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Suzuki GS GSX 250 400 450 1979-1985 Service Repair Manual

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This manual covers the GS and GSX series motorcycles produced between 1979 and 1985, including models with 250cc, 400cc, and 450cc engine variants. These motorcycles are known for their robust...
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Typ: Motorcycle
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Art.-Nr: 58019
Suzuki GS GSX 250 400 450 1979-1985 Service Repair ManualSuzuki GS GSX 250 400 450 1979-1985 Service Repair ManualSuzuki GS GSX 250 400 450 1979-1985 Service Repair ManualSuzuki GS GSX 250 400 450 1979-1985 Service Repair Manual
This manual covers the GS and GSX series motorcycles produced between 1979 and 1985, including models with 250cc, 400cc, and 450cc engine variants. These motorcycles are known for their robust engineering, offering a blend of performance and reliability that made them popular in their era. The GS series laid the groundwork for larger displacement offerings, evolving into the sportier GSX line, which often featured advancements like DOHC valve trains and responsive handling. With a focus on mechanical integrity and rider feedback, these models represent a significant chapter in motorcycle heritage. This comprehensive service repair workshop manual provides detailed, vehicle-specific information for owners and technicians. It covers a wide range of essential topics, including general information, routine maintenance procedures, detailed specifications, periodic checks, lubrication, cooling systems, transmissions, drive chains, fuel systems, steering, suspension, bodywork, intake and exhaust, and the electrical system. The manual offers step-by-step instructions for engine overhaul, advanced troubleshooting, and component repair, mirroring the procedures used by authorized dealer service departments. It is designed to facilitate effective maintenance and repair, ensuring the longevity and optimal performance of your GS or GSX motorcycle.
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
GS / GSX
Engine Variants Covered:
250cc, 400cc, 450cc
Generation
Production Years:
1979-1985
Codes
Chassis Codes:
Various GS/GSX series designations
👋 Introduction
Market Position
Target Audience:
Suzuki GS/GSX 250/400/450 motorcycle owners and independent repair shops.
Competitive Analysis
Value Proposition:
Provides dealership-level repair and maintenance information at a fraction of the cost, enabling cost savings on repairs and proactive maintenance.
Key Features
Accuracy And Completeness:
Vehicle-specific, not generic. Contains exact same specifications and procedures used by authorized dealer service departments.
Ease Of Use:
Accurate, clear, and concise text combined with illustrations and step-by-step instructions make complex repairs accessible.
📋 Manual Details
Coverage Areas
Topics:
General Information, Routine Maintenance, Specifications, Periodic Checks and Adjustments, Lubrication, Cooling System, Transmission, Drive Chain, Sprockets, Engine Specifications, Engine Removal and Installation, Fuel System, Steering System, Shocks, Body Work, Intake & Exhaust, Electrical System, Advanced Troubleshooting, Wiring Diagram
Page Count
Estimated Page Count:
Extensive (specific number not provided, but implied to be comprehensive)
Manual Type
Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, component testing, tuning, troubleshooting
Transmission:
Gearbox inspection, maintenance, repair, clutch service
Electrical System:
Wiring diagrams, component testing, troubleshooting ignition, lighting, charging systems
Fuel System:
Carburetor service and tuning, fuel pump, fuel lines
Suspension And Steering:
Front forks, rear shocks, steering head bearings, linkage maintenance
Braking System:
Disc brake service, caliper maintenance, fluid changes (implied by general repair)
Cooling System:
Air cooling system checks and maintenance (for relevant models)
Drive Train:
Drive chain adjustment, sprocket replacement, maintenance
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, chain lubrication, air filter cleaning/replacement
Troubleshooting:
Systematic diagnostic procedures for common and advanced issues
Repair Procedures:
Step-by-step instructions for component disassembly, repair, and reassembly
Engine Overhaul:
Complete engine rebuild instructions, including piston, ring, valve, and bearing replacement
Electrical Diagnostics:
Fault finding for ignition, charging, lighting, and starting systems using wiring diagrams
Carburetor Tuning:
Detailed instructions for adjusting and rebuilding carburetors
Technical Depth
Depth:
Comprehensive coverage suitable for both DIY enthusiasts with basic mechanical skills and professional mechanics.
Level Of Detail:
Detailed step-by-step instructions, diagrams, illustrations, and specifications mirroring dealership service procedures.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printable:
Yes, individual pages can be printed.
Binding Type
Binding:
N/A (Digital PDF download)
Paper Type
Paper Type:
N/A (Digital PDF download)
Compatibility
Operating Systems:
All Versions of Windows AND Mac
Requirements
Software:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Types:
Inline-twin and inline-four cylinder configurations, air-cooled (primarily).
Performance
Horsepower And Torque:
Specific figures vary by model and engine size (e.g., 250cc, 400cc, 450cc). Manual provides exact specifications.
Fuel System
Carburetion:
Typically utilizes multi-carburetor setups (e.g., dual Mikuni or Keihin carburetors).
Engine Design
Valve Train:
DOHC (Double Overhead Camshaft) is common on these models, providing efficient valve control.
🔧 Transmission
Standard
Type:
Constant-mesh, 5-speed or 6-speed manual transmission (model dependent).
Optional
Optional Types:
N/A (Typically manual transmissions for this era).
Features
Clutch Type:
Wet, multi-plate clutch operation.
📐 Dimensions
Exterior
Overall Length Width Height:
Varies by model and specific GS/GSX variant. Manual provides detailed dimensions.
Weights
Dry Weight:
Varies significantly by engine size and model (e.g., from ~140kg for 250cc to ~170kg for 450cc). Manual provides specific figures.
🛡️ Safety Features
Ratings
Crash Test Data:
N/A for motorcycles of this era in the way car crash data is presented. Focus is on mechanical integrity and safe operation.
Active Features
Braking System:
Front disc brakes, rear drum or disc brakes depending on the model. Manual covers their service and maintenance.
Passive Features
Frame Construction:
Steel cradle frames, designed for stability and handling. Manual details frame inspection.
💡 Technology Features
Infotainment
Infotainment System:
N/A for this era of motorcycle. Technology focused on mechanical function and performance.
Driver Assistance
Rider Aids:
Minimal; focus on rider skill and mechanical feedback. Some models may have offered 'anti-dive' front fork systems.
Connectivity
Connectivity Features:
N/A.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 km or 6-12 months. Manual provides precise intervals.
Spark Plug Replacement:
Recommended at intervals specified in the manual, often around 10,000-15,000 km, depending on plug type and usage.
Fluid Specifications
Engine Oil Type:
API SF or SG classification, SAE 10W-40 or 20W-50 recommended. Manual provides precise specifications and quantities.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual specifies exact type and replacement intervals.
Known Issues
Carburetor Issues:
Carburetor synchronization and jetting issues can arise due to age and fuel deposits. Manual offers detailed troubleshooting and adjustment procedures.
Electrical Gremlins:
Age-related electrical connections can become corroded, leading to intermittent issues. The detailed wiring diagrams in the manual are crucial for diagnosis.
Suspension Wear:
Fork seals and rear shock absorbers can wear over time, affecting ride quality and handling. The manual details seal replacement and fluid changes.
📚 Vehicle History
Brand Heritage
Suzuki Motorcycles:
Suzuki has a long history of producing reliable and performance-oriented motorcycles, with the GS and GSX series being iconic sportbikes and standards of their time.
Model Evolution
Gs Gsx Series:
The GS series represented Suzuki's entry into the larger displacement motorcycle market, evolving into the sportier GSX line with technological advancements like anti-dive front forks and improved engine performance.
Production
Manufacturing Locations:
Primarily Japan, with potential assembly in other regions.
🏆 Awards & Recognition
Recognitions
Performance Awards:
The GS/GSX series were highly regarded in their time for performance, handling, and reliability, often receiving positive reviews in motorcycle publications.
Ratings
Reliability Ratings:
Generally considered reliable if properly maintained, with the manual being key to achieving this.
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