Market Position:
The Suzuki GS450 was a popular mid-sized motorcycle in its era, known for its reliability, comfortable riding position, and accessible performance. It competed with other Japanese manufacturers' offerings in the 400-500cc class.
Competitors:
• Honda CB450/CB550
• Kawasaki KZ400/KZ550
• Yamaha XS400/XS500
Key Features:
Parallel-twin engine, shaft drive (on some models), classic styling, user-friendly maintenance.
Manual Usefulness:
Essential for owners and technicians to maintain, diagnose, and repair the Suzuki GS450. Provides the necessary technical data for correct servicing and ensures longevity.
Engine Mechanical:
Detailed breakdown of engine components, including cylinder head, valves, pistons, connecting rods, crankshaft, and timing system. Includes specifications for clearances, torque values, and overhaul procedures.
Engine Electrical:
Covers starting system, charging system (stator, rectifier/regulator), ignition system (CDI, coils, spark plugs), and lighting circuits. Includes wiring diagrams and troubleshooting guides.
Fuel System:
Detailed information on carburetor(s) (likely Mikuni VM series), fuel pump, fuel lines, and air filter. Includes disassembly, cleaning, adjustment, and troubleshooting procedures.
Transmission Clutch:
Covers clutch operation, components (plates, springs, hub), and adjustments. Details the gearbox, including gear selection, shifting mechanisms, and lubrication.
Brakes:
Comprehensive coverage of front and rear braking systems, including hydraulic lines, master cylinders, calipers, brake pads/shoes, and disc/drum wear limits and replacement procedures.
Suspension Steering:
Details front telescopic forks (oil type, level, seal replacement) and rear shock absorbers/swingarm bearings. Covers steering head bearings and linkage maintenance.
Maintenance Procedures:
Routine checks, oil changes, filter replacements, spark plug servicing, brake fluid replacement, chain adjustment, and lubrication schedules.
Repair Overhaul:
Step-by-step instructions for disassembling, inspecting, repairing, and reassembling major vehicle components, including engine rebuilds, gearbox overhauls, and brake system servicing.
Troubleshooting:
Diagnostic procedures for identifying common problems and malfunctions across various systems, with symptom-based troubleshooting charts.
Technical Depth:
Comprehensive, covering basic maintenance to complete engine and drivetrain rebuilds. Suitable for both novice mechanics and experienced technicians.
Engine Type:
Air-cooled, 4-stroke, parallel-twin
Bore X Stroke:
65.0 mm x 64.6 mm (approximate, confirm with manual)
Valve Train:
DOHC, 2 valves per cylinder (typical for the era)
Horsepower:
Approximately 35-40 HP (varies by specific model and tuning, confirm with manual)
Torque:
Approximately 35-40 Nm (varies, confirm with manual)
Carburetor Type:
Dual Mikuni VM series (e.g., VM26SC or similar), side-draft
Fuel Type:
Unleaded gasoline, octane rating as per owner's manual (typically 87-91 RON)
Oil Type:
API SE/SF classification, SAE 10W-40 or 20W-50 motorcycle specific oil (refer to manual for precise recommendation)
Oil Capacity:
Approximately 2.5 - 3.0 Liters with filter change (confirm with manual)
Ignition System:
Transistorized Ignition (CDI)
Wheelbase:
Approximately 1400-1450 mm (confirm with manual)
Seat Height:
Approximately 760-780 mm (confirm with manual)
Dry Weight:
Approximately 170-185 kg (varies by model, confirm with manual)
Fuel Tank Capacity:
Approximately 14-16 Liters (confirm with manual)
Infotainment Features:
N/A (Classic motorcycle technology: Analog gauges for speedometer, tachometer, odometer, and indicator lights).
Driver Assistance Features:
N/A
Connectivity Features:
N/A
Lighting Technology:
Incandescent bulbs for headlights, taillights, turn signals, and indicator lights.
Oil Change Interval:
Every 3,000-5,000 km or 6 months (refer to manual for precise interval and conditions)
Spark Plug Service:
Every 6,000-10,000 km (confirm gap and type in manual)
Valve Clearance Check:
Every 12,000-18,000 km (crucial for engine health)
Brake Fluid Flush:
Every 2 years or as per manual recommendation
Front Fork Oil Type:
Telescopic fork oil (e.g., SAE 10W or 20W), specific quantity per fork leg detailed in manual.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid (confirm in manual).
Common Issues:
• Carburetor synchronization and cleaning
• Stator and rectifier/regulator failure (common in older Japanese bikes)
• Wear on steering head bearings
• Chain and sprocket wear
• Oil leaks from engine seals
• Electrical connector corrosion
Oil Filter Part Number:
Varies by manufacturer (e.g., HiFlofiltro HF133, K&N KN-133 or equivalent Suzuki OEM - consult manual or parts fiche).
Spark Plug Part Number:
NGK DR8ES-L or equivalent (confirm with manual for exact type and heat range).
Brand Heritage:
Suzuki has a long and successful history in motorcycle manufacturing, known for innovation and performance across various categories, from sportbikes to cruisers to off-road machines.
Model Evolution Gs450:
The GS450 line was part of Suzuki's successful 'GS' series of motorcycles, which debuted in the late 1970s. It represented Suzuki's effort to capture the mid-size market with a reliable and versatile parallel-twin engine configuration.
Production Locations:
Japan (primary manufacturing)
Sales Performance:
The GS450 was a well-received model, contributing to Suzuki's strong market presence in the 1980s. Its reliability and ease of maintenance made it popular for both commuting and touring.
