Market Position:
This manual is targeted at owners and independent repair shops of Suzuki GS250 and GS450 motorcycles from the late 1970s and early 1980s, providing factory-level repair information.
Competitive Analysis:
Competes with other aftermarket service manuals (e.g., Haynes, Clymer) but is presented as the original factory resource, offering potentially higher accuracy and detail.
Key Features:
Factory-level detail, hundreds of pages, detailed photos & diagrams, step-by-step instructions, exploded diagrams, lifetime access, multi-device compatibility, printability.
Coverage Scope:
Complete factory service, repair, and troubleshooting for Suzuki GS250 and GS450 models.
Page Count Estimated:
Hundreds of pages (exact number not specified, but described as 'very detailed').
Manual Type:
Factory Service Repair Workshop Manual
Manual Purpose:
Service, repair, and workshop manual.
Language:
English (implied by context and common industry practice for manuals sold in this market)
Format:
Digital Download (PDF)
Engine Systems:
Engine overhaul, tuning, lubrication system, cooling system, fuel system (carburetors), ignition system, exhaust system.
Transmission Systems:
Gearbox overhaul, clutch operation, gear selection mechanism, final drive.
Chassis Systems:
Frame inspection and repair, suspension (front forks, rear shocks), steering system, wheel bearings, brake system (discs/drums).
Electrical Systems:
Wiring diagrams, lighting system, charging system (alternator, battery), ignition switch, starter system, instrumentation.
Bodywork And Trim:
Panel removal and installation, fairings, seat, fenders, fuel tank, minor body repairs.
Fuel Tank And Petcock:
Removal, installation, cleaning, and testing of fuel delivery components.
Instrumentation And Controls:
Repair and adjustment of gauges, levers, and cables.
Maintenance Procedures:
Regular servicing, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance adjustment, brake pad/shoe replacement.
Repair Procedures:
Engine rebuilds, transmission overhauls, carburetor tuning and rebuilding, suspension fork seal replacement, wheel truing, electrical fault diagnosis.
Troubleshooting Procedures:
Diagnostic flowcharts for common performance issues, starting problems, electrical faults, and operational anomalies.
Diagnostic Procedures:
Includes methods for diagnosing engine, electrical, and mechanical faults, often with step-by-step troubleshooting guides and symptom-based diagnosis.
Engine Timing Adjustment:
Procedures for setting ignition timing, critical for performance and emissions.
Technical Depth:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds. Includes detailed specifications for torque settings, clearances, and adjustments. Designed for professional mechanics and skilled DIY enthusiasts.
Torque Specifications:
Detailed torque specifications for all critical fasteners, essential for correct assembly and preventing damage.
Electrical Diagrams:
Comprehensive wiring diagrams for all electrical systems, crucial for troubleshooting and repair.
Illustrations Quality:
High-quality, detailed photos and exploded diagrams for visual guidance.
File Format Compatibility:
PDF; compatible with Windows, macOS, tablets, and smartphones.
Print Capability:
Printable: Allows printing of individual pages or the entire manual.
Binding Type:
N/A (Digital format)
Paper Type:
N/A (Digital format)
Licensing Terms:
Lifetime access, unlimited installations on multiple devices, no expiry dates, no renewal fees.
Engine Type Gs250:
4-stroke, DOHC, air-cooled, parallel-twin (exact specifications vary by sub-model and year)
Engine Type Gs450:
4-stroke, DOHC, air-cooled, parallel-twin (exact specifications vary by sub-model and year)
Valve Train Type:
DOHC (Double Overhead Camshaft), 2 valves per cylinder
Displacement Gs250 Approx:
248 cc
Displacement Gs450 Approx:
448 cc
Bore Stroke Gs250 Typical:
54.0 mm x 54.0 mm (typical, requires manual verification)
Bore Stroke Gs450 Typical:
66.0 mm x 65.2 mm (typical, requires manual verification)
Horsepower Gs250 Approx:
26-30 HP (at crankshaft, model dependent)
Horsepower Gs450 Approx:
37-43 HP (at crankshaft, model dependent)
Fuel System Type:
Carbureted (typically dual Mikuni VM or BST series carburetors)
Carburetor Sizing Typical:
Mikuni VM24SS or BST34 (for GS450) (requires manual verification)
Fuel Delivery:
Carbureted (manual provides detailed calibration and adjustment procedures).
Ignition System Type:
CDI (Capacitor Discharge Ignition)
Oil Change Interval:
Typically every 3,000-5,000 km or 6-12 months (consult manual for precise intervals).
Valve Clearance Check:
Typically every 6,000-10,000 km (consult manual for precise intervals).
Brake Fluid Change Interval:
Typically every 2 years or as per manual recommendation.
Engine Oil Type Typical:
SAE 10W-40 API SE or SF (consult manual for exact specification)
Engine Oil Capacity Approx:
2.0-2.5 Liters (with filter change, consult manual for exact capacity)
Brake Fluid Type Typical:
DOT 3 or DOT 4 (consult manual for exact specification)
Fork Oil Type Typical:
SAE 10W or SAE 15W (consult manual for exact specification)
Common Wear Items:
Carburetor diaphragm cracks, intake manifold leaks, rear shock absorber wear, clutch wear, cam chain noise.
Electrical Issues:
Corroded connectors, failing voltage regulator, worn headlight bulbs.
Engine Performance Issues:
Carburetor synchronization problems, vacuum leaks, spark plug fouling, timing issues.
