Suzuki GS-GSX 450 Twins 1979-1985 Repair Service Manual

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Taper: Motorcycle

Distributeur:

UGS: 66044

Mots clés: 1979 1980 1981 1982 1983 1984 1985 GS 450 Twins GSX 450 Twins Misc Motorcycle Motorcycles Suzuki

Variantes de produits

Description

The Suzuki GS450E, GS450EX, GS450ST, and GS450TX "Twins" represent a significant segment of lightweight to mid-size Japanese motorcycles produced from 1979 to 1985. These models are powered by an air-cooled, SOHC, parallel-twin engine with a displacement of 448 cc, known for its tractable and torquey power delivery, making them suitable for general riding and commuting. Offering a range of variants from standard to semi-faired, custom, and sport, Suzuki catered to diverse rider preferences. The motorcycles feature a robust steel tube frame, telescopic front forks, and dual rear shock absorbers, contributing to a stable and reliable riding experience. Their market reputation highlights dependability and a comfortable ride, positioning them as strong performers in their class. This comprehensive workshop service manual provides detailed guidance for the maintenance, repair, and overhaul of the Suzuki GS450E/EX/ST/TX models. Covering a wide array of systems including the engine, transmission, electrical components, chassis, brakes, and fuel system, this manual is an essential resource for owners and technicians. It includes step-by-step procedures for routine servicing, troubleshooting common issues, and performing complete component rebuilds. With its extensive coverage of maintenance schedules, fluid specifications, and technical data, this manual empowers users to effectively maintain and repair their motorcycles, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GS450E / GS450EX / GS450ST / GS450TX

Model Variant:

Twins

Codes

Chassis Codes:

GS450E, GS450EX, GS450ST, GS450TX

👋 Introduction

Market Position

Segment:

Lightweight to Mid-size Japanese Motorcycle

Competitive Analysis

Competitors:

Honda CB550/CB650, Yamaha XS650, Kawasaki KZ650.

Key Features

Engine Configuration:

Air-cooled, SOHC, parallel-twin cylinder engine.

Powertrain Layout:

Longitudinal engine crankshaft, chain drive.

Drivability:

Known for a torquey and tractable power delivery suitable for general riding and commuting.

Variants:

Offered in standard (E), semi-faired (EX), custom/cruiser (ST), and sport (TX) variations, catering to different rider preferences.

📋 Manual Details

Coverage Areas

Covered Years:

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

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Language

Language:

English (Likely, based on typical market distribution)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, disassembly, assembly, tuning, lubrication system, cooling system, fuel system (carburetion), ignition system.

Transmission:

Gearbox removal and installation, internal component inspection and repair, clutch operation and maintenance.

Electrical:

Wiring diagrams, charging system (alternator, regulator), ignition system (points, coils, spark plugs), lighting, instrumentation, starting system.

Chassis:

Frame inspection, front forks and steering system maintenance, rear suspension (shocks, swingarm) service, wheel bearing maintenance.

Brakes:

Front and rear brake system service, hydraulic system maintenance, pad/shoe replacement, caliper/master cylinder service.

Fuel System:

Carburetor identification, disassembly, cleaning, adjustment, fuel tank and petcock maintenance.

Procedures Included

Maintenance:

Regular servicing, oil changes, filter replacements, chain adjustment, brake fluid checks, tire pressure checks.

Troubleshooting:

Diagnosis of common engine, electrical, and mechanical problems with step-by-step guidance.

Repair:

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

Rebuild:

Comprehensive instructions for engine and major component rebuilds.

Technical Depth

Depth:

Intermediate to Expert. Covers routine maintenance through complete engine and component overhauls.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

Digital (PDF) - quality depends on original scan/creation.

Binding Type

Binding Type:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, four-stroke, SOHC, parallel-twin

Displacement:

448 cc (27.3 cu in)

Bore X Stroke:

67.0 mm x 63.4 mm (2.64 in x 2.50 in)

Compression Ratio:

9.2:1 (Typical)

Valve Train:

SOHC, 2 valves per cylinder

Performance

Horsepower:

Approx. 40-45 HP @ 8000 RPM (Model Dependent)

Torque:

Approx. 36-39 Nm (26-29 lb-ft) @ 6500 RPM (Model Dependent)

Fuel System

Carburetion:

Twin Mikuni VM26SS or similar downdraft carburetors

Fuel Type:

Unleaded gasoline (premium recommended)

Ignition

Ignition System:

CDI (Capacitor Discharge Ignition) with breaker points (early models) or fully electronic (later models).

🔧 Transmission

Standard

Transmission Type:

5-speed constant mesh, sequential return type

Primary Drive:

Final Drive:

Chain

Features

Clutch Type:

Wet, multiple-disc

Clutch Actuation:

Cable operated

📐 Dimensions

Exterior

Length:

Varies by model (approx. 2100-2200 mm)

Width:

Varies by model (approx. 750-800 mm)

Height:

Varies by model (approx. 1150-1250 mm)

Weights

Dry Weight:

Approx. 170-185 kg (375-408 lbs) (Model Dependent)

Fuel Capacity:

Approx. 17 Liters (4.5 US gallons)

Wheelbase:

Approx. 1430 mm (56.3 in)

🛡️ Safety Features

Ratings

Crash Safety Standards:

Not applicable for motorcycles of this era in the same way as cars; safety focus on rider control and braking performance.

Active Features

Braking System:

Front: Single Disc Brake; Rear: Drum Brake (Some later models may have optional disc brake).

Suspension Performance:

Telescopic front forks, dual rear shock absorbers contributing to stability and handling.

Passive Features

Frame Construction:

Steel tube frame, providing a rigid and stable platform.

💡 Technology Features

Infotainment

Instrumentation:

Analog speedometer, tachometer, fuel gauge (on some models), indicator lights for turn signals, neutral, oil pressure, high beam.

Driver Assistance

Not equipped with Anti-lock Braking System (ABS).

Connectivity

Bluetooth Connectivity:

Not equipped with Bluetooth connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km or 6 months (Refer to Manual for specifics)

Spark Plug Replacement:

Every 6,000 km or 12 months (Refer to Manual)

Valve Clearance Check:

Every 6,000 km or 12 months (Refer to Manual for adjustment procedures)

Chain Lubrication And Adjustment:

Every 1,000 km or as needed

Fluid Specifications

Engine Oil Type:

SAE 10W-30 API SE or SG classification (Refer to Manual for exact grade)

Engine Oil Capacity:

Approx. 2.5 Liters (2.6 US quarts) with filter change

Brake Fluid Type:

DOT 3 or DOT 4 (Check manufacturer recommendation)

Fork Oil Type:

SAE 10W (Refer to Manual for specific grade and quantity)

Known Issues

Carburetor Issues:

Common for older carburetors to clog or require synchronization. Diaphragm wear can also occur.

Ignition System Wear:

Breaker points and condensers can wear and require regular adjustment or replacement on earlier models. CDI units can be prone to failure with age.

Electrical Connections:

Corrosion and loose connections in wiring harness can lead to intermittent electrical faults.

Engine Oil Leaks:

Seals and gaskets can degrade over time, leading to minor oil leaks, particularly around the cylinder head and crankcase.

📚 Vehicle History

Brand Heritage

Brand Origin:

Suzuki Motor Corporation, Japan.

Model Evolution

Predecessor:

Suzuki GS550 series.

Successor:

Suzuki GSX400F, GS550/GS650 models.

Production

Production Years:

1979-1985

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Market Reputation:

Generally well-regarded for its reliability, manageable power, and comfortable ride for its class. A solid performer in the 450cc twin segment of its era.