Vanakkam Bro, This is happening to my bike as well.The oil was leaking in the engine head and the starter motor cover side as well.Later identified due to excess oil filled from the service center, i realized later after 1000km of running. I inspected later in the oil check glass window level it was full and drained my self and almost 400ml was taken to keep the quantity at middle of full mark. Also check the crankcase drain pipe under the aircleaner box, if any oil filled due to this.Clean that as well.Due to more internal pressure build up would cause the weakest part of the engine, thats the gasket to blow out. we need to seal it with new gasket & sealant.This will happen mostly if we revv to redline frequently or on longer high speed ride for 2-3 hrs, with excess oil in it.
It seems that the authorized centers are hard to trust nowadays,i did the service in APPLE SUZUKI Banshankari (Bangalore).The oil change was not in due, but they billed for topup for 300rs, just for this amount they made the bike like this pathetic service centers and i am going to do all this myself further. Luckily this should not create any further harmful like piston ring seal damage,blow-by crank issue etc due to excessive oil..... Low oil or excess oil the damage its going to give is same thats WORST.

Hi Bro, I believe it should be inspect(I) as per periodic maintenance chart.the FI cleaning required only if had ridden in very dusty/off-road kinda of stuff and air filter change will be enough. or If you had clocked more than 10k or 20k FI cleaning once would be fine. Better you can use Liquimoly FI cleaner of 80ml into 10 liters of petrol will take care of it.
Regards to valve adjustment.....please refrain it from doing it until if you hear any tappet noise. Else don't touch it, since this is engine is shim type valve(similar to cbr250r), it would take at-least 50k or 75k kilometers the shim to reduce .mm until then no worries.

Regarding the jerkiness, check with different petrol pump or give a shell power of 10 ltr full tank and see, also if there are any rpm fluctuation change the airfilter once.

Also one more interesting thing, the oil strainer is on the left magneto case side in gixxer 250. usually it will be below the oil filter area (Right side clutch case cover).
so it should be easier to clean the oil strainer after First oil change for any metal shavings or dirt......but again the service guys wont do it :-(

Guys if anyone have service manual kit thats used by technicians in authorized service station will be helpful to diagnosis ourself.
since its very new bike we are not getting it, hopefully we need figure that out....

Thanks man! Will do the Liquimoly FI cleaner as 11k clocked. Will avoid the tappet adjustment. Shell power makes sense, also a colleague recommended Essar for fuel. So will try that.

Hi everyone
i recently bought a used gixxer sf 250 only 600 at odo First service has been done
When i start the engine in neutral gear there is throaty sound from engine
But as soon as i press the clutch, engine becomes very smooth and silent and only exhaust is audible

Any one else facing this?

Hi there !

Yes even it happens in my bike
I noticed this in cold morning start but need to check this whether it happens rest of the day.....
but not sure why that gruffness in engine comes in neutral....even i tried adjusting the clutch but nothing helped.

glad to know i'm not alone.
hope others might have experienced this too and have some solution it its really a problem

Gixxer / SF 250 engine idle sound issue

Hi guys, suffering from the same problem. There’s a rattle or a ‘sharp knocking’ sound mixed in with the engine idle sound, when the bike’s on neutral. It goes away when you engage (press) the clutch. Once you let go of the clutch, the slight ‘knocking’ ‘tappety’ sound returns. Also happens when the bike is in movement and in between when you press clutch while gear shifting (for this you have to focus a little, and you’ll recognise the sound is there on signals when you stop in between)

Seems like this problem is prevalent with all Gixxer/sf 250 engines, so I’m not alone. I noticed it right away after taking the delivery of the bike, but in my excitement, I decided to ignore it at that time. But the very next day, I notified the Suzuki service centre. Got my engine oil changed at 100km as a standard practice, thinking it would help, but it didn’t.

Checked with the service centre and took the bike to them. Initially they said it’s normal and will go away with time. But the manager at the service centre was kind to notice this and said that there is definitely a sound coming from the engine.

They escalated it to the Suzuki plant in Gurgaon and have asked me to get the bike to the service centre. We’ve not been able to coordinate, but I’m going there tomorrow, and some guys from the Suzuki R&D centre are going to inspect my bike. This has been going on since I took the delivery for my bike some 20 days ago.

Possible diagnosis

I researched this on my end, and after going thoroughly through the forums and internet, I’ve come to a conclusion that this is due to a ‘loose’ clutch basket or bell. It can be due to a number of reasons, loose nut, worn out bushes. But since this is happening in a new bike, it might be due to a loose nut somewhere in the assembly. I found out on youtube, that in another bike (not Gixxer, Suzuki SV650), it was due to not enough torque on the nut holding the clutch basket. Due to which there was a ‘play’ in the whole basket. When the clutch is engaged, it is tight and doesn't make any sound, but when the clutch is disengaged, it’s loose and it rattles.

So it seems like a production issue with the bike which can be fixed with small corrections at the manufacturing level. I hope it turns out to be a simple fix.

Thanks for the info bro....
But not sure I am getting the "knocking" or tappet noise, but there is additional gruff sound that comes in neutral.
This is the exact sound and explained that's not an issue - https://www.youtube.com/watch?v=tOz78nmMfgo

If they are able to figure and fix it that would be really a great......Yes Please let us know how it went on the inspection.
I am just worried if riding something like loose clutch/nut/bushes would worsen the life of it very soon 😒

An update regarding my visit to the service centre. I visited the service centre at around 10.30 am and there was someone from the Suzuki plant there. Also the service centre had specially opened up for my bike's inspection. Got to know that a lot of different teams were visiting, heard, someone from Suzuki R&D was also joining. I waited, and then different officials kept coming. And finally at around 3.30 there main team came, so in all around 7-8 people from different Suzuki teams had come.

They had gotten a Gixxer 250 as a reference bike. So I explained my issue to the Japanese engineer (maybe from R&D team), but communication (english) was a big problem. He did understand that there was a sound and recorded on his phone and sent it to some team. Now I was urged by some other people to go and wait in the customer’s lounge while my bike was being inspected.

An hour later I went back and saw that they had opened up the right side case of my bike and were working on it. One of the guys explained that they are checking the torque on each nut bolt and seeing if there is anything loose.

Again I returned to the customer area. An hour later and they said the bike is ready for inspection.

After checking, I could hear the sound again. Then they had the 2nd Gixxer 250 also on standby. After assembling that, I asked to check the idle sound on that and felt the same sound was coming on that bike too.

The group explained that this is normal and within the tolerance dB levels. I had nothing to say after that, since, their reference bike also had the same sound. So in conclusion I told them that although I’m not convinced, but can’t say much. They assured me that there'll be no issue with the bike and I should just ride the bike carefree. If the sound increases, then I should come back and inform them. So I spent the entire day at the service centre, thanked the teams for taking the time and rode back. All in all, these are the updates, and I’ve mentally decided to just ride the bike for at least 3000kms and see if all this improves.

Thanks for sharing bro ! Good to know that Suzuki is taking things seriously and inspected from R&D engineering is something to appreciate.
Also now I am bit relief on this sound, its nature of the clutch design or thats how it is....thou not bothering much.

One more thing, mine is completed 6k odo.....the clutch has become bit hard and throttle is not as smooth it was before, on longer drives its bit painfull on wrist....any suggestion ?

Hi Shiva, I have the same sound when idling. On my research I read it somewhere even Hayabusa have the same sound coming when in idle. Then I thought it is common for most of the suzuki bikes and left it alone as I don't have any other issues.

Try adjusting the clutch play, then lube the clutch cable a little, if doesn't work Change the clutch cable if possible.

With regards to throttle try cleaning throttle body and see if it helps.

Hi Barney,

Sure , will try it, thanks. Also off late bit of rusting issues started creeping in on few welded area's and bolts 🤦‍♂️.
I am using normal tap water to wash and properly dry it shows salty white patches on bolts.....i am applying some oil to those places.

Rusting issues was there is 150 now in 250 as well....not sure how are the recent bikes.....
Does any body know whether this bike has fuel filter similar to honda cbr 250 and where its located , either along with Fuel Pump or outside below the tank.
Since no service manual, not able to check all these info.

Apart from these things, the bikes performance is fun on everytime i hoot around the roads literally smokes away everyone on signals, especially the throaty intake growl on 3rd gear upto 8-9k rpm is smooth addictive rumble .......that feeling is killer one, enjoying with my "Black Mamba" 🤣

Just see this - https://youtu.be/IlVL6Az7TXQ
how they are ripping like anything..

Thanks

Regarding the idle knocking sound, I've left it and moved on for the time being. I'll have to wait for an identical bike and if the sound is not there take that person to the Suzuki service centre. Maybe then they can compare and accept if something is off. But they have given me assurance that this bike will not give you any problem, and I've actually started feeling that.

I've crossed a 1000kms after the first service and the engine brings a smile on my face. I haven't revved the bike really high, maybe I'll try that after the second service. For now, I just vary the rpms while keeping it under 5k rpm.

siva23 : I've not experienced the hard clutch issue but will be on the lookout for such symptoms. Also haven't faced any rusting issues till now. I have gotten my bike washed only once in this last month. But rust and water patches (flaky) are different. Rust is serious and should be addressed, water patches in my opinion are due to improper drying and not really a problem.

Long distance comfort mods
My biggest issue with the bike is the fit and the posture. It's anyway a relaxed bike and the posture is not committed as the competitors. But still my other bike is a RE Bullet, and that is a sofa. My personal project is to make this bike as comfortable as my Bullet and make this a touring specific bike. So I'm close to finalising the modifications for the seat, the clip-ons and the footpegs.

Seat is going to be similar to my Bullet, mainly bucket seat (something like Corbin Gunfighter & lady seat). Handlebar conversion is pretty straightforward, direct swap of the Tee plate & handlebar from naked Gixxer 250. The footpegs are what I've not been able to solve. As to how to make them forward set, that would require some local fabrication. And in addition to this, a better wind visor (I have got the Apache RR310 visor, but haven't affixed it). But I'll check with the service centre if it may void the warranty. If anybody has any inputs on these or suggestions, do let me know.

theblur You can modify the seat and handlebar from naked gixxer, however i would advice not to tinker with placement of foot pegs, it is not worth the time and money and it may lead to lot of other issues. You have to entirely alter the brake & gear lever placements, as far as I have noticed it is close to impossible. Even if you manage to do that it might affect the braking performance. Just the swap the handlebar and see if it is comfortable for your liking before altering the foot pegs.

Yes there are some rusting issues I have noticed as well, apart from minor niggles the bike had been hassle free so far. Hope to continue the bond for years to come.