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Suzuki GS250 GSX250 400 450 TWINS Service Repair Workshop Manual 1979-1985

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This manual covers the GS250, GSX250, GS400, and GS450 Twins, produced between 1979 and 1985. These parallel-twin motorcycles, known for their reliability and performance, were manufactured in Japan. They represent...
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Tipo: Motorcycle
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SKU: 132118
Suzuki GS250 GSX250 400 450 TWINS Service Repair Workshop Manual 1979-1985
This manual covers the GS250, GSX250, GS400, and GS450 Twins, produced between 1979 and 1985. These parallel-twin motorcycles, known for their reliability and performance, were manufactured in Japan. They represent a significant part of heritage in the motorcycle market, offering a blend of engineering quality and user-friendly operation. The models feature air-cooled, 4-stroke parallel-twin engines with varying displacements from 247cc to 448cc, and typically utilize a 5-speed transmission and a wet, multi-plate clutch. Common configurations include a front disc brake and a rear drum brake, along with essential lighting systems. This comprehensive service repair workshop manual provides factory-issued, technician-level detail for all models and repairs, covering all systems from A-Z. It includes step-by-step instructions, detailed illustrations, exploded views, and complete wiring schematics for the engine, fuel system, ignition, transmission, brakes, electrical system, and chassis components. The manual is designed to assist GS series twin motorcycle owners and independent mechanics in performing routine maintenance, troubleshooting, and in-depth repairs, ultimately empowering them to maintain and optimize their vehicles.
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
GS250/GSX250/GS400/GS450 Twins
Product Type:
Service Repair Workshop Manual
Codes
Production Years Covered:
1979-1985
👋 Introduction
Market Position
Target Audience:
Suzuki GS series twin motorcycle owners and independent mechanics
Value Proposition:
Empowers owners to perform their own maintenance and repairs, saving money
Competitive Analysis
Information Accuracy:
Vehicle/model specific, not generic
Authenticity:
Same type of manual used by dealership technicians
Key Features
Instruction Style:
Complete step-by-step instructions
Visual Aids:
Diagrams and illustrations
Electrical Data:
Wiring schematics included
Completeness Claim:
The only service repair workshop manual you will ever need
📋 Manual Details
Coverage Areas
Coverage Scope:
All models and all repairs A-Z
Page Count
Page Count:
Not specified, but described as 'factory highly detailed'
Manual Type
Manual Type:
Workshop Manual / Service Manual / Repair Manual
Language
Language:
English
Format
File Format:
PDF
Availability
Delivery Method:
Instant Download
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, inspection, and repair
Fuel System:
Carburetor tuning, cleaning, rebuilding, fuel tank, fuel lines
Ignition System:
Ignition timing, spark plugs, coils, CDI unit
Transmission:
Gearbox inspection, repair, clutch service
Drivetrain:
Final drive, shaft drive (if applicable), swingarm
Suspension:
Front forks, rear shocks, bearings
Brakes:
Hydraulic systems, caliper service, master cylinder, brake fluid replacement
Electrical System:
Wiring schematics, lighting, charging system, starter motor
Cooling System:
Air-cooled engine specifications, fin cleaning
Bodywork Chassis:
Frame inspection, fairings, seat, fuel tank mounting
Wheels Tires:
Wheel bearing service, tire pressure recommendations
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain lubrication, spark plug replacement
Troubleshooting:
Diagnostic procedures for common and uncommon issues
Rebuilding:
Engine rebuilds, carburetor rebuilds, brake caliper rebuilds
Adjustment:
Valve clearance adjustment, carburetor synchronization, idle speed adjustment
Diagnosis:
Step-by-step diagnostic flowcharts
Installation:
Component replacement and installation guides
Technical Depth
Depth Of Coverage:
Comprehensive, technician-level detail
Information Source:
Factory-issued documentation
Diagrams:
Detailed illustrations and exploded views
Schematics:
Complete wiring schematics
📊 Manual Specifications
File Format
File Type:
PDF
Platform Compatibility:
Windows (all versions), Mac
Required Software:
Adobe PDF Reader
Print Quality
Printability:
All pages printable
Image Enhancement:
Images can be blown up and printed enlarged
Binding Type
Binding Type:
Digital Download (no physical binding)
Paper Type
Paper Type:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, parallel-twin (common across GS250, GSX250, GS400, GS450 models)
Cylinder Displacement Gs250:
247cc (approximate)
Cylinder Displacement Gs400:
398cc (approximate)
Cylinder Displacement Gs450:
448cc (approximate)
Valve Train:
DOHC (Double Overhead Camshaft) for GSX models, SOHC (Single Overhead Camshaft) for GS models
Performance
Horsepower Gs250:
Typically in the 20-25 HP range (varies by year and tuning)
Horsepower Gs400:
Typically in the 30-35 HP range (varies by year and tuning)
Horsepower Gs450:
Typically in the 35-40 HP range (varies by year and tuning)
Fuel System
Carburetion Type:
Mikuni VM series or similar constant velocity (CV) carburetors, often dual carburetor setup
Fuel Delivery:
Gravity feed from fuel tank
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 5-speed (common for these models)
Features
Clutch Type:
Wet, multi-plate
Gear Selection:
Foot operated sequential shift
📐 Dimensions
Exterior
Body Styles:
Standard naked bikes, some with fairings
Weights
Dry Weight Gs250:
Approximately 160-170 kg (varies by model and equipment)
Dry Weight Gs450:
Approximately 180-190 kg (varies by model and equipment)
🛡️ Safety Features
Ratings
Safety Standards:
Adherence to relevant automotive safety standards of the era
Active Features
Braking System:
Front disc brake, rear drum brake (common configurations)
Passive Features
Lighting:
Headlight, taillight, turn signals, brake light
💡 Technology Features
Infotainment
Infotainment System:
N/A (Classic motorcycle technology)
Driver Assistance
Driver Assistance Features:
N/A (Classic motorcycle technology)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 km or annually (refer to manual for exact specifications)
Valve Adjustment Interval:
Typically every 6,000-10,000 km (refer to manual for exact specifications)
Fluid Specifications
Engine Oil Type:
API SE/SF or SG, SAE 10W-40 or 20W-50 motorcycle specific oil recommended (verify with manual)
Engine Oil Capacity:
Approximately 2.0-2.5 liters (dry fill) (verify with manual)
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (verify with manual)
Known Issues
Common Wear Items:
Carburetor diaphragms, fork seals, drive chain and sprockets, brake components
Electrical Concerns:
Age-related degradation of wiring insulation and connectors
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation, Japan
Model Evolution
Heritage:
Part of Suzuki's successful range of parallel-twin motorcycles known for reliability and performance in their class.
Gsx Designation:
GSX often indicated a more performance-oriented variant, potentially with DOHC engine design.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Awards And Recognitions:
These models were generally well-regarded for their balance of performance and reliability in their respective displacement classes during their production era.
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