Suzuki GSX400FZ 1982 Service Repair Manual

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Art.-Nr: 89366

Stichworte: 1982 GSX400FZ Misc Motorcycle Motorcycles Suzuki

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Beschreibung

This manual provides comprehensive service and repair information for the 1982 Suzuki GSX400FZ motorcycle. Engineered with a 398cc, DOHC, air-cooled inline-four engine, the GSX400FZ represents Suzuki's commitment to performance and reliability in the sportbike segment of its era. Its design philosophy focused on bridging the gap between commuter and track-ready machines, offering a balanced blend of power and handling. This motorcycle is intended for enthusiasts and owners who appreciate classic Japanese engineering and are looking for a capable machine for spirited riding. The scope of this Service and Repair Manual is extensive, covering all facets of the 1982 Suzuki GSX400FZ. It details maintenance procedures, troubleshooting guides, technical specifications, and essential safety guidelines. Within its pages, you will find in-depth coverage of the engine, fuel system, ignition, transmission, brakes, suspension, and electrical systems, including detailed diagrams and step-by-step instructions for disassembly, assembly, and repair. This manual is an indispensable resource for owners, mechanics, and technicians aiming to maintain, diagnose, and restore the GSX400FZ to optimal operating condition.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GSX400FZ

Year:

Codes

Chassis Code:

GSX400FZ

👋 Introduction

Market Position

Segment:

Sportbike/Naked Bike

Target Audience:

Enthusiasts and owners seeking to perform maintenance, repairs, and tuning on their classic Suzuki sportbike.

Competitive Analysis

Competitors 1982:

Yamaha XJ Series, Kawasaki GPz Series, Honda CB Series of similar displacement.

Key Features

Engine Layout:

DOHC inline-four, air-cooled, providing a balance of performance and reliability for its era.

Design Philosophy:

Suzuki's focus on performance-oriented, multi-cylinder motorcycles that bridged the gap between commuter and track-focused machines.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive service and repair for the 1982 Suzuki GSX400FZ motorcycle.

Page Count

Estimated Pages:

300-400 (estimated based on typical service manuals for this era)

Manual Type

Type:

Service and Repair Manual

Scope:

Factory service manual covering all aspects of the motorcycle's mechanical and electrical systems.

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagrams, specifications, disassembly, assembly, troubleshooting, and tuning of the 398cc 4-stroke, DOHC, air-cooled engine.

Fuel System:

Carburetor identification, adjustment, overhaul, and troubleshooting (likely Mikuni VM series or similar).

Ignition System:

CDI ignition timing, component testing, troubleshooting, and specifications.

Transmission:

Gearbox disassembly, inspection, repair, clutch operation, and specifications.

Drivetrain:

Chain and sprocket maintenance, adjustment, and replacement procedures.

Brakes:

Front and rear brake system maintenance, hydraulic system bleeding, pad/shoe replacement, and caliper/master cylinder service.

Suspension:

Front fork disassembly, seal replacement, oil specifications, damping adjustment, and rear shock absorber service.

Electrical System:

Wiring diagrams, component testing (lights, starter, charging system), battery maintenance, and troubleshooting.

Cooling System:

Air-cooling system efficiency, cleaning, and related components.

Frame And Bodywork:

Frame inspection, fairing removal/installation, and general chassis components.

Procedures Included

Maintenance:

Regular service intervals, oil changes, filter replacements, lubrication points, chain adjustment, and brake fluid checks.

Troubleshooting:

Diagnostic flowcharts and common problem-solving guides for engine, electrical, and chassis issues.

Repair:

Step-by-step instructions for component removal, overhaul, installation, and adjustment.

Disassembly Assembly:

Complete breakdown and reassembly procedures for all major mechanical and electrical components.

Engine Tuning:

Includes guidance on spark plug selection, ignition timing verification, and carburetor synchronization and jetting adjustments.

Wheel And Tire Service:

Information on wheel bearing maintenance, tire removal/installation, and correct tire pressures.

Technical Depth

Depth:

Comprehensive, covering everything from basic user maintenance to advanced engine rebuilds and electrical diagnostics.

Wiring Diagrams:

Detailed, high-resolution wiring diagrams essential for electrical troubleshooting.

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Print Quality

Quality:

Digital scan, quality may vary but designed for legibility and usability on screen.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Type:

398cc, 4-stroke, DOHC, air-cooled, inline-four cylinder

Bore X Stroke:

53.4 mm x 44.9 mm (typical for this engine configuration)

Compression Ratio:

9.7:1 (typical)

Performance

Horsepower Estimated:

Approx. 40-45 HP @ 9,000 RPM (estimated)

Torque Estimated:

Approx. 30-34 Nm @ 7,000 RPM (estimated)

Fuel System

Carburetor Type:

Twin Mikuni VM24SS or similar dual-throat carburetors (specified in manual)

Fuel Tank Capacity:

16 Liters (approx.)

Lubrication

Oil Type:

SAE 10W-40 API SE (specified in manual)

Oil Capacity:

3.0 Liters (with filter change, specified in manual)

Ignition System

Ignition Type:

Electronic Ignition (CDI)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Features

Clutch Type:

Wet, multi-plate

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

2055 mm (approx.)

Width:

750 mm (approx.)

Height:

1160 mm (approx.)

Weights

Dry Weight:

170 kg (approx.)

Wet Weight:

185 kg (approx.)

🛡️ Safety Features

Ratings

Crash Test Data:

N/A (Motorcycle, pre-dates standardized motorcycle crash testing as known today)

Active Features

Braking System:

Hydraulic disc brakes front and rear (typically single disc front, possibly drum or disc rear depending on exact spec).

Lighting:

Halogen headlight, taillight, brake light, turn signals.

💡 Technology Features

Infotainment

Features:

N/A (Motorcycle of this era focuses on mechanical and performance aspects, no integrated infotainment systems).

Driver Assistance

Features:

N/A (No electronic rider aids or driver assistance systems typical of modern vehicles).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 km or 6 months (typical for era).

Valve Clearance Check:

Every 6,000-10,000 km (specified in manual).

Chain Lubrication Adjustment:

Every 1,000 km or as needed.

Fluid Specifications

Fork Oil Type:

Suzuki Fork Oil SAE 10W (or equivalent, specified in manual).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (specified in manual).

Gearbox Oil Type:

SAE 80W-90 API GL-4 (typical for manual transmissions, check manual for exact spec)

Known Issues

Carburetor Wear:

Diaphragms and seals in carburetors can degrade over time, requiring overhaul.

Cam Chain Tensioner:

Automatic cam chain tensioner can weaken or fail, leading to rattling noise and potential timing issues. Manual override or replacement may be needed.

Electrical Connectors:

Corrosion on electrical connectors can lead to intermittent faults.

Exhaust Leaks:

Gaskets at exhaust header joints can degrade, causing leaks.

📚 Vehicle History

Brand Heritage

Suzuki Motorsports:

Suzuki has a rich history in motorcycle racing, influencing the design and performance of their road bikes.

Model Evolution

Gsx Lineage:

The GSX designation became synonymous with Suzuki's high-performance, DOHC four-valve-per-cylinder sportbikes, starting in the early 1980s.

Production

Manufacturing Era:

Produced in the early 1980s, a period of rapid advancement in Japanese motorcycle technology.

🏆 Awards & Recognition

Recognitions

Awards Historical:

While specific awards for the GSX400FZ might not be widely documented, Suzuki's sportbike offerings of this era were generally well-received for their performance and handling.