Model Variant:
All Models (GS250, GS450)
Chassis Codes:
Likely includes variations for GS250 (e.g., GS250T, GS250E) and GS450 (e.g., GS450T, GS450E, GS450L), specific chassis codes would be detailed within the manual.
Historical Context:
The GS250 and GS450 were part of Suzuki's popular line of versatile motorcycles, known for their reliability and performance in the late 70s and early 80s, catering to riders looking for a balance of commuting practicality and weekend enjoyment.
Competitors:
Competed with similar displacement models from Yamaha (e.g., XS400), Honda (e.g., CB450), and Kawasaki (e.g., KZ440).
Manual Value Proposition:
Provides factory-level technical information essential for maintaining and repairing these classic Suzuki motorcycles, enabling owners to perform complex tasks and save on dealership costs.
Data Accuracy:
Emphasizes 'NOT GENERIC REPAIR INFORMATION' and 'VEHICLE/MODEL SPECIFIC,' ensuring accuracy and relevance for technicians and owners.
Coverage Type:
Comprehensive Service, Repair, and Workshop Manual
Repair Scope:
All Repairs A-Z
Page Count:
Not specified, but described as 'Factory Highly Detailed' and 'Complete Step-by-Step Instructions'
Manual Type:
Workshop Repair Manual
Target Audience:
Dealership Technicians, Professional Mechanics, DIY Enthusiasts
Delivery Method:
Instant Download
Compatibility:
Windows (7, Vista 32/64, XP, ME, 98, NT, 2000), Mac Computers, Tablets
Required Software:
Adobe PDF Reader
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly for both GS250 and GS450 variants.
Fuel System:
Carburetor service, adjustment, and rebuilding; fuel pump operation and troubleshooting.
Ignition System:
CDI unit testing, spark plug specifications, timing adjustments, and component diagnostics.
Transmission:
Gearbox disassembly, clutch service, inspection of gears and shafts, shift mechanism repair.
Drivetrain:
Shaft drive system maintenance, universal joint inspection and lubrication, final drive unit service.
Suspension:
Front fork servicing (oil changes, seal replacement), rear shock absorber inspection and replacement, linkage maintenance.
Braking System:
Front and rear brake caliper overhaul, master cylinder service, brake fluid replacement, and bleeding procedures.
Electrical System:
Complete wiring schematics, charging system (stator, rectifier/regulator), lighting circuits, starter motor, battery maintenance.
Cooling System:
For air-cooled engines, this would focus on cylinder head cooling fins, but might include any oil cooling systems if present.
Frame And Bodywork:
Frame inspection, fairing and body panel removal/installation, seat servicing, luggage rack mounting.
Wheels And Tires:
Wheel bearing maintenance, spoke tension adjustment (if applicable), tire pressure specifications.
Scheduled Maintenance:
Regular service checks, oil and filter changes, chain lubrication and adjustment (if applicable).
Troubleshooting Guides:
Diagnostic procedures for common problems, fault finding charts, electrical system diagnosis.
Rebuild Procedures:
Detailed instructions for overhauling major components like the engine and transmission.
Adjustment Procedures:
Carburetor synchronization, valve clearance adjustment, brake lever free play.
Inspection Guidelines:
Visual inspection points for wear and damage on critical components.
Depth:
Factory-level, highly detailed, covering all aspects from basic maintenance to complete mechanical and electrical repairs.
Diagrams Illustrations:
Includes numerous step-by-step diagrams, exploded views, and illustrations for clarity.
Schematics:
Complete and detailed wiring schematics for electrical systems.
Engine Type:
Air-cooled, four-stroke, parallel-twin cylinder (typical for GS250/GS450)
Displacement:
GS250: Approximately 248cc; GS450: Approximately 448cc. Precise specifications detailed in manual.
Bore X Stroke:
Specifics for each model variant will be in the manual, crucial for engine rebuilds.
Compression Ratio:
Factory specifications provided for optimal performance and diagnostics.
Horsepower:
Range typically from mid-20s for GS250 to mid-30s for GS450 hp. Exact figures available in manual.
Torque:
Specific torque figures for engine RPM will be detailed in the manual.
Carburetion:
Likely Mikuni or similar twin carburetor setup. Manual will detail jetting, float levels, and synchronization.
Ignition Type:
Transistor Controlled Ignition (TCI) or CDI (Capacitor Discharge Ignition) system.
Oil Type Capacity:
Specifications for engine oil grade (e.g., 10W-40, 20W-50) and capacity will be included.
Crash Safety:
N/A (Motorcycles typically do not have formal crash ratings like cars; manual focuses on mechanical safety and rider control).
Braking System Performance:
Manual will cover brake fluid type (DOT 3 or DOT 4), disc/drum configurations, and required maintenance for optimal stopping power.
Lighting System:
Detailed information on headlight, taillight, brake light, and turn signal operation and troubleshooting.
Oil Change:
Typically every 3,000-5,000 km or 6 months, with precise intervals in the manual.
Valve Clearance Check:
Recommended intervals for checking and adjusting valve clearances (e.g., every 6,000-10,000 km).
Spark Plug Replacement:
Intervals for spark plug inspection and replacement will be specified.
Engine Oil:
Recommended SAE viscosity grade and API classification (e.g., SAE 10W-40, API SE/SF).
Brake Fluid:
Typically DOT 3 or DOT 4.
Fork Oil:
Specific grade and volume for front fork oil will be detailed.
Gear Oil:
For shaft drive, specific gear oil recommendations will be provided.
Carburetor Issues:
Common issues like gummy carburetors due to fuel degradation, necessitating thorough cleaning and rebuilding.
Electrical Connections:
Corroded or loose electrical connectors, particularly in the charging system and lighting circuits, leading to intermittent failures.
Fork Seals:
Leaking front fork seals are a common wear item requiring replacement.
Valve Stem Seals:
Potential for oil consumption due to wear on valve stem seals.
Suzuki Motorcycle Division:
Suzuki has a long history in motorcycle manufacturing, known for innovation and reliable performance across various classes.
Gs Series:
The GS series represented Suzuki's entry into the larger displacement four-stroke motorcycle market, evolving through various engine sizes and configurations.
Manufacturing Location:
Primarily manufactured in Japan.
