20 Most Recent 2003 Suzuki GZ 250 Marauder Questions & Answers


Hi, Ryan if you have a dash or instrument light that is out and you have confirmed that the bulb is good then you need to do some quick diagnostics all you need is a test light and a wiring diagram usually found in the back of your service or owners manual.
1. Make sure your battery is fully charged with "CLEAN" and "TIGHT" connections and the instrument light fuse is not blown.
2. Inspect the bulb socket for corrosion and clean as necessary, a spray can of electrical contact cleaner and compressed air works the best.
3. Confirm your test light is working properly by connecting one end to the battery negative post and touching battery positive post with the sharp probe, the test light should illuminate.
4. With the ignition turned on to confirm you have power to the bulb socket by connecting your test light to battery negative or ground and probe the center contact, the test light should illuminate if not you need to check the integrity of the switch or sending unit the light represents, if that is ok then you have a short in the wiring between the component and the light bulb, if all is ok proceed to the next step.
5. Confirm you have a good ground to the light bulb socket by connecting the test light to battery positive and probe any metal part of the socket housing, the test light should illuminate, if not you need to find the short and repair as necessary.
6. Inspect the integrity of the spring loaded positive contact insulation tab by pushing against it with your test light to see if it goes down and springs back fully to it's operating position again contact cleaner and compressed air works best to restore proper function.
7. If your bike has a lot of mileage the vibration can cause bulbs to become loose in the socket by wearing down the soldered contact thus losing spring pressure from the tab and eventually stop making contact this can be fixed by replacing the bulb or putting a drop of solder on the worn out end to ensure contact.
8. If all of your dash lights are out but are good then you most likely have a faulty connection to the dash wiring harness, inspect the connector for corroded, broken, or loose pins/sockets.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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2003 Suzuki GZ... | Answered on Apr 27, 2019


Hi, Anonymous for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your Suzuki, despair not, for a mere zero $0 you can download another one.
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2003 Suzuki GZ... | Answered on Apr 17, 2019


Hi, Anonymous engine "BOG" is mainly caused by a rich air and lean fuel condition but it can also be caused by a lean air and rich fuel condition this situation rarely occurs and is only caused by the misinformed weekend warrior that owns a toolbox. If the bike has been sitting for months or years you will have to completely disassemble the carburetor and submerge the parts (except rubber parts) in "Carburetor Dip" It usually comes in a gallon bucket with a wire mesh basket that can be purchased at any automotive store. If it is not the above scenario then the following explanation will apply.
The more you open your throttle the more vacuum you are creating in your carburetor venturi and your intake manifold. When you are operating at higher RPM any unmetered air that leaks into your system can become more obvious.
Unmetered air is air that is getting into your system after the fuel has been delivered. If you have unmetered air getting into your system between the butterfly/slide of the carburetor and the cylinder head this will create a lean condition.
All of the rubber components of the fuel system like vacuum hoses and intake manifold that you mount the carburetor to are made of rubber. If none of these components have been changed they are more than likely highly degraded and probably cracked in places to allow unwanted-unmetered-contaminated air into the combustion chamber. Check all of your vacuum lines and vacuum plugs for carburetor synchronization. The vacuum plugs are in the head just after the rubber intake manifolds. The petcock has a vacuum line as well as part of the emission system.
1. Check the intake manifold for fissures.
2. Ensure the bands used to tighten the manifolds down on the intake are secure and have not bound up the manifold.
3. Make sure air box fittings are not warped and fit completely over the carburetor.
Your airbox is metering air and is the first step in the process of consuming air and fuel. The system requires the resistance of the air filter in order to get the proper vacuum to "SUCK" the fuel out of the float bowl and create the proper venturi effect.
Improper mounting and sealing of the airbox will create a small lean effect. This might seem like no big deal but you are inviting dust and debris in your engine that is doing slow damage by not having proper fitment. Fix it so you know it's not contributing to your issue. Pick the low-hanging fruit first.
Do not go and start adjusting anything at this point. It ran fine before. There is something wrong with the assembly or a component. Do not adjust your floats. Get it back to where it was. The moment you start tweaking everything is the moment you lose OEM settings which are a must-have for fine-tuning and maximum performance.
Fine-tuning your carburetor and multi carb syncing come at the very end following the proper procedure established by the Carburetor Gods.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.youtube.com/watch?v=p22QZSCDDLw
How to diagnose carburetor vacuum leaks on your motorcycle Suzuki GZ250 Service Manual
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2003 Suzuki GZ... | Answered on Apr 13, 2019


Hi, Kendall and the usual suspects are:
1. Fuel tank empty.
2. The fuel tank has old dead gas.
3. Fuel tank bottom contaminated with ethanol sludge, dirt, water, rust, etc.
4. Fuel supply valve/petcock turned off.
5. Fouled spark plugs.
6. Engine flooded as a result of overuse of the choke.
7. Vacuum hose to the fuel supply valve/petcock disconnected, broken, cracked, or pinched.
8. Fuel valve/petcock or filter clogged.
9. Fuel line to carburetor or throttle body pinched, kinked or blocked.
10. Carburetor float stuck.
11. Fuel injectors clogged.
12. Fuel injectors stuck open.
13. Quick disconnect check ball stuck.
14. Compression below 75 PSI.
15. A stuck-bent-burnt valve.
16. Improper valve clearance (too tight)
17. Severely discharged or a damaged battery should have 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a cursory reading of 12.5 volts or more but little or zero amperage the battery is faulty and must be replaced, AGM batteries fail in this scenario more so than lead-acid batteries.
18. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
19. Loose or corroded wire connection at the coil or plug between ignition sensor and ECM module.
20. Spark plug cables in bad condition and shorting check for spark leakage in the dark, cable connections are loose or connected to the wrong cylinders.
21. Ignition timing incorrect due to a faulty ignition coil, ignition module or MAP, CMP, CKP, O2, TPS, ETP, IAC sensors.
22. Faulty neutral, clutch, kickstand safety switch.
23. Faulty fuel pump or fuse or relay.
24. Faulty or corroded run/stop switch.
25. Tilt sensor needs a reset.
26. Security system not disarming alarm needs a reset.
27. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://www.youtube.com/watch?v=z7faM8SUAVQ
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Suzuki GZ250 Owner Manual

2003 Suzuki GZ... | Answered on Apr 05, 2019


Hi, Anonymous I would love to help you with your engine or chassis noise but I just loaned my brand new pair of listening ears to your local dealer's chief technician so he could take your bike for a test ride and give you his professional opinion and estimate about your noise and repair cost. If you are a little short on "DRACHMA" and a Dealership is not on your list of fun places to visit then perhaps the list below will help soothe your worried mind so you can make an informed decision.
1. Bearings---SCREECH---WHINE
2. Belts---CHIRP
3. Brake Rotors---BUZZ
4. Cam Chains---CLICKIT
5. Clutches---CHATTER
6. Cylinders---PING
7. Fairing Panels---WHISTLE
8. Fenders---SCRAPE
9. Fronk Forks---Plunk
10. Fuel pumps---WHIRR
11. Gears---WHINE
12. Head Gasket---HISS
13. Hydraulic Lifters---TAP
14. Instrument Clusters---BUZZING
15. Kick Starter---GRINDS
16. Pistons---SLAP
17. Power Valves---CLINK& RATTLE
18. Radiators---GURGLE
19. Rear Chains---RATTLE
20. Rear Shocks---SQUEAK
21. Relays---CLICK&BUZZ
22. Shaft Drives---WHIRR
23. Shifting Trans---CLUNK
24. Solid Lifters---TICK
25. Speedometers---bzzz
26. Starters---CLICK
27. Rods Go---KNOCK-KNOCK---who's there, it's me "*****"
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
https://community.spiceworks.com/topic/99321-motorbike-engine-ticking-noise
https://ch-me.org/videos/suzuki-marauder-gz-125-VYwcjafxggo.html
Suzuki GZ250 Service Manual
https://www.partsfish.com/page/oem-parts-for-suzuki
Suzuki GZ250 Owner Manual

2003 Suzuki GZ... | Answered on Feb 26, 2019


Hi, Lynne you need to make sure you have no intake leaks by spraying some Brake Kleen, Contact Cleaner, Starting Fluid etc. around the intake manifold and seals, if the RPM's go up or down significantly then you have a leak that needs to be fixed before you can continue with the carburetor adjustment.
The engine should be at operating temperature with the choke off to set the idle between 950-1050 rpm. Turn the idle skrew clockwise to increase the idle speed and counterclockwise to decrease the idle speed. If you have access to your air-fuel mixture skrew you may turn it as well, if not there is a video below on how to gain access, make sure you start with clean or new spark plugs. Gently turn the air-fuel mixture skrew clockwise until it starts to bottom out "STOP" do not over tighten as it will damage the taper on the end, now back the skrew out 1-1/2 full turns to establish a starting point start the engine and check the idle rpm's and turn the idle skrew accordingly for 950-1050 rpm if necessary, turn the air-fuel mixture skrew 1/4 turn at a time and let the engine settle for about 10 seconds, turn the skrew clockwise for a leaner mixture and counterclockwise for a richer mixture, you are seeking the highest rpm your air-fuel mixture skrew can acquire without going past 3 full turns from the bottom then resetting the idle skrew back down to 950-1050 rpm If you can not detect any rpm change and can not stall the engine by turning the air-fuel mixture skrew all the way in then your pilot/low-speed jet is too big and needs to be replaced with the next size smaller. Final adjustment should be made with a clean air filter mounted to the carburetor.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
Bike stalling when idle GZ 250 Forums
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Suzuki GZ250 Marauder Owner Manual

2003 Suzuki GZ... | Answered on Nov 12, 2018


Hi, Don, I believe so, for this scenario you will need your service manual that has all fastener torque specs and a wiring diagram on the back pages, parts fiche, and owners manual if you can't find the best tool you ever bought for your Kawasaki, despair not, for a mere zero $0 you can download another one.
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2003 Suzuki GZ... | Answered on Mar 30, 2018


Hi, Wayne valve clearance (when cold): IN. : 0.03-0.08 mm (0.001-0.003 in)
EX.: 0.08-0.13 mm (0.003-0.005 in) For this scenario you will need your service/owners manual if you can't find the first and best tool you ever bought for your Yamaha, despair not, for a mere zero $0 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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Valve adjustment for the GZ250 Page 3 GZ 250 Forums
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2003 Suzuki GZ... | Answered on Dec 08, 2016


Hi, Galen and the usual suspects are:
1. Throttle cables improperly adjusted, pinched or need lubrication.
2. Idle adjusting screw needs to be backed off.
4. Air fuel mixture adjusted too lean start with 2 full turns.
5. Intake system air leak.
6. Fast idle choke ramp is not releasing.
7. Broken throttle return spring.
8. Damaged diaphragm or slide.
9. Faulty MAP, TPS, ATS, O2, sensors or wiring/connector
10. Multi carburetors not in sync.
For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
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2003 Suzuki GZ... | Answered on Oct 16, 2016


check out your side stand safety switch

2003 Suzuki GZ... | Answered on Jun 13, 2014


First remove the speedometer housing by removing the small screw below the speedo. remove the bolte at the front and rear of the tank.
Lifting the tank and tilting it, remove the three lines going to the bottom and front of the tank. Remember where they go,(mark them if necessary). Carefully lift tank free of bike frame. Check large rubber pads (if installed) and reinstall them as found.

2003 Suzuki GZ... | Answered on Apr 13, 2014


The only way to remove the seal is to pry it out, be caerful and don't damage the shaft or case.

2003 Suzuki GZ... | Answered on Apr 03, 2014


Sounds like the oil is thick. Do you know what weight oil was installed last? If there was 40 weight put in and its getting colder out it get thicker. You can change the oil to a 30 weight and change the filter to see if that helps.

2003 Suzuki GZ... | Answered on Apr 09, 2013


The first thing to do is take the battery out and have it charged and tested. I am betting that it is bad. If the battery turns out to be good you have an open circut draining the battery, but like I said I'm betting on the battery being bad.

2003 Suzuki GZ... | Answered on Jan 11, 2013


I doubt its electrical in that sense.
1. check fuses
2. check alternator
3. check ignition components

For more help with above, see your owner's maual and buy a service manual. The library can help too. Service manuals are in reference 646

2003 Suzuki GZ... | Answered on Jan 11, 2013


I assume you have checked and that you do have spark.
Remove the water trap bowl at the bottom of the petcock, (gas valve). Is there any water or trash in the bowl? Drain a cup of gas from the tank. Is there any water or trash in the cup? Dump it, clean it and re-mount it, ( not all bikes have a water trap bowl ).

Drain the carburetor. There should be a screw on the lower side of the carb float bowl. Remove the screw then replace it after the fuel drains. Turn the gas back on and wait a minute for the carb to fill with gas. Install a new stock NGK spark plug and try to start the engine. If the bike doesn't start and run properly then shut off the gas and remove the carburetor from the engine.

Remove the float bowl and clean the entire carb with a spray carb cleaner from the auto parts store. Wear protective goggles to avoid getting spray in your eyes. Spray into all the little airways and fittings in the carb. Remove the idle screw and the air screw on the outside throat of the
carb and spray into the screw holes as well.
< < READ CLOSELY > >
Be sure to put these two screws back in the same hole they came out of. IMPORTANT > do not tighten these two screws down. Only screw these in until they LIGHTLY seat. Now turn each screw one and one half turns outward. Put the rest of the
carb back together, clean the air filter and install the carb. Let the float bowl fill then start the engine.

Please rate this solution. Thanks!

2003 Suzuki GZ... | Answered on Oct 19, 2010


If the bike has sat around for a while,there is a very good chance the clutch plates have fused together or the slide mechanism is seized.Get the clutch off and have a look at these things.ALWAYS make sure the clutch plates go back together in exactly the same order as they came out.And also the same sides of the plates that touch each other.Its not a big job.I hope this helps

2003 Suzuki GZ... | Answered on Nov 03, 2009


Hi, Anonymous for most bikes fuel valve long part of lever positions are as follows:
1. ON--- 6 o'clock position.
2. OFF--- 9 o'clock position.
3. RESERVE---12 o'clock position.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the links below. Good luck and have a wonderful day.
http://www.gz250bike.com/forum/showthread.php?t=5807
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Suzuki GZ 250... | Answered on Feb 25, 2019


Hi, Billy 369 ml sounds about right sorry you can't find the first and best tool you ever bought for your Suzuki despair, not for a mere $0 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need please visit the websites below. Good luck and have a nice day.
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Suzuki GZ 250... | Answered on Mar 23, 2016


Hi Bridges_debb, the following applies to carbureted also fuel injected models and the usual suspects are:
1. Severely discharged or damaged battery, 9 volts or lower.
2. Faulty alternator/generator and or voltage regulator.
3. Loose or corroded battery terminals and or cables especially the "NEGATIVE" cable, look for loose, corroded, or broken connectors inside the cable harness at "BOTH" ends.
4. Faulty main circuit breaker or ignition switch, check for loose connections and continuity.
5. Faulty system and or ignition relay, check for continuity.
6. Faulty ignition coil, ignition/electronic module.
7. Faulty CKP, CPS, CMP, MAP, TPS, or BAS sensor, corrroded, loose or broken wire connector pins/sockets.
8. Water or dirt in the fuel system, carburetor or filter.
9. . Restricted, blocked or kinked fuel line.
10. Fuel tank empty.
11. Gas cap is not venting properly or fuel tank venting system blocked.
12. A faulty fuel pump, pressure regulator and or fuel injectors.
13. Vacuum line from intake manifold to petcock broken, cracked, or not attached, carburetor vent line plugged.
14. Needle and seat stuck closed in the float bowl.
For more information about your issue, please visit the websites below. Good luck and have nice a day.
2001 Suzuki Motorcycle Service Repair Workshop Manuals

Btw, I’m available to help over the phone in case u need at https://www.6ya.com/expert/gregg_c0ec1df182c7330e

Suzuki GZ 250... | Answered on Oct 03, 2015

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