Suzuki GSXR400 GSX R400 1984-1987 Full Service Repair Manual

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Art.-Nr: 148932

Stichworte: 1984 1985 1986 1987 GSX R400 GSX Series GSXR400 Motorcycle Motorcycles Suzuki

Produktvarianten

Beschreibung

This manual covers the GSXR400 (also known as GSX-R400) motorcycle models produced from 1984 to 1987, including chassis code GK71B. Engineered with renowned performance heritage, the GSXR400 embodies the spirit of its larger GSX-R siblings, offering a lightweight and agile package for sport riding. Its inline-four, liquid-cooled engine, paired with a 6-speed transmission and robust perimeter frame, delivers exhilarating performance that made it a respected contender in the 400cc supersport class of its era. The model is characterized by its distinctive styling and a focus on delivering a thrilling riding experience. This comprehensive service repair manual provides detailed instructions and technical specifications for maintaining, troubleshooting, and repairing your GSXR400. It covers all essential mechanical and electrical systems, including the engine, fuel system, transmission, drivetrain, suspension, brakes, and electrical components. With step-by-step procedures, diagnostic guides, and detailed illustrations, this manual is an indispensable resource for professional motorcycle technicians and dedicated enthusiasts alike, ensuring the optimal performance and longevity of your GSXR400.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GSXR400

Model Alias:

GSX-R400

Production Years Covered:

1984, 1985, 1986, 1987

Codes

Chassis Codes:

GK71B (common for early models)

👋 Introduction

Market Position

Target Audience:

Professional motorcycle technicians and experienced DIY mechanics aiming to maintain, repair, or restore their Suzuki GSXR400.

Competitive Analysis

Value Proposition:

Provides professional-grade technical information for immediate download, saving on shipping costs and wait times compared to physical manuals.

Key Features

Diagnostic Emphasis:

Strong focus on diagnostic procedures and troubleshooting, integrated with detailed wiring diagrams.

Visual Guidance:

Includes detailed illustrations, drawings, photos, and enlarged inset diagrams to aid in part identification and procedure execution.

📋 Manual Details

Coverage Areas

Mechanical Systems:

Engine, Fuel System, Exhaust System, Transmission, Drivetrain, Suspension, Brakes, Steering, Cooling System, Lubrication System, Frame, Wheels, Tires

Electrical Systems:

Ignition System, Lighting System, Charging System, Starting System, Instrument Cluster, Wiring Harnesses, Diagnostic Procedures

Page Count

Estimated Pages:

Refer to specific manual edition for exact count, typically 500+ pages for comprehensive coverage.

Manual Type

Type:

Full Service Repair Manual

Language

Language:

English

Format

Format:

Delivery Method:

Instant Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed overhaul procedures, component testing, timing procedures, carburetor tuning and synchronization, oil pump operation, valve adjustment.

Fuel System:

Fuel tank inspection and cleaning, fuel pump testing, fuel filter replacement, carburetor removal, disassembly, cleaning, reassembly, and adjustment.

Transmission Drivetrain:

Clutch operation, gear selection, transmission disassembly and reassembly, final drive inspection and maintenance.

Suspension Steering:

Front fork disassembly, oil replacement, seal replacement, rear shock absorber inspection and adjustment, steering head bearing service.

Brakes:

Brake caliper overhaul, brake pad replacement, brake fluid flush and bleeding, master cylinder inspection, rear brake adjustment.

Electrical:

Wiring diagrams, troubleshooting of electrical faults, starter motor testing, alternator output checks, battery maintenance, lighting circuit diagnostics.

Procedures Included

Maintenance:

Regular service schedules, oil and filter changes, chain adjustment and lubrication, spark plug replacement, air filter cleaning/replacement.

Troubleshooting:

Comprehensive fault finding guides for common and complex issues across all systems, including starting problems, poor running, electrical failures.

Repair Rebuild:

Step-by-step instructions for component disassembly, repair, and reassembly, including engine internal work, suspension overhauls, and brake system repairs.

Diagnostics:

Diagnostic procedures for engine performance, electrical systems, and mechanical components, often involving measurement of resistance, voltage, and pressure.

Technical Depth

Depth:

Extensive, covering detailed rebuilds, precise adjustments, and advanced diagnostic techniques suitable for professional technicians and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

File Type:

Software Requirements:

Adobe PDF Reader, WinRAR (for extraction if applicable)

Print Quality

Printability:

Fully printable, allowing users to print specific sections or the entire manual.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

Compatibility

Operating Systems:

Compatible with all Windows and Mac versions.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Inline-four, 4-stroke, DOHC, 16-valve

Displacement:

398 cc (approx.)

Bore X Stroke:

Approx. 55.0 mm x 42.0 mm (specific values may vary by sub-model)

Performance

Horsepower:

Approx. 50-59 PS (37-44 kW) at peak RPM (varies by market and specific model year)

Torque:

Approx. 3.7-4.0 kgf⋅m (36-39 Nm) at peak RPM (varies by market and specific model year)

Fuel System

Carburetion:

Mikuni VM Series Constant Velocity (CV) Carburetors (e.g., VM26SS or similar, typically 4-carb setup)

Fuel Tank Capacity:

Approx. 16 liters

Cooling System

Cooling Method:

Liquid-cooled

Lubrication System

Oil Type Specification:

API SG or higher, SAE 10W-40 or 20W-50 (refer to manual for exact Suzuki recommendation)

Engine Components

Ignition System:

Digital CDI (Capacitor Discharge Ignition)

🔧 Transmission

Standard

Transmission Type:

Constant mesh, 6-speed sequential

Features

Clutch Type:

Wet, multiple-disc, cable-operated

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 2060 mm

Width:

Approx. 740 mm

Height:

Approx. 1160 mm

Weights

Dry Weight:

Approx. 153 kg (dry)

Wet Weight:

Approx. 174 kg (fully fueled and ready to ride)

Wheels Tires

Front Tire Size:

110/70-17

Rear Tire Size:

130/70-17

Wheel Base:

Approx. 1410 mm

🛡️ Safety Features

Ratings

Safety Features Era:

Focus on chassis dynamics and braking for the era; advanced electronic safety systems not present.

Active Features

Braking System:

Dual front disc brakes with twin-piston calipers, single rear disc brake with single-piston caliper.

Passive Features

Frame Construction:

Steel perimeter (beam) frame, designed for rigidity and handling.

💡 Technology Features

Infotainment

Instrument Cluster:

Analog speedometer, tachometer, fuel gauge, temperature gauge, and warning lights.

Driver Assistance

Electronic Aids:

None; this era of motorcycle predates widespread electronic rider aids like ABS or traction control.

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 3,000-5,000 km or 6 months, whichever comes first.

Chain Maintenance:

Clean and lubricate every 500-1,000 km, adjust tension as needed.

Valve Clearance Check:

Every 10,000-12,000 km (refer to manual for precise intervals and procedures).

Fluid Specifications

Coolant Type:

Ethylene glycol based antifreeze with corrosion inhibitors (e.g., Suzuki Super Long Life Coolant or equivalent).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid (refer to manual for specific recommendation).

Known Issues

Carburetor Issues:

Aging carburetors can suffer from worn diaphragms, clogged jets, and vacuum leaks, leading to poor idle, hesitation, or surging.

Electrical Corrosion:

Corrosion in electrical connectors and wiring can lead to intermittent faults or system failures.

Suspension Wear:

Front fork seals and rear shock absorber seals can degrade over time, leading to leaks and loss of damping performance.

Engine Wear Points:

High-mileage engines may require attention to valve guides, piston rings, and crankshaft bearings.

📚 Vehicle History

Brand Heritage

Suzuki Motorcycle Legacy:

Suzuki has a long history of producing high-performance motorcycles, particularly in the sportbike segment, with the GSX-R line being a prominent example of their racing heritage.

Model Evolution

Gsxr400 Introduction:

The GSXR400 was introduced in the mid-1980s as part of Suzuki's strategy to compete in the popular 400cc supersport class, particularly in markets where licensing and insurance favored smaller displacements.

Design Philosophy:

Embodied the 'GSX-R' philosophy of lightweight, high-revving performance derived from racing technology, aiming for a balance of power and agility.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Market Reputation:

The GSXR400 series was well-regarded in its class for its performance, handling, and styling, often considered a benchmark for the 400cc supersport segment during its production years.