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

Normaler Preis: $16.99
Verkaufspreis: $16.99
Normaler Preis
Grundpreis: pro

The Suzuki GS and GSX Twins represent a significant era in Japanese motorcycle engineering, produced between 1979 and 1985. These models, available in 250cc, 400cc, and 450cc engine variants, were...

18 people are viewing this right now

Typ: Motorcycle

Anbieter:

Art.-Nr: 89393

Stichworte: 1979 1980 1981 1982 1983 1984 1985 GS 250 GS 400 GS 450 GSX 250 GSX 400 GSX 450 Misc Motorcycle Motorcycles Suzuki

Produktvarianten

Beschreibung

The Suzuki GS and GSX Twins represent a significant era in Japanese motorcycle engineering, produced between 1979 and 1985. These models, available in 250cc, 400cc, and 450cc engine variants, were designed with an emphasis on DOHC engine technology and sporty styling, positioning them as performance-oriented machines in a competitive market. Known for their robust construction and advanced features for the time, such as sophisticated suspension systems, these motorcycles have become classics, appreciated for their reliability and engaging riding experience. This comprehensive factory service manual provides essential guidance for the maintenance, repair, and restoration of your Suzuki GS/GSX Twins. Covering all models from 1979 through 1985, this over 500-page English-language guide details every major system, including the engine, fuel, ignition, transmission, drivetrain, suspension, brakes, and electrical systems. It offers step-by-step repair procedures, routine maintenance schedules, troubleshooting diagnostics, and technical specifications, making it an indispensable resource for owners and technicians seeking to preserve the performance and longevity of these iconic motorcycles.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GS / GSX Twins

Engine Variants:

250cc, 400cc, 450cc

Codes

Product Code:

Suzuki_GS_GSX_250_400_450_Twins_1979_1985_Service_Manual_PDF_Download

👋 Introduction

Market Position

Segment:

Performance-oriented Japanese motorcycles of the early 1980s, competing in the lightweight to mid-weight sportbike and standard categories.

Competitive Analysis

Competitors:

Yamaha XS/XJ series, Honda CB/CB-F series, Kawasaki KZ/GPz series of similar displacements.

Key Features

Design Philosophy:

Emphasis on DOHC parallel-twin or inline-four engines, advanced suspension for the era, and sporty styling.

Manual Value Proposition:

Essential guide for owners and technicians to maintain, repair, and restore these classic Suzuki twins, ensuring longevity and optimal performance.

📋 Manual Details

Coverage Areas

Years Covered:

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

Models Covered:

Suzuki GS/GSX 250cc Twins, Suzuki GS/GSX 400cc Twins, Suzuki GS/GSX 450cc Twins

Page Count

Estimated Page Count:

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine removal, disassembly, inspection, repair, reassembly, tuning, lubrication, cooling system, oil pressure.

Fuel System:

Carburetor identification, adjustment, overhaul, fuel pump, fuel lines, fuel tank.

Ignition System:

CDI unit, ignition coils, spark plugs, timing, troubleshooting.

Transmission:

Gearbox removal, disassembly, inspection, repair, clutch operation, shift mechanism.

Drivetrain:

Final drive, chain maintenance, sprockets, swingarm, rear suspension linkage.

Suspension:

Front forks (telescopic), rear shock absorbers, spring rates, oil levels, seals.

Brakes:

Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake fluid specifications, bleeding procedures, disc and pad wear.

Electrical System:

Wiring diagrams, battery, alternator, starter motor, lighting, horn, switches, fuses, relays, troubleshooting electrical faults.

Frame And Bodywork:

Frame inspection, fork gaiters, fuel tank, seat, fenders, side covers, instrument panel.

Procedures Included

Maintenance:

Regular service checks, oil changes, filter replacements, spark plug replacement, chain adjustment, lubrication points.

Troubleshooting:

Diagnostic guides for common engine, electrical, and mechanical problems, symptom-based fault finding.

Repair:

Detailed step-by-step instructions for component removal, repair, and reinstallation for all major systems.

Disassembly Reassembly:

Complete breakdown and reassembly procedures for engine, transmission, suspension, and other key components.

Adjustments:

Carburetor synchronization, valve clearance adjustment, brake lever travel, clutch cable play.

Technical Depth

Depth:

Comprehensive rebuild and diagnostic information suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

Quality:

High-resolution scans, searchable text (OCR).

Print Quality

Printability:

Printable pages for workshop use.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Configuration:

DOHC, Parallel-Twin (250, 450cc), DOHC, Inline-Four (400cc - though some 400 twins existed)

Bore Stroke 250:

Varies by specific model, typically around 50mm x 31.8mm (GS250)

Bore Stroke 400:

Varies by specific model, e.g., 52mm x 47mm (GS400 Inline-Four)

Bore Stroke 450:

Varies by specific model, typically around 65mm x 65mm (GS450 Twin)

Cooling System:

Air-cooled

Performance

Horsepower 250:

Approx. 26-30 HP (varies by model and tuning)

Horsepower 400:

Approx. 35-45 HP (varies by model and tuning)

Horsepower 450:

Approx. 35-40 HP (varies by model and tuning)

Fuel System

Carburetor Type:

Mikuni VM or BS series, Keihin CV (Constant Velocity) carburetors, typically dual carbs.

Fuel Tank Capacity:

Typically 10-14 liters (2.6-3.7 US gallons) depending on model.

🔧 Transmission

Standard

Type:

6-speed constant mesh manual transmission.

Optional

Type:

N/A (Manual transmission was standard)

Features

Clutch:

Wet, multi-plate, cable-actuated clutch.

Final Drive:

O-ring sealed chain drive.

📐 Dimensions

Exterior

Wheelbase:

Varies by model, typically around 1380-1440 mm (54.3-56.7 inches).

Weights

Dry Weight:

Varies by model, typically 150-180 kg (330-397 lbs).

🛡️ Safety Features

Ratings

Crash Test Data:

N/A (Motorcycle specific safety ratings from this era are not directly comparable to automotive standards).

Active Features

Braking System:

Front disc brake(s) and rear drum or disc brake, depending on model and year. Linked braking systems were not common.

Passive Features

Lighting:

Halogen headlight, taillight, brake light, turn signals.

💡 Technology Features

Infotainment

Features:

Basic analog instrumentation (speedometer, tachometer, odometer, fuel gauge on some models), no electronic infotainment systems.

Driver Assistance

Features:

N/A (No electronic rider aids or driver assistance features).

Connectivity

Features:

N/A (No digital connectivity features).

🔧 Maintenance

Service Intervals

Oil Change:

Typically every 3,000-5,000 km (2,000-3,000 miles) or annually, whichever comes first.

Valve Adjustment:

Recommended every 6,000-12,000 km (4,000-7,500 miles) or as specified in the manual.

Chain Lubrication:

Recommended every 500-1000 km (300-600 miles) and after washing or riding in rain.

Fluid Specifications

Engine Oil Viscosity:

Typically SAE 10W-40 or SAE 20W-50 (refer to specific model in manual).

Engine Oil Type:

API SE or SF classification motorcycle specific oil.

Brake Fluid:

DOT 3 or DOT 4, depending on original specification.

Fork Oil Viscosity:

Typically SAE 10W or SAE 15W (refer to specific model).

Known Issues

Carburetor Issues:

Clogged jets, worn needle valves, vacuum leaks due to aging rubber components, synchronization drift.

Electrical Issues:

Degrading wiring insulation, corroded connectors, failing rectifier/regulator, weak charging systems.

Engine Wear:

Valve stem seal leaks, cam chain wear, piston ring wear, potential for early ignition component failure.

Suspension Wear:

Worn fork seals, weakened rear shock absorbers.

📚 Vehicle History

Brand Heritage

Legacy:

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

Model Evolution

Gs Series:

The GS series represented Suzuki's move towards more performance-oriented motorcycles, evolving from earlier designs with DOHC engines becoming a hallmark.

Gsx Series:

The GSX designation often indicated further performance enhancements, such as improved aerodynamics or updated engine technology.

Production

These models were part of the significant growth period for Japanese motorcycles in the late 1970s and early 1980s, a time of rapid technological advancement.

🏆 Awards & Recognition

Recognitions

Industry Impact:

These models contributed to Suzuki's reputation for building competitive and reliable motorcycles in a highly contested market segment during their production run.