Bandit250 LIMITED (1991)
INDEX
The following data is the one of "GSF250/45H.P/Separate handle type" as long as there is especially no annotation.
VALVE + GUIDE
| ITEM |
45H.P. STANDARD |
LIMIT |
40H.P. STANDARD |
LIMIT |
| Valve diam. |
IN. 18.9-19.1 mm | * | <- | <- |
| EX. 15.9-16.1 mm | * | <- | <- |
| Valve Lift |
IN. 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 | * | <- | <- |
| EX. 3.65-3.66 mm | * | <- | <- |
| Valve stem runout |
IN. & EX. * | 0.05 mm | <- | <- |
| Valve seat width |
IN. 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 |
45H.P. STANDARD |
LIMIT |
40H.P. STANDARD |
LIMIT |
| Cam height |
IN. 32.77-32.83 mm | 32.47 mm | IN. 32.27-32.33 mm | 31.97 mm |
| EX. 32.17-32.23 mm | 31.87 mm | EX. 31.77-31.83 mm | 31.47 mm |
| Camshaft journal oil clearance |
IN. & EX. 0.032-0.066 mm | 0.15 mm | <- | <- |
| Camshaft journal holder I.D. |
IN. & EX. 22.012-22.025 mm | * | <- | <- |
| 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 |
LIMIT |
| Compression 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 mm |
| Cylinder 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 mm |
| Piston ring free end gap |
1st. R Approx. 7.0 mm | 5.6 mm |
| 2nd. RN Approx. 5.2 mm | 4.16 mm |
| Piston ring end gap |
1st. 0.1-0.25 mm | 0.7 mm |
| 2nd. 0.25-0.45 mm | 0.7 mm |
| Piston ring to groove clearance |
1st. * | 0.18 mm |
| 2nd. * | 0.15 mm |
| Piston ring groove width |
1st. & 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 mm |
| Piston pin O.D. |
13.995-14.0 mm | 13.98 mm |
[RETURN INDEX]
CONROD + CRANKSHAFT
| ITEM |
STANDARD |
LIMIT |
| Conrod small end I.D. |
14.01-14.018 mm | 14.054 mm |
| Conrod big end side clearance |
0.1-0.2 mm | 0.3 mm |
| Conrod 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 thickness |
Right 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]
CLUTCH
| ITEM |
STANDARD |
LIMIT |
| Clutch cable play |
10-15 mm | * |
| Drive plate (No.1) thickness |
2.9-3.1 mm | 2.6 mm |
| Driven plate distortion |
0-0.1 mm | 0.2 mm |
| Clutch spring free length |
38.2 mm | 36.29 mm |
| Primary backlash |
0.02 mm | * |
[RETURN INDEX]
TRANSMISSION + DRIVE CHAIN
| ITEM |
45H.P. 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 groove clearance |
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 / RK 520SMOZ9 | * | <- | <- |
| Links 116 | * | <- | <- |
| 20-pitch length 317.5 mm | 319.4 mm | <- | <- |
| Drive chain slack |
25-35 mm | * | <- | <- |
| Gear shift lever height |
40-50 mm | * | <- | <- |
[RETURN INDEX]
CARBURETOR
| ITEM |
45H.P. SPECIFICATION |
40H.P. SPECIFICATION |
| Carburetor type |
BDST30 | <- |
| Bore size |
30 mm | <- |
| I.D. No |
11D0 | 11D1 |
| Idle r/min. |
1,600r/min. | <- |
| Float height |
(NO DATA) | 8.06 mm |
| Main jet (M.J.) |
#105 | <- |
| Main air jet (M.A.J.) |
0.7 | <- |
| Jet needle (J.N.) |
5CF9-3 | 5CF9-2 |
| Needle jet (N.J.) |
0-1 | <- |
| Pilot jet (P.J.)Exp.1 |
#15 | #12.5 |
| By-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 mm |
| Throttle 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 |
NOTE |
| Ignition timing |
20 degree/1,800 r/min. BTDC | * |
| Firing order |
1-2-4-3 | * |
| Spark plug |
Type 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 coil resistance |
Primary 2.5-3.8 ohm (tap to tap) | Tester range: X1 ohm |
| Secondary 13-18 kilo-ohm (wire to wire. Plug cap removed) | Tester range: X1 kilo-ohm |
| Regurator voltage |
13-16 V(5,000 r/min.) | * |
| Starter motor |
Brush length Limit: 3.5 mm | * |
| Commutator under-cut Limit: 0.5 mm | * |
| Starter relay resistance |
3.5-5.0 ohm | Tester range: X1 ohm |
| Battery |
Type designation YTX7A-BS | * |
| Capacity 12 V / 6 Ah (10 HR) | * |
| Standard electrolyte S.G. 1.32(20 degree centigrade) | * |
| Fuse size |
Headlight 10A | * |
| Signal 10A | * |
| Ignition 10A | * |
| Main 25A | * |
[RETURN INDEX]
WATTAGE
| ITEM |
SPECIFICATION |
GSF250ZM/ZP SPECIFICATION |
| Headlight |
Hi 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 | 3w |
| Tachometer light |
1.7w x 2pcs | 3w |
| Water temp meter light |
NOTHING | 1.7w |
| Turn signal indicator light |
3.4w | 2w |
| High beam indicator light |
1.7w | 2w |
| Neutral indicator light |
3w | 2w |
| Oil pressure indicator light |
3.4w | 2w |
| Water temp. check light |
3.4w | NOTHING |
[RETURN INDEX]
BRAKE + WHEEL
| ITEM |
STANDARD |
LIMIT |
| Rear 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 thickness |
Front 4.5 mm(0.2 mm of plus or minus) | 4.0 mm |
| Rear 6.0 mm(0.2 mm of plus or minus) | 5.5 mm |
| Brake disc runout (Rear) |
* | 0.30 mm |
| Master 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 | * |
| 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 mm |
| Wheel axle runout |
Front & Rear * | 0.25 mm |
| Tire size |
Front 110/70-17 54H | * |
| Rear 140/70-17 66H | * |
| Tire type |
Front DUNLOP K505F | * |
| Rear DUNLOP K505 | * |
| Tire tread depth |
Front * | 1.6 mm |
| Rear * | 2.0 mm |
[RETURN INDEX]
TIRE PRESSURE
COLD INFLATION
TIRE 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 free length |
315 mm | 302 mm | 315 mm | 298 mm | 285.5 mm | 275.1 mm |
| 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 tube diam. |
41 mm | * | <- | <- | <- | <- |
| Front fork outer tube bore |
42 mm | * | <- | <- | <- | <- |
| Rear shock absober spring adjuster |
4/7 | * | <- | <- | <- | <- |
| Rear wheel travel |
131 mm | * | <- | <- | <- | <- |
| Swing arm pivot shaft runout |
* | 0.25 mm | <- | <- | <- | <- |
[RETURN INDEX]
FUEL + OIL
| ITEM |
SPECIFICATION |
| Fuel type |
Gasoline used should be graded 85-95 octane or higher. An unleaded gasoline is recommended. |
| Fuel tank including reserve |
14L |
| Reserve Approx. 3.5L |
| Engine oil type |
SAE 10W/40, API SE or SF |
| Engine oil capacity |
Change 2,700 ml |
| Filter change 3,000 ml |
| Overhaul 3,400 ml |
[RETURN INDEX]
THERMOSTAT + RADIATOR + COOLANT
| ITEM |
SPECIFICATION |
| Thermostat valve |
Opening temperature 74.5-78.5 degree Centigrade |
| Lift Over 7 mm(90 degree Centigrade) |
| Radiator cap valve opening pressure |
0.95-1.25 kg/cm2 |
| Cooling fan thermo-switch operating temperature |
ON:Approx. 102-108 degree Centigrade |
| OFF:Approx. 97-103 degree Centigrade |
| Water thermo-switch operating temperature |
ON:Approx. 117-123 degree Centigrade |
| OFF:Approx. 110-116 degree Centigrade |
| Coolant including |
Reserve tank 150-250 ml |
| Engine 1,700 ml |
| Coolant type |
Use an anti-freeze/coolant compatible with aluminiun radiator,mixed with distilled water only, at the ratio of 50:50. |
[RETURN INDEX]
It quotes from-
SUZUKI Bandit250 Service guide book(1989)
SUZUKI Bandit250 Owner's manual(1990 Separate handle type)
