Suzuki GS250 GSX250 GSX400 GS450 Twins Motorcycle Complete Workshop Manual 1979 1980 1981 1982 1983 1984 1985

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Art.-Nr: 155460

Stichworte: 1979 1980 1981 1982 1983 1984 1985 GS Series GS250 GS450 Twins GSX250 GSX400 Motorcycle Motorcycles Suzuki

Produktvarianten

Beschreibung

This manual covers the GS250, GSX250, GS400, and GS450 motorcycle models, produced between 1979 and 1985. These parallel-twin powered machines offered a balance of performance and reliability, making them popular choices for riders seeking capable and enjoyable motorcycles for commuting and general recreation. Engineering during this era focused on robust construction and accessible performance, establishing a strong legacy in the motorcycle market. The GSX variants often featured enhancements such as DOHC engines, providing a sportier experience compared to their GS counterparts. This comprehensive service repair workshop manual provides detailed instructions for maintenance, troubleshooting, and repair of your GS or GSX Twins. It covers all essential systems, including the engine, fuel, ignition, transmission, drivetrain, suspension, brakes, and electrical systems. With step-by-step procedures, diagnostic charts, and detailed illustrations, this manual is an invaluable resource for owners and technicians alike. Whether performing routine oil changes, complex engine overhauls, or electrical diagnostics, this manual equips you with the knowledge to keep your motorcycle in optimal condition.

🏷️ Basic Information

Identification

Make:

Suzuki

Model Lineup:

GS250, GSX250, GS400, GS450

Model Variants:

Twins (referring to parallel-twin engine configurations)

Codes

Product Code Example:

Likely a specific internal catalog number for the manual, not publicly stated.

Generation

Covered Years:

1979, 1980, 1981, 1982, 1983, 1984, 1985

👋 Introduction

Market Position

Target Audience:

Owners and independent mechanics seeking to perform all service and repair tasks on Suzuki GS/GSX Twins.

Value Proposition:

Significant cost savings through DIY maintenance and repair, empowering owners with technical knowledge.

Competitive Analysis

Competitors:

Other aftermarket service manuals (Haynes, Clymer) and official Suzuki factory service manuals.

Differentiation:

Comprehensive coverage across multiple models and years in a single, easily accessible digital format.

Key Features

User Friendliness:

Step-by-step instructions with accompanying pictures to simplify complex procedures.

Accessibility:

Instant delivery via email, usable on various devices.

Lifetime Access:

Purchased manual is owned permanently by the customer.

📋 Manual Details

Coverage Areas

Primary Regions:

Global, as it covers common service and repair procedures applicable across markets.

Specific Countries Implied:

Likely to include major markets where these models were sold, such as North America, Europe, and Japan.

Page Count

Estimated Page Count:

Typically in the range of 300-600 pages for a comprehensive workshop manual covering multiple models and years.

Manual Type

Type:

Complete Service Repair Workshop Manual

Functionality:

DIY repairs, professional servicing, troubleshooting, and in-depth maintenance.

Language

Language:

English

Format

Delivery Method:

Downloadable Digital File

Accessibility:

Printable, Tablet/Smartphone Compatible

📖 Manual Coverage

Systems Covered

Engine:

Engine disassembly, assembly, tuning, lubrication, cooling, and troubleshooting for parallel-twin configurations.

Fuel System:

Carburetor adjustment, cleaning, rebuilding, fuel pump service, and fuel tank maintenance.

Ignition System:

Ignition timing, spark plug specifications, coil testing, CDI unit service, and starter system.

Transmission:

Clutch service, gearbox disassembly/assembly, gear shift linkage, and transmission fluid specifications.

Drivetrain:

Final drive (chain/sprocket) inspection, replacement, lubrication, and rear wheel hub servicing.

Suspension:

Front fork overhaul, rear shock absorber inspection and replacement, and linkage maintenance.

Brakes:

Front and rear brake system service (hydraulic and mechanical), caliper rebuilding, master cylinder, brake fluid replacement, and pad/shoe specifications.

Electrical System:

Wiring diagrams, battery maintenance, charging system (alternator/stator, regulator/rectifier), lighting, instrumentation, and starter motor operation.

Frame And Bodywork:

Chassis inspection, steering head bearing service, wheel bearing replacement, body panel removal/installation, seat, and tank servicing.

Procedures Included

General Maintenance:

Oil changes, filter replacements, chain adjustments, brake adjustments, and general lubrication.

Troubleshooting:

Diagnostic charts and procedures for common performance issues, electrical faults, and mechanical problems.

Engine Overhaul:

Complete engine rebuild procedures, including piston, ring, valve, and gasket replacement.

Carburetor Rebuild:

Step-by-step instructions for disassembling, cleaning, and reassembling carburetors with detailed diagrams.

Electrical Diagnosis:

Methods for testing components like coils, stators, regulators, and starter solenoids.

Suspension Servicing:

Front fork seal replacement, oil changes, and rear shock absorber servicing.

Brake System Overhaul:

Master cylinder and caliper rebuilding, fluid bleeding, and pad/shoe replacement.

Wheel And Tire Service:

Tire inspection and replacement, wheel balancing, and bearing service.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds.

Diagnostic Level:

Advanced, with detailed troubleshooting flowcharts and component testing procedures.

Diagrams:

Includes detailed illustrations, exploded views, and wiring diagrams.

📊 Manual Specifications

File Format

File Type:

Searchability:

Typically searchable text within the PDF for quick information retrieval.

Print Quality

Printability:

High quality, allowing for clear printing of individual pages or chapters.

Binding Type

Binding Style:

N/A (Digital Download)

Paper Type

Paper Quality For Print:

N/A (Digital Download) - Recommended for printing on durable, oil-resistant paper for workshop use.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Parallel-twin cylinder, 4-stroke, Air-cooled

Valve Train:

DOHC (Double Overhead Camshafts) or SOHC (Single Overhead Camshafts) depending on the specific model variant (e.g., GSX models often featured DOHC).

Performance

Gs250 Displacement:

Approximately 247 cc

Gsx250 Displacement:

Approximately 249 cc

Gs400 Displacement:

Approximately 398 cc

Gs450 Displacement:

Approximately 447 cc

Power Output Range:

Varies by model, typically from ~25-35 HP for 250cc models to ~35-45 HP for 450cc models. Exact figures would be in the manual.

Fuel System

Fuel Delivery:

Carburetor(s) (e.g., Mikuni VM series or similar Japanese brands)

Fuel Type:

Unleaded gasoline (though leaded gasoline may have been common during the production years, the manual will specify current recommendations).

🔧 Transmission

Standard

Type:

Constant mesh, 5-speed or 6-speed manual transmission (model dependent).

Optional

Optional Transmissions:

N/A - Manual transmissions were standard across these models.

Features

Clutch:

Wet, multi-plate clutch operated by cable.

Gear Ratios:

Specific gear ratios for each model and transmission variant will be detailed within the manual.

📐 Dimensions

Exterior

Wheelbase Range:

Typically between 1350mm and 1450mm, depending on the specific model.

Weights

Dry Weight Range:

Ranging from approximately 140 kg to 170 kg, model dependent.

🛡️ Safety Features

Ratings

Safety Ratings:

N/A - Motorcycles of this era did not have standardized crash test ratings like modern cars.

Active Features

Braking System:

Combination of disc brakes (front, sometimes rear) and drum brakes (rear, sometimes front), depending on the model and year.

Passive Features

Lighting:

Headlight, taillight, brake lights, turn signals.

💡 Technology Features

Infotainment

Infotainment Systems:

N/A - These are classic motorcycles with no modern infotainment systems.

Driver Assistance

Driver Assistance Features:

N/A - No electronic driver assistance features available.

Connectivity

Connectivity Features:

N/A - No connectivity features.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000 - 5,000 km or 6 months, whichever comes first. Manual will provide exact interval.

Valve Clearance Check:

Often around 6,000 - 10,000 km. Manual will specify precise interval.

Fluid Specifications

Engine Oil Type:

Typically SAE 10W-40 or 20W-50 motorcycle-specific oil. Manual will confirm viscosity and API classification.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid. Manual will confirm exact specification.

Fork Oil Type:

Various weights, often 10W or 15W. Manual will specify grade and quantity.

Known Issues

Carburetor Issues:

Gumming and blockage due to fuel deterioration if not run regularly; vacuum slide diaphragm wear.

Electrical Issues:

Corrosion in connectors, faulty rectifier/regulator, and stator coil failure can occur with age.

Engine Wear:

Cam chain wear, worn valve guides, and piston ring wear are common on higher mileage engines.

Fuel System Degradation:

Older fuel lines can become brittle; petcock seals may degrade.

📚 Vehicle History

Brand Heritage

Suzuki Legacy:

Suzuki has a long history in motorcycle manufacturing, known for reliable and performance-oriented bikes.

Model Evolution

Gs Series Era:

The GS series represented Suzuki's entry into the larger displacement parallel-twin market, evolving from earlier models.

Gsx Enhancements:

The GSX designation typically indicated sportier features, such as DOHC engines and improved suspension/braking compared to standard GS models.

Production

Manufacturing Location:

Primarily Japan.

Market Impact:

These models were popular in the 1980s for their balance of performance, reliability, and relatively affordable pricing, competing with Yamaha XJ, Kawasaki KZ, and Honda CB series.

🏆 Awards & Recognition

Recognitions

Industry Awards:

N/A - Specific awards for these individual models from the 1970s/80s are not widely documented in a consolidated manner.

Ratings

Long Term Reliability Reputation:

Generally regarded as reliable and robust motorcycles for their era, particularly the GS series, which were workhorses.