Suzuki GSX400 1981-1983 Service Repair Manual

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Typ: Motorcycle

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Art.-Nr: 89363

Stichworte: 1981 1982 1983 GSX400 Katana Models Motorcycle Motorcycles Suzuki

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Beschreibung

The Suzuki GSX400, produced for the 1981, 1982, and 1983 model years, represents a significant entry in Suzuki's line of sport-oriented motorcycles. Known for its air-cooled, 4-stroke, DOHC inline-4 cylinder engine, typically displacing around 398cc, this model offered a blend of performance and engineering that was well-regarded during its era. With an estimated 40-45 horsepower and a 6-speed transmission, the GSX400 was designed for riders seeking an engaging and reliable machine, embodying Suzuki's reputation for quality manufacturing in Japan. Its robust construction and characteristic GSX series sporty attributes made it a popular choice for enthusiasts and daily riders alike. This comprehensive Factory Service Repair Manual in English is designed to assist do-it-yourself enthusiasts and professional mechanics in maintaining and repairing the Suzuki GSX400. It covers all essential systems, including detailed procedures for the engine, fuel system, cooling system, clutch, drivetrain, wheels and tires, brakes, suspension, steering, frame, and electrical system. The manual provides step-by-step instructions for routine maintenance, troubleshooting common issues, and complete disassembly and reassembly. With hundreds of photos and illustrations, it offers a complete resource for ensuring the longevity and optimal performance of your motorcycle.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GSX400

Model Years Covered:

1981, 1982, 1983

Codes

Chassis Code Variants:

Specific chassis codes may vary by market, but common variations include GK72A for early models.

👋 Introduction

Market Position

Target Audience:

Do-it-yourself enthusiasts and experienced mechanics.

Competitive Analysis

Comparison To Physical Manuals:

Offers greater convenience and cost-effectiveness compared to older paper manuals.

Key Features

Convenience:

Digital format allows for easy access, printing of specific pages, and portability.

Cost Effectiveness:

An inexpensive way to maintain and repair the vehicle, saving on labor costs.

Information Completeness:

Provides all necessary service information without extra fees or expiry dates.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

PDF Download

File Format:

Printability:

Yes, all pages printable

Compatibility:

All Windows versions, Mac, Smartphones, Tablets, Web Browser Access

Software Requirements:

Adobe PDF Reader, Winzip (free)

📖 Manual Coverage

Systems Covered

Engine Overview:

Comprehensive coverage of the engine, including top-end, lubrication, removal, and installation.

Fuel System:

Detailed information on the fuel delivery system, carburetors, and fuel tank.

Cooling System:

Coverage of the cooling system, including radiator, coolant, and related components.

Clutch System:

In-depth details on clutch operation, maintenance, and repair.

Drivetrain:

Covers crankshaft, transmission, and final drive components.

Wheels Tires:

Information on wheel and tire maintenance, mounting, and balancing.

Brakes:

Complete brake system service and repair instructions.

Suspension:

Detailed guidance on front and rear suspension systems.

Steering:

Information on the steering system for safe operation and repair.

Frame:

Coverage of the motorcycle frame, including inspection and minor repairs.

Electrical System:

Extensive coverage of the electrical system, including wiring diagrams, ignition, and lighting.

Appendix Information:

Includes supplementary data and often troubleshooting guides.

Procedures Included

Maintenance:

Routine maintenance tasks, fluid changes, filter replacements, and tune-ups.

Repair:

Step-by-step instructions for diagnosing and repairing all major components and systems.

Troubleshooting:

Diagnostic procedures and solutions for common and uncommon issues.

Disassembly Reassembly:

Complete disassembly and reassembly instructions for all major systems.

Technical Depth

Depth Of Coverage:

Complete full factory service repair manual, covering all styles and levels of repair.

Illustration Quality:

Hundreds of photos and illustrations guiding procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable within the PDF.

Print Quality

Resolution:

Assumed to be high-resolution for clear printing of text and images.

Binding Type

Binding Format:

Digital download, printable for physical binding.

Paper Type

Paper Recommendation:

Standard printer paper recommended for printing.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Air-cooled, 4-stroke, DOHC, Inline-4 Cylinder (typical for this model range)

Displacement:

Approximately 398cc (1981-1983 models)

Bore X Stroke:

Specific dimensions would be detailed in the manual, typically around 53.0mm x 40.0mm.

Compression Ratio:

Generally around 9.2:1 to 9.5:1.

Performance

Horsepower:

Estimated 40-45 HP at 9,000-9,500 RPM (specifications vary by market and specific tuning).

Torque:

Estimated 30-33 Nm at 7,500-8,000 RPM.

Fuel System

Fuel Delivery:

Carburetor(s) - likely Mikuni VM series or similar twin-carburetor setup.

Carburetor Size:

Typically 26mm or 28mm.

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-plate

Features

Gear Ratios:

Specific gear ratios will be detailed in the manual.

📐 Dimensions

Exterior

Length:

Specifications vary slightly by year and market, typically around 2,155 mm.

Width:

Typically around 750 mm.

Height:

Typically around 1,160 mm.

Weights

Dry Weight:

Approximately 170-180 kg.

Wet Weight:

Approximately 180-190 kg.

Fuel Capacity:

Approximately 16 liters (including reserve).

🛡️ Safety Features

Ratings

Safety Standards:

Met Japanese and international safety standards of the era.

Active Features

Braking System:

Front: Disc brake; Rear: Drum brake or Disc brake (depending on variant).

Passive Features

Lighting:

Standard headlight, taillight, and turn signals.

💡 Technology Features

Infotainment

Instrument Cluster:

Analog speedometer, tachometer, odometer, and indicator lights.

Driver Assistance

Not typically equipped with ABS.

Connectivity

Usb Charging:

Not applicable; no onboard electronic connectivity features.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 km or 6-12 months.

Valve Clearance Check:

Recommended every 6,000-12,000 km.

Fluid Specifications

Engine Oil Type:

10W-40 or 20W-50 API SG or higher (consult manual for precise specification).

Coolant Type:

Ethylene glycol-based antifreeze/coolant (if liquid-cooled components are present, though GSX400 is primarily air-cooled).

Brake Fluid Type:

DOT 3 or DOT 4.

Transmission Oil:

Specific gear oil or engine oil depending on transmission design (detailed in manual).

Known Issues

Carburetor Synchronization:

Carburetors can drift out of sync over time, requiring periodic adjustment.

Electrical Connections:

Corrosion or loose connections in wiring harness can cause intermittent issues.

Cam Chain Tensioner:

Tensioner may require adjustment or replacement on higher mileage units.

Exhaust Leaks:

Gaskets at the exhaust manifold can degrade, causing leaks.

📚 Vehicle History

Brand Heritage

Suzuki Motorcycles:

Suzuki has a long-standing reputation for producing reliable and performance-oriented motorcycles.

Model Evolution

Gsx Series:

The GSX designation typically represents Suzuki's sport-oriented models, often featuring advanced engineering for their time.

Production

Manufacturing Location:

Japan

Era Context:

The early 1980s was a period of significant development in motorcycle technology, with Japanese manufacturers leading in performance and innovation.

🏆 Awards & Recognition

Recognitions

Model Reputation:

The GSX400 series was generally well-regarded for its performance, handling, and reliability within its class.