The Suzuki GSX450, produced between 1979 and 1985, was Suzuki's offering in the mid-displacement sportbike category. Known for its reliable 4-stroke, DOHC, air-cooled inline-four engine with a displacement of approximately 448 cc, it delivered accessible performance suitable for everyday riding and sport touring. This model competed with other Japanese manufacturers' offerings and was appreciated for its comfortable ergonomics and value. Its design featured a 5-speed transmission, chain drive, disc front brake, and drum rear brake, embodying the engineering advancements of its era. This comprehensive workshop service manual provides detailed repair and overhaul instructions for Suzuki GSX450 models from 1979 to 1985. Covering all essential systems, including the engine, transmission, chassis, and electrical components, this manual offers step-by-step guidance for routine maintenance, troubleshooting common issues, and performing complete component rebuilds. It is an indispensable resource for owners, mechanics, and technicians seeking to maintain, repair, and ensure the optimal performance and longevity of their GSX450. 🏷️ Basic Information Identification Make: Suzuki Model: GSX450 Production Years: 1979-1985 👋 Introduction Market Position Positioning: The Suzuki GSX450 series represented Suzuki's entry into the competitive mid-displacement sportbike segment during the late 1970s and early 1980s, aiming to offer performance and value. Competitive Analysis Competitors: Competed with models like the Yamaha XJ400, Honda CB450N, and Kawasaki GPZ400. Key Features Features: Known for its reliable engine, comfortable ergonomics for its class, and accessible performance for everyday riding and sport touring. 📋 Manual Details Coverage Areas Coverage: Repair and overhaul of Suzuki GSX450 (1979-1985 models) Page Count Page Count: 232 Manual Type Type: Workshop Service Manual Language Language: English (Assumed, based on typical workshop manual conventions) Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete overhaul, tuning, lubrication, cooling, fuel system, ignition system Transmission: Clutch, gearbox operation, maintenance, repair Chassis: Frame, suspension (front and rear), steering, wheels, brakes Electrical: Ignition, lighting, charging system, battery, starter motor, wiring diagrams Bodywork: Body panel removal/installation, minor repairs Procedures Included Maintenance: Routine servicing, oil changes, filter replacements, adjustments Troubleshooting: Diagnostic charts and procedures for common issues Repair: Step-by-step instructions for component repair and replacement Overhaul: Detailed procedures for complete engine and component rebuilds Technical Depth Depth: Comprehensive coverage from basic maintenance to full engine rebuilds and advanced diagnostics 📊 Manual Specifications File Format File Format: PDF Print Quality Quality: High-resolution scans suitable for printing or on-screen viewing Binding Type Binding: N/A (Digital PDF download) Paper Type Paper Type: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Type: 4-stroke, DOHC, air-cooled, inline-four cylinder Displacement: 448 cc (approx. 450cc) Performance Horsepower: Approximately 45-50 HP (varies by year and specific market tuning) Torque: Approx. 27-30 lb-ft (varies by year and specific market tuning) Fuel System Carburetors: Mikuni VM or BS series (typically twin-sided or single with butterfly valve) Fuel Type: Unleaded gasoline Lubrication Oil Type: API SE, SF or SG grade multi-viscosity oil (e.g., 10W-40, 20W-50, depending on climate) Ignition System: CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Type: 5-speed constant mesh Optional Options: N/A (Standard 5-speed) Features Clutch: Wet, multi-plate, cable-actuated Final Drive: Chain drive 📐 Dimensions Exterior Length: Varies by model year, approx. 2150 mm (84.6 in) Width: Varies by model year, approx. 780 mm (30.7 in) Height: Varies by model year, approx. 1150 mm (45.3 in) Weights Dry Weight: Approx. 180-190 kg (397-419 lbs) Fuel Capacity: Approx. 16-18 Liters (4.2-4.8 US gal) 🛡️ Safety Features Ratings Crash Test Results: Not applicable (Motorcycle) Active Features Braking Front: Disc brake (single or dual depending on variant) Braking Rear: Drum brake Passive Features Lighting: Halogen headlight, taillight, turn signals 💡 Technology Features Infotainment Infotainment System: N/A (Basic motorcycle instrumentation) Driver Assistance Assistance Features: N/A Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change: Every 3,000 km (1,800 miles) or 6 months, whichever comes first Air Filter Cleaning: Every 6,000 km (3,600 miles) Valve Clearance Check: Every 12,000 km (7,200 miles) Spark Plug Replacement: Every 6,000 km (3,600 miles) Fluid Specifications Engine Oil Capacity: Approx. 2.4 - 2.8 Liters (2.5 - 3.0 US qt) with filter change Brake Fluid Type: DOT 3 or DOT 4 (as specified in manual) Fork Oil Type: SAE 10W (as specified in manual) Known Issues Carburetor Sync: Carburetors require regular synchronization for smooth running. Cam Chain Tensioner: Can become noisy with age; manual provides replacement procedures. Electrical Connections: Corrosion or loose connections in wiring harnesses can lead to intermittent issues. Filter Part Numbers Oil Filter: Suzuki OEM Part Number (e.g., 16510-07100, or equivalent aftermarket such as HF138, KN-138) Air Filter: Suzuki OEM Part Number (specific to model year, e.g., 13780-34410, or equivalent aftermarket) 📚 Vehicle History Brand Heritage Heritage: Suzuki has a long history in motorcycle manufacturing, known for innovative engines and performance-oriented bikes across various displacements. Model Evolution Evolution: The GSX450 was part of Suzuki's evolution towards more modern inline-four engines and sportier styling, building on earlier models...