1979-1985 Suzuki GS250 GSX250 GSX400 GS450 Twins Service Repair Workshop Manual (1979 1980 1981 1982 1983 1984 1985)

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Taper: Motorcycle

Distributeur:

UGS: 151574

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

Variantes de produits

Description

This manual covers the GS250, GSX250, GSX400, and GS450 Twins models produced between 1979 and 1985. These versatile motorcycles, powered by air-cooled, 4-stroke parallel-twin engines with displacements ranging from approximately 249cc to 448cc, were designed to offer a balance of performance and manageability. Known for their robust engineering and reliability, these models provided an accessible entry into performance motorcycling, with the GSX variants often representing sportier iterations. Their design emphasized functional simplicity and dependable operation, making them popular choices for commuting and recreational riding during their production era. This comprehensive Factory Service Repair Workshop Manual provides detailed instructions for the maintenance, troubleshooting, and repair of your motorcycle. It covers all essential systems, including the engine, fuel system, transmission, drivetrain, suspension, brakes, and electrical system, with in-depth procedures for disassembly, assembly, and diagnostics. The manual is presented in an easy-to-read format with abundant, high-quality illustrations and diagrams, ensuring that both do-it-yourself enthusiasts and professional mechanics can efficiently complete any task correctly. It serves as an indispensable resource for keeping these classic models in optimal working condition.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GS250, GSX250, GSX400, GS450 Twins

Production Years Covered:

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

Codes

Chassis Codes Implied:

Various, specific to each model variant (e.g., GS250T, GSX400F, GS450E, GS450L)

Engine Codes Implied:

Various, specific to each model variant (e.g., GS250 engine code, GSX400 engine code)

👋 Introduction

Market Position

Target Audience:

Do-it-yourself enthusiasts and experienced mechanics

Competitive Analysis

Value Proposition:

Inexpensive way to keep vehicles working properly, saving on professional labor costs

Key Features

Instruction Style:

Easy-to-read text sections with top-quality diagrams and step-by-step instructions

Efficiency Focus:

Designed to show how to complete jobs correctly and efficiently

Completeness:

Covers every single detail on the machine

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service, repair, and workshop procedures

Secondary Coverage:

Maintenance, troubleshooting, fault finding, specifications

Page Count

Estimated Page Count:

Not explicitly stated, but implied to be extensive given the coverage

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

File Format:

Compatibility:

All Versions of Windows & Mac

📖 Manual Coverage

Systems Covered

Engine:

Complete engine service, disassembly, assembly, troubleshooting

Fuel System:

Carburetor service, tuning, fuel delivery

Transmission:

Gearbox service, removal, installation, repair

Drivetrain:

Driveshaft (if applicable, often via final drive), chain adjustment, sprockets

Suspension:

Front suspension (forks), rear suspension (shocks/monoshock if present)

Brakes:

Brake servicing procedures (front and rear, hydraulic/mechanical)

Electrical System:

Wiring diagrams, ignition system, charging system, lighting

Exhaust System:

Exhaust system service and component identification

Cooling System:

Cooling system components and service (air-cooled likely, but some models might have oil coolers)

Bodywork:

Bodywork repair and disassembly

Procedures Included

Maintenance:

Factory maintenance schedules, routine checks

Diagnostics:

Fault finding, troubleshooting guides

Repair:

Step-by-step repair instructions for all major components

Disassembly Assembly:

Complete disassembly and reassembly procedures

Clutch:

Clutch removal and installation

Timing:

Timing chain service and adjustment

Technical Depth

Depth:

High; covers complete disassembly, rebuilds, and in-depth diagnostics suitable for experienced mechanics and serious DIYers

Illustrations:

Abundant illustrations, highly detailed exploded pictures and diagrams

📊 Manual Specifications

File Format

PDF Quality:

Implied high quality with clear text and diagrams for easy reading

Searchability:

Likely searchable PDF content

Print Quality

Printable:

All pages are printable

Binding Type

Binding:

Digital (PDF) - no physical binding

Paper Type

Paper Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 4-stroke, Parallel-Twin (typically SOHC or DOHC depending on model variant)

Displacement Gs250:

Approximately 249cc

Displacement Gsx250:

Approximately 249cc (often with different tuning or features than GS250)

Displacement Gsx400:

Approximately 398cc

Displacement Gs450:

Approximately 448cc

Performance

Horsepower Typical Range:

Ranges from ~25 HP (GS250/GSX250) to ~35-40 HP (GSX400/GS450), varies by model and tuning

Torque Typical Range:

Varies by displacement and tuning

Fuel System

Fuel Delivery:

Carburetor(s) (e.g., Mikuni VM Series, CV carbs)

Ignition System:

CDI (Capacitor Discharge Ignition), electronic ignition

Engine Firing Order

Firing Order:

Provided within the manual, typically 180 or 360 degree firing interval for parallel twins

Timing Chain

Timing Chain Service:

Covered, including tensioner adjustment and replacement

🔧 Transmission

Standard

Type:

Constant mesh, 5-speed or 6-speed manual transmission (depending on model)

Optional

Optional Transmissions:

N/A for this era of Suzuki motorcycles

Features

Clutch Type:

Wet, multi-plate clutch

Final Drive:

Chain drive (typically)

📐 Dimensions

Exterior

Dimensions:

Varies significantly by model (GS250 vs. GS450). Manual provides specific dimensions for each.

Weights

Dry Weight:

Varies by model, typically in the range of 330-390 lbs (150-177 kg)

Wet Weight:

Varies by model, includes fluids

🛡️ Safety Features

Ratings

Safety Ratings:

N/A for this era of motorcycle publications

Active Features

Braking System:

Front: Disc brake (hydraulic); Rear: Drum brake or Disc brake (hydraulic) depending on model

Passive Features

Frame Type:

Steel cradle frame (typical)

💡 Technology Features

Infotainment

Infotainment System:

N/A (basic motorcycle technology of the era)

Driver Assistance

Assistance Features:

N/A (basic motorcycle technology of the era)

Connectivity

Connectivity Options:

N/A (basic motorcycle technology of the era)

Instrumentation

Dashboard Features:

Analog speedometer, tachometer, odometer, trip meter, indicator lights (neutral, turn signals, high beam, oil pressure/warning).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 miles or annually, as specified in the manual.

Tune Up Interval:

Spark plug checks, carburetor synchronization, and valve clearance adjustments at prescribed intervals (e.g., 5,000-10,000 miles).

Fluid Specifications

Engine Oil Type:

API SE or SF, SAE 10W-40 or 20W-50 (specific grade depends on ambient temperature, detailed in manual)

Brake Fluid Type:

DOT 3 or DOT 4, depending on the specific braking system (detailed in manual)

Gearbox Oil Type:

API GL-1 or GL-4 gear oil, SAE 80 or 90 (manual will specify)

Known Issues

Common Wear Items:

Carburetor cleaning/rebuilding (gumming from old fuel), worn fork seals, aging electrical connections, clutch wear, cam chain wear.

Typical Troubleshooting:

Hard starting, poor running, electrical gremlins, brake fade.

📚 Vehicle History

Brand Heritage

Brand:

Suzuki Motor Corporation, a long-standing manufacturer of motorcycles, automobiles, and marine engines.

Model Evolution

Series Context:

These models represent Suzuki's efforts in the mid-size to entry-level performance motorcycle segment, often featuring parallel-twin engines for a balance of power and compact design. The 'GSX' designation often denoted higher performance or sporting variants.

Production

Production Period:

1979-1985 covers a significant period of evolution in motorcycle technology and design.

🏆 Awards & Recognition

Recognitions

Model Specific Awards:

Not readily available for individual models of this vintage, but Suzuki motorcycles of this era were generally well-regarded for reliability and performance relative to their price point.

Ratings

Manual Quality Rating:

High, based on description of detail and clarity.

Certifications

Manual Certification:

N/A (factory manual standard)