Suzuki GS250 GS450 GSX250 GSX400 Full Service & Repair Manual 1979-1985

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Taper: Motorcycle

Distributeur:

UGS: 148616

Mots clés: 1979 1980 1981 1982 1983 1984 1985 GS Series GS250 GS450 GSX250 GSX400 Motorcycle Motorcycles Suzuki

Variantes de produits

Description

This manual covers a range of motorcycles, including the GS250, GS450, GSX250, and GSX400 models, produced between 1979 and 1985. These versatile motorcycles, encompassing standard sportbike, cruiser, and cafe racer styles, were known for their air-cooled, 4-stroke, DOHC inline twin engines, offering a blend of performance and affordability. The GS and GSX series represented a significant step in mid-size motorcycle offerings, building on a reputation for reliable and performance-oriented machines. This comprehensive factory service and repair workshop manual provides detailed English-language instructions for maintaining and repairing these classic models. It covers all essential aspects, from routine maintenance and engine overhauls to troubleshooting electrical systems and chassis components. With hundreds of pages featuring detailed photos and exploded diagrams, this manual is an invaluable resource for owners and technicians seeking to ensure the longevity and optimal performance of their GS or GSX series motorcycles.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GS250, GS450, GSX250, GSX400

Model Codes:

GS250E, GS250T, GS450E, GS450L, GS450ST, GSX250E, GSX250ET, GSX400E, GSX400ET, GSX400F, GSX400FS, GSX400T, GSX400TX

Production Years Covered:

1979-1985

👋 Introduction

Market Position

Target Audience:

Suzuki motorcycle owners, independent repair shops, motorcycle enthusiasts undertaking their own maintenance and repairs.

Value Proposition:

A comprehensive, factory-authorized resource for maintaining and repairing a range of popular Suzuki motorcycles from the late 1970s and early 1980s.

Competitive Analysis

Manual Superiority:

Provides factory-level detail often missing in aftermarket manuals; lifelong access and multi-device compatibility offer superior value over subscription or limited-use manuals.

Key Features

Comprehensiveness:

Covers all aspects of repair, servicing, and troubleshooting, ensuring no task is beyond the scope of the owner or technician.

Durability And Access:

Lifetime access and multi-device usability make it a perpetually valuable resource without recurring costs.

📋 Manual Details

Coverage Areas

Manual Type:

Full Factory Service & Repair Workshop Manual

Language:

English

Format:

Digital Download (PDF)

Digital Features:

Printable, Usable on multiple devices and computers, Lifetime access, No expiry

Page Count

Estimated Page Count:

Hundreds of pages (specific count not provided, but described as 'very detailed')

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete engine disassembly, inspection, repair, and reassembly procedures for all covered models and variants.

Fuel System:

Carburetor tuning, cleaning, and rebuilding; fuel pump operation; fuel tank and line maintenance.

Ignition System:

Ignition timing adjustment, spark plug specifications, coil testing, CDI unit diagnosis.

Transmission And Drivetrain:

Clutch operation, gearbox disassembly and assembly, final drive maintenance, chain and sprocket care.

Suspension And Steering:

Front fork servicing (oil changes, seal replacement), rear shock absorber maintenance, steering head bearing adjustment, swingarm lubrication.

Braking System:

Front and rear brake caliper maintenance, master cylinder servicing, brake pad replacement, brake fluid bleeding procedures.

Electrical System:

Wiring diagrams, lighting system diagnosis, battery testing, charging system (stator, regulator/rectifier) troubleshooting, starter motor operation.

Chassis And Bodywork:

Frame inspection, fairing removal and installation, seat maintenance, fuel tank removal and installation, exhaust system care.

Procedures Included

Routine Maintenance:

Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment, brake checks, tire pressure checks.

Troubleshooting:

Diagnostic procedures for common problems, symptom-based troubleshooting guides, electrical fault finding.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension upgrades, electrical system repairs.

Component Replacement:

Step-by-step guides for replacing all major and minor components.

Technical Depth

Depth Of Information:

Comprehensive, covering everything from basic servicing to full engine and transmission rebuilds, including detailed torque specifications and clearances.

Diagrams And Illustrations:

Hundreds of detailed photos and exploded diagrams to guide repair processes.

📊 Manual Specifications

File Format

Primary File Format:

Compatibility:

Windows and MAC OS

Searchability:

Likely text-searchable PDF (implied by 'professional manual' and digital format, though not explicitly stated)

Print Quality

Print Capability:

Single pages or entire manual printable

Binding Type

Binding Format:

Not Applicable (Digital Download)

Paper Type

Paper Quality:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Configurations:

Air-cooled, 4-stroke, DOHC (Double Overhead Camshaft), inline twins.

Engine Configurations Detail

Gs250 / Gsx250:

Typically 247cc displacement, 2 valves per cylinder.

Gs450 / Gsx400:

Typically 448cc (GS450) or 398cc (GSX400) displacement, 2 valves per cylinder.

Performance

Gs250 Power Output:

Approx. 26-30 hp (specific figures vary by model variant and year).

Gs450 Power Output:

Approx. 40-45 hp (specific figures vary by model variant and year).

Gsx250 Power Output:

Approx. 30-35 hp (specific figures vary by model variant and year).

Gsx400 Power Output:

Approx. 45-50 hp (specific figures vary by model variant and year).

Fuel System

Carburetor Type:

Twin Mikuni VM or similar side-draft carburetors (specific model dependent).

Fuel Delivery:

Gravity feed from fuel tank to carburetors.

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh manual transmission.

Optional

Shaft Drive Availability:

Some GS450 models (e.g., GS450L) featured shaft drive as an alternative to chain drive.

Features

Clutch Type:

Wet, multi-plate, cable-actuated clutch.

📐 Dimensions

Exterior

Body Styles:

Standard Naked Sportbike, Cruiser (GS450L style), Cafe Racer (GSX-F variants).

Weights

Dry Weight:

Varies significantly by model, typically ranging from 150 kg to 180 kg (approx. 330 lbs to 395 lbs).

🛡️ Safety Features

Ratings

Safety Standards:

Designed to meet safety regulations of their respective production years.

Active Features

Braking System Type:

Front: Disc brake; Rear: Disc or Drum brake (model dependent).

Passive Features

Lighting:

Headlight, taillight, brake light, turn signals.

💡 Technology Features

Infotainment

Infotainment Features:

Not applicable; these are 1979-1985 motorcycles with no electronic infotainment systems.

Driver Assistance

Driver Assistance Features:

Not applicable; these motorcycles predated modern rider assistance technologies.

Connectivity

Connectivity Features:

Not applicable.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 km (approx. 1,800-3,000 miles) or 6-12 months, whichever comes first (refer to manual for exact specification).

Valve Adjustment Interval:

Typically every 6,000-10,000 km (approx. 3,700-6,200 miles) (refer to manual for exact specification).

Fluid Specifications

Engine Oil Type:

API SE or SF classification, SAE 10W-40 or 20W-50 viscosity recommended (refer to manual for precise specification).

Engine Oil Capacity:

Approx. 2.0 - 2.5 liters (depending on model and filter change) (refer to manual for exact specification).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (refer to manual for exact specification).

Fork Oil Type:

Typically SAE 10W fork oil (refer to manual for exact specification).

Known Issues

Common Wear Items:

Cam chain tensioner, clutch plates, fork seals, wheel bearings, and rectifier/regulator units are common wear items.

Electrical Reliability:

Older electrical components, particularly the regulator/rectifier and stator, can be prone to failure over time.

Carburetor Issues:

Gumming and blockage of carburetors due to old fuel or infrequent use is a common issue requiring cleaning and rebuilding.

Maintenance Schedule

Comprehensive Schedule:

The manual provides detailed, mileage-based (or time-based) maintenance schedules for all major systems.

📚 Vehicle History

Brand Heritage

Suzuki Motorcycle Legacy:

Suzuki has a long-standing reputation for producing reliable, performance-oriented motorcycles across various classes.

Model Evolution

Gs Series Development:

The GS series represented Suzuki's expansion into the popular mid-size and performance motorcycle market in the late 1970s and early 1980s, offering a blend of performance and affordability.

Gsx Series Development:

The GSX designation often indicated a more performance-oriented variant, sometimes with DOHC engines and sportier styling.

Production

Manufacturing Location:

Primarily Japan.

🏆 Awards & Recognition

Recognitions

Model Achievements:

While specific awards for these individual models from that era are not readily cataloged, Suzuki's GS/GSX series were generally well-received for their performance, reliability, and value within their respective market segments.