1977-1983 Suzuki GS400, GS450 Twins Service Manual

Technical reference for GS400 and GS450 Twins models, covering 1977-1983. Documents engine, chassis, and electrical system repairs. PN 0-89287-237-3.

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Document Details

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Document Number / Seller:
29779 / Margaret Bell
File Size:
194.68 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Bike
Last updated / verified
Oct 9, 2025

Models Covered & Key Technical Specifications

Suzuki GS400/GS450 Twins (0-89287-237-3) Manual: ´77-83 Data-Compendium For GS400, GS450 Twins: diagnostics, service, and parts diagrams for 1977-1983 models. This comprehensive repository and guide ensures optimal performance. Library.

  • System Coupling Torques: 3.5-7.0 ft-lb. establishes the standard fastener torque requirements.
  • Core Twist Specifications: For engine components, 3.0-3.4 mkg supports critical baseline tension.
  • Specific Holding Capacity: The primary engine casing requires 9.5-16.5 ft-lb. for secure assembly.
  • Critical Load Capacity: The transmission gears are designed for 21.5-25.0 ft-lb. of holding power.
  • Universal Cycle Rate: The ignition system's timing is calibrated to 10 degrees BTDC for optimal operation.
  • Calibrated Torque Data: For critical fasteners, 11-18 ft-lb. defines the upper limit.

Professional Workshop Service Manual & Technical Specifications

Suzuki GS400/GS450 Twins (0-89287-237-3) Manual: ´77-83 Data-Compendium

Equipment-Series: 1977-1983 Suzuki GS400, GS450 Twins // Technical-Domain: Motorcycle Service Manual / Engine Logic // Equipment-Series: 150+ pages with diagrams and specifications.

TOP

Assessment-Parameter Operational-Logic Framework
Covers 1977-1983 GS400 & GS450 Twins Motorcycle Repair & Maintenance Comprehensive Data
Engine, Transmission, Clutch, Electrical Systems Detailed Procedures Exploded Views & Part Numbers
Troubleshooting & Specifications Diagnostic Assistance Performance Tuning

The manual presents information on General Information, Troubleshooting, Periodic Maintenance and Lubrication, Engine, Clutch, Transmission and Kickstarter, Fuel and Exhaust Systems, Electrical System, Front Suspension and Steering, Rear Suspension, Brakes, and Performance Improvement.

Quality checks are addressed for

the engine and driveline components, including thorough inspections and component testing procedures to ensure longevity.

The engine section documents

procedures for disassembly, inspection, and assembly of key engine components such as the camshafts, cylinder head, and crankcase.

The troubleshooting chapter addresses

common issues and provides systematic diagnostic steps to identify and resolve problems efficiently.

Cooling system maintenance is addressed in

the periodic maintenance and lubrication chapter, covering fluid checks and component servicing.

Testing requirements are specified for

the electrical system, including charging system output, alternator stator, and ignition system tests.

This manual documents torque specifications for various engine and chassis components to ensure proper assembly and service interval reliability.

FAQ

Assess the **critical** calibration settings for ignition timing. keyboard_arrow_down

10° BTDC below 1,500 rpm is the standard calibration for the ignition timing on the GS400 and GS450 models, ensuring optimal engine performance.

What components have **required** clearance measurements? keyboard_arrow_down

Valve clearances require precise measurement, with standard intake and exhaust clearances ranging from 0.025-0.055 mm for intake and 0.030-0.060 mm for exhaust.

Confirm the **specified** torque specifications for the crankcase bolts. keyboard_arrow_down

3.0-4.0 mkg (21.5-29.0 ft-lb.) is the specified torque for crankcase bolts on GS450 models, ensuring secure assembly.

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This service manual is incredibly detailed and well-structured. I found the troubleshooting section especially helpful for diagnosing issues. The download process was smooth, and I received the link promptly via email. Highly recommended!