Target Audience:
Suzuki GS450/GS450E owners, independent repair shops, motorcycle enthusiasts seeking to perform their own maintenance and repairs
Value Proposition:
Offers significant cost savings compared to professional dealership service by enabling owner self-sufficiency in maintenance and repairs.
Ease Of Use:
Step-by-step instructions and accompanying pictures aim to simplify complex procedures.
Accessibility:
Downloadable format allows for immediate access and on-demand printing of relevant sections.
Years Covered:
1979, 1980, 1981, 1982, 1983, 1984, 1985
Models Covered:
All GS450 and GS450E models and trim levels
Estimated Pages:
Extensive (typical for comprehensive workshop manuals, likely 300+ pages)
Type:
Complete Workshop Service Repair Manual
Delivery Method:
Downloadable (email delivery)
File Type:
Digital (PDF likely)
Powertrain:
Engine, transmission, clutch, drivetrain
Chassis:
Frame, suspension (front fork, rear shock absorbers), wheels, tires, brakes (front and rear drums/discs), steering
Electrical:
Ignition system, charging system (stator, regulator/rectifier), lighting, starting system, battery, wiring diagrams, instrumentation
Fuel System:
Carburetors (twin Mikuni VM or similar), fuel tank, fuel lines, fuel pump (if applicable)
Exhaust:
Exhaust system components and installation
Bodywork:
Body panels, seat, fuel tank, fenders, trim pieces
Maintenance:
Oil changes, filter replacement, spark plug service, chain adjustment, brake adjustments, lubrication points, battery maintenance
Troubleshooting:
Diagnostic procedures for common performance issues, electrical faults, starting problems
Repair:
Engine disassembly and reassembly, carburetor tuning and rebuilding, brake caliper service, fork seal replacement, electrical component testing and replacement
Technical Data:
Specifications, torque values, clearances, fluid capacities, electrical resistance values
Special Tools:
Identification and usage of any specialized tools required for specific procedures
Engine Rebuild:
Detailed procedures for engine disassembly, inspection, honing, piston and ring replacement, crankshaft and bearing service, cylinder head overhaul, and reassembly.
Suspension Overhaul:
Complete instructions for front fork disassembly, seal replacement, oil changes, and rear shock absorber inspection and replacement.
Electrical Diagnostics:
In-depth troubleshooting guides for ignition, charging, starting systems, including wiring diagrams and component testing procedures.
Depth:
Comprehensive A-Z coverage, suitable for both novice DIY mechanics and experienced technicians
Compatibility:
PC, Mac, Tablets, Smartphones (requires Adobe Reader)
Printable:
Yes, individual pages or chapters can be printed
Binding:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Text Search:
Likely (if PDF is text-searchable), enhancing ease of information retrieval
Engine Type:
4-stroke, DOHC, Air-cooled, Parallel-Twin
Displacement:
448 cc (27.3 cubic inches)
Bore X Stroke:
Approximately 65.0 mm x 66.0 mm
Compression Ratio:
Approximately 9.2:1
Power Output:
Estimated 40-45 HP (figures vary by market and specific tuning)
Torque Output:
Estimated 25-30 lb-ft
Carburetion:
Twin Mikuni VM-type carburetors (e.g., VM26SS or similar)
Fuel Type:
Unleaded gasoline
Ignition System:
CDI (Capacitor Discharge Ignition)
Oil Type:
SAE 10W-40 API SE or SF motorcycle specific oil
Oil Capacity:
Approximately 2.2 - 2.4 Liters (with filter change)
Cooling System:
Air-cooled
Transmission Type:
Constant mesh, 5-speed, sequential return
Clutch Type:
Wet, multi-plate, cable-actuated
Gear Ratios:
Specific gear ratios will be detailed in the manual, crucial for performance tuning and understanding.
Transmission Oil Type:
Typically uses the same engine oil, but this should be verified in the manual.
Overall Length:
Varies slightly by year and specific configuration, but typically around 2150 mm
Overall Width:
Varies, typically around 750 mm
Overall Height:
Varies, typically around 1150 mm
Dry Weight:
Approximately 170-180 kg
Wet Weight:
Approximately 190-200 kg (with fluids)
Fuel Tank Capacity:
Approximately 16-17 Liters (including reserve)
Safety Features General:
As a motorcycle of its era, primary safety relies on rider skill and proper maintenance. The manual will cover brake system maintenance crucial for stopping power.
Braking System:
Front disc brake, Rear drum brake (some later models may have rear disc option). Manual covers inspection, pad/shoe replacement, fluid flush (if applicable).
Lighting System:
Headlight, taillight, brake light, turn signals. Manual details bulb replacement and electrical checks.
Instrumentation:
Analog speedometer, tachometer, odometer, trip meter, neutral indicator, turn signal indicators, high beam indicator.
N/A:
Not applicable for this model and era of motorcycle.
N/A:
Not applicable for this model and era of motorcycle.
Oil Change Interval:
Typically every 3,000-5,000 km or 6-12 months, as specified in the manual.
Spark Plug Replacement Interval:
Around 6,000-10,000 km, dependent on plug type and usage.
Chain Lubrication And Adjustment:
Regularly, every 500-1000 km, and adjustment as needed due to wear. Manual will provide slack specifications.
Brake Fluid:
DOT 3 or DOT 4 recommended, refer to manual for specific caliper recommendations.
Carburetor Sync And Cleaning:
Carburetors can become out of sync or clogged over time, affecting idle and performance. Manual details synchronization and cleaning procedures.
Charging System Reliability:
Stator and regulator/rectifier can be potential failure points as the bikes age. Manual guides testing these components.
Fork Seals:
Aging fork seals are common, leading to oil leaks. Manual covers seal replacement.
Valve Clearance:
Critical for engine performance and longevity. Manual provides exact intake and exhaust valve clearance specifications and adjustment procedures.
Suzuki Motorcycle History:
Suzuki has a long-standing history of producing reliable and performance-oriented motorcycles across various segments, known for innovation and value.
Gs Series Development:
The GS series represented Suzuki's entry and growth in the motorcycle market, with the GS450 fitting into the popular mid-size, versatile standard motorcycle category, often serving as a step-up from smaller displacement bikes.
Manufacturing Location:
Primarily Japan
Market Segment:
Mid-size standard/commuter motorcycle, also popular for general sport riding.
General Reputation:
The GS450 was generally well-regarded for its reliable engine, comfortable riding position, and practicality as a mid-size all-rounder, often praised for its value for money.
Consumer Reviews:
Owner reviews from the era and modern retrospectives often highlight its dependability and ease of maintenance, especially with the availability of comprehensive service manuals.
