Download Suzuki GS400-450!77!87 PDF

TitleSuzuki GS400-450!77!87
TagsTire Brake Carburetor Clutch Ignition System
File Size80.0 MB
Total Pages247
Document Text Contents
Page 1

INTRODUCTION
This detailed, comprehensive manual covers the Suzuki

400-450 series twins from 1977-1987.
The expert text gives complete information on maint-

enance, tune-up, repair and overhaul. Hundreds of photos
and drawings guide you through every step. The book in-
cludes all you will need to know to keep your Suzuki run-
ning right. Throughout this book where differences occur
among the models, they are clearly identified.

A shop manual is a reference. You want to be able to find
information fast. As in all Clymer books, this one is de-
signed with you in mind. All chapters are thumb tabbed.
Important items are extensively indexed at the rear of the
book. All procedures, tables, photos, etc., in this manual
are for the reader who may be working on the bike for the
first time or using this manual for the first time. All the
most frequently used specifications and capacities are
summarized in the Quick Reference Data pages at the front
of the book.

Keep the book handy in your tool box. It will help you
better understand how your bike runs, lower repair costs
and generally improve your satisfaction with the bike.

Page 2

QUICK REFERENCE DATA

STATIC TIMING

IDLE SPEED SCREW

TUNE-UP SPECIFICATIONS

Recommended spark plug
1977-1985
1986-on

Spark plug gap
Breaker point ignition (GS400, GS425)

Point gap
Dwell angle
GS400
GS425

Valve clearance (cold)
Ignition timing *
GS400, GS425

GS450

Idle speed
Carburetor air screw
All models manufactured

after January 1978
All earlier models

* Timing on GS450 models is pre-set.

NGK B8ES or ND W24ES
NGK B8ES or NO W24ES-U
0.6-0.8 mm (0.024-0.031 in.)

0.3-0.4 mm (0.012-0.016 in,)

180°
190°
0.03-0.08 mm ((0.0012-0.0031 in.)

10° BTDC below 1,500 rpm
40'' BTDC above 3,600 rpm
10° BTDC below 1,650 rpm
40° BTDC above 3,500 rpm
1,100-1,300 rpm

Pre-set @ factory (non-adjustable)
1 1/4 turns open

No routine timing adjustment is necessary,

VII

Page 123

120
CHAPTER FOUR

5. Assemble the 2 pump rotors with the punch
marks positioned as shown in Figure 264.
Carefully examine the rotors for signs of
excessive wear or damage.
6. Install the pump rotors into the pump body.
The chamfered edge of the rotor is positioned
toward the inside of the pump.
7. Use a feeler gauge and measure the clear-
ance between the inner and outer rotors
(Figure 265). The clearance limit is 0.2 mm
(0.008 in.).
8. Measure the outer rotor clearance as shown
in Figure 266. The clearance limit is 0.25 mm
(0.010 in.).
9. Use a straight edge with a feeler gauge and
measure the pump side clearance (Figure 267).
The clearance must not exceed 0.15 mm (0.006
in.).
10. When reassembling the pump, use blue
ixKtite (Lock N' Seal No. 2114) on the screw
securing the pump assembly.

CAM CHAIN TENSIONER

Removal/Installation

NOTE
If the engine is still installed in the mo-
torcycle, it is necessary to remove the
carburetors to gain access to the ten-
sioner assembly. Refer to Chapter Six
and perform Carburetor Removal.

Page 124

ENGINE 121

1. Loosen the locknut securing the lockscrew
and tighten the lockscrew to hold the tensioner
plunger (Figure 268).
2. Remove the bolts securing the tensioner to
the cylinder and remove the tensioner assem-
bly (Figure 269).
3. Before installing the tensioner, completely
compress the spring-loaded plunger and secure
it with the lockscrew.
4. Make sure the gasket is installed on the
tensioner assembly and install the assembly to
the cylinder block. Torque the mounting bolts
to 0.6-0.8 mkg (4.5-6.0 ft.-lb.).

Page 246

WIRING DIAGRAMS 243

1983 GS450TXD

Illiilllilii

Page 247

244 WIRING DIAGRAMS

1987 GS450LH

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