1980-1986 Suzuki GS/GSX 400-1100 Service Manual (P/N SD-0001 E-01)
Suzuki Models Covered & Key Technical Specifications
Models: GS400, GSX400, GSX400L, GS450, GS450L, GS550, GS550D, GS550E, GS550L, GSX750, GSX750E, GSX750L, GS850G, GS850GL, GS1000, GSX1100, GSX1100L
Sub-models / Variants: E-01, E-02, E-04, E-15, E-16, E-17, E-18, E-21, E-22, E-24, E-25, E-26, E-27, E-28, E-30, E-34, E-39
Trade Names: GS, GSX
Model Years: 1980–1986
Technical Data:
- Engine oil capacity: 2600–3000 ml
- Valve clearance: 0.03–0.13 mm
- Spark plug gap: 0.6–0.8 mm
- Compression pressure: 9–14 kg/cm²
- Oil pressure: 3.0–5.5 kg/cm²
Suzuki Manual Features & Content Preview
- Covers 1980–1986 Suzuki GS and GSX 400 through 1100 models, documenting factory service specifications for various international market variants
- Official Suzuki Motor Co., Ltd. publication containing 145 pages of technical specification tables for engine, transmission, electrical, and chassis components
- Delivers essential data for maintenance and rebuild projects, including valve clearances, piston ring gaps, and ignition timing
- Establishes the factory tolerance benchmarks for the GS and GSX range, detailing specific E-code market regional differences
Technical Documentation Details
The 1980–1986 Suzuki GS/GSX 400–1100 service data manual organizes critical tolerances by model variant. It covers the GS400, GS450, GS550, GS750, GS850, and GS1100 series motorcycles. Each section presents standard and service-limit dimensions for internal engine components. Examples include valve guides, piston rings, crankshaft journals, and transmission gear backlashes. Understanding the structure of this factory documentation helps ensure that engine assembly and chassis calibration remain within manufacturer-specified operating parameters across diverse international markets.
Specification Highlights
Engine maintenance sections provide detailed fluid capacities. This includes specific volumes for oil changes and filter replacements. Compression pressure is documented between 9 and 14 kg/cm², while ignition system electrical values list coil resistance and regulated voltage targets. Fuel system data breaks down MIKUNI carburetor bore sizes and jet specifications for various global markets.
For the cylinder head, intake valve clearance is listed at 0.03–0.13 mm. The Suzuki GS/GSX oil pressure maintains 3.0–5.5 kg/cm² at 3000 rpm. Front fork oil capacity ranges from 145 to 302 ml per leg, depending on the exact model configuration. Safety during any major rebuild or maintenance procedure relies on verifying these baseline factory tolerances before beginning work. Always follow standard workshop safety protocols and exercise professional judgment when applying these specifications to a live engine.
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