 mmPrimary backlash 0.02 mm *

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TRANSMISSION + DRIVE CHAIN

ITEM STANDARD LIMIT 40H.P.STANDARD LIMIT

Primary reduction ratio 2.285 * = =Final reduction ratio 3.769 * = =

Gear ratios

1st 3.083 * = =2nd 2.200 * = =3rd 1.722 * = =4th 1.450 * = =5th 1.315 * 1.285 *6th 1.227 * 1.150 *

Shift fork to grooveclearance No.1,No.2 0.1-0.3 mm 0.5 mm = =

Shift fork to groove width No.1 x 2 & No.2 5.0-5.1 mm * = =Shift fork thickness No.1 x 2 & No.2 4.8-4.9 mm * = =

Drive chain

Type D.I.D 520V7 / RK520SMOZ9 * = =

Links 116 * = =

20-pitch length 317.5 mm 319.4mm = =

Drive chain slack 25-35 mm * = =Gear shift lever height 40-50 mm * = =

[RETURN INDEX]

CARBURETOR

ITEM SPECIFICATION 40 H.P. SPECIFICATIONCarburetor type BDST30 =


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Bore size 30 mm =I.D. No 11D0 11D1Idle r/min. 1,600r/min. =Float height (NO DATA) 8.06 mmMain jet (M.J.) #105 =Main air jet (M.A.J.) 0.7 =Jet needle (J.N.) 5CF9-3 5CF9-2Needle jet (N.J.) 0-1 =Pilot jet (P.J.)Exp.1 #15 #12.5By-pass (B.P.) #1:0.8 #2:0.7 #3:0.8 #4:0.8 =Pilot outlet (P.O.) 0.7 mm =Valve seat (V.S.) 1.7 mm =Starter jet (G.S.) #40 =Pilot screw (P.S.) Approx 1 returning =Pilot air jet (P.A.J.)Exp.1 1.3 mm 1.35 mmThrottle cable play 2-4 mm =

Exp.1 GSF250ZM(45H.P.) is Pilot jet and Pilot air jet are proportionate to 40H.P. model.

[RETURN INDEX]

ELECTRICAL

ITEM SPECIFICATION NOTEIgnition timing 20 degree/1,800 r/min. BTDC *Firing order 1-2-4-3 *

Spark plugType NGK CR8E / ND U24ESR-N *Gap 0.7-0.8 mm *

Spark performance Over 8 mm at 1 atm *Signal coil resistance 269-404 ohm Tester range: X10 ohm

Ignition coilresistance

Primary 2.5-3.8 ohm (tap to tap) Tester range: X1 ohmSecondary 13-18 kilo-ohm (wire to wire. Plug capremoved)

Tester range: X1kilo-ohm

Regurator voltage 13-16 V(5,000 r/min.) *

Starter motorBrush length Limit: 3.5 mm *Commutator under-cut Limit: 0.5 mm *

Starter relayresistance 3.5-5.0 ohm Tester range: X1 ohm

BatteryType designation YTX7A-BS *Capacity 12 V / 6 Ah (10 HR) *Standard electrolyte S.G. 1.32(20 degree centigrade) *


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Fuse size

Headlight 10A *Signal 10A *Ignition 10A *Main 25A *

[RETURN INDEX]

WATTAGE

ITEM SPECIFICATION GSF250ZM/ZPSPECIFICATION

HeadlightHi 60w =Lo 55w =

position and parking light(Exept 45H.P.models) 4w =

Tail/Brake light 5w/21w =Turn signal light 15w =Speedometer light 1.7w x 2pcs 3wTachometer light 1.7w x 2pcs 3wWater temp meter light NOTHING 1.7wTurn signal indicator light 3.4w 2wHigh beam indicator light 1.7w 2wNeutral indicator light 3w 2wOil pressure indicator light 3.4w 2wWater temp. check light 3.4w NOTHING

[RETURN INDEX]

BRAKE + WHEEL

ITEM STANDARD LIMITRear brake pedal height 40-50 mm *Front brake lever play 5-20 mm *Front brake lever adjuster "2" *Rear brake pedal play 5-15 mm *

Brake disc thicknessFront 4.5 mm(0.2 mm of plus or minus) 4.0 mmRear 6.0 mm(0.2 mm of plus or minus) 5.5 mm

Brake disc runout (Rear) * 0.30 mmMaster cylinder bore Front & Rear 12.700-12.743 mm *Master cylinder piston diam. Front & Rear 12.657-12.684 mm *Brake caliper cylinder bore Front: small 27.00-27.076 mm *


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Front: large 33.96-34.036 mm *Rear 38.18-38.256 mm *

Brake caliper piston diam.Front: small 26.02-26.97 mm *Front: large 33.884-33.934 mm *Rear 38.098-38.148 mm *

Wheel rim runout Front & Rear : Axial/Radial * 3.0 mmWheel axle runout Front & Rear * 0.25 mm

Tire sizeFront 110/70-17 54H *Rear 140/70-17 66H *

Tire typeFront DUNLOP K505F *Rear DUNLOP K505 *

Tire tread depthFront * 1.6 mmRear * 2.0 mm

[RETURN INDEX]

TIRE PRESSURE

COLD INFLATIONTIRE PRESSURE SOLO RIDING DUAL RIDING SOLO(HIGHWAY) DUAL(HIGHWAY)

Front 2.00 kg/cm2 2.00 kg/cm2 2.00 kg/cm2 (NO DATA)

Rear 2.25 kg/cm2 2.50 kg/cm2 2.25 kg/cm2 (NO DATA)

[RETURN INDEX]

SUSPENTION

ITEM STANDARD LIMIT GSF250N/NP/NR(PIPE HANDLE) LIMIT GSF250ZP LIMIT

Front fork stroke 120 mm * = = = =Front fork spring freelength 315 mm 302 mm 315 mm 298

mm 285.5 mm 275.1mm

Front fork oil level 84 mm * 82 mm * 103 mm *Front fork oil type Fork oil #10 * = = = =Front fork oil capacity 570 ml * 516 ml * 550 ml *Front fork inner tubediam. 41 mm * = = = =

Front fork outer tube bore 42 mm * = = = =Rear shock absober springadjuster 4/7 * = = = =

Rear wheel travel 131 mm * = = = =


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Swing arm pivot shaftrunout * 0.25

mm = = = =

[RETURN INDEX]

FUEL + OIL

ITEM SPECIFICATION

Fuel type Gasoline used should be graded 85-95 octane or higher. An unleaded gasolineis recommended.

Fuel tank includingreserve

14LReserve Approx. 3.5L

Engine oil type SAE 10W/40, API SE or SF

Engine oil capacityChange 2,700 mlFilter change 3,000 mlOverhaul 3,400 ml

[RETURN INDEX]

THERMOSTAT + RADIATOR + COOLANT

ITEM SPECIFICATION

Thermostat valveOpening temperature 74.5-78.5 degree CentigradeLift Over 7 mm(90 degree Centigrade)

Radiator cap valve openingpressure 0.95-1.25 kg/cm2

Cooling fan thermo-switchoperating temperature

ON:Approx. 102-108 degree CentigradeOFF:Approx. 97-103 degree Centigrade

Water thermo-switch operatingtemperature

ON:Approx. 117-123 degree CentigradeOFF:Approx. 110-116 degree Centigrade

Coolant includingReserve tank 150-250 mlEngine 1,700 ml

Coolant type Use an anti-freeze/coolant compatible with aluminiun radiator,mixedwith distilled water only, at the ratio of 50:50.

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It quotes from-SUZUKI Bandit250 Service guide book(1989)SUZUKI Bandit250 Owner's manual(1990 Separate handle type)

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Create: November 01, 2004 / Update: December 17, 2005Copyright (C) shun 2004-2005 Sunnyside feelin'


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SUZUKI Bandit250 GSF250.Service Data

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