Suzuki GSX-R400 Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 129889

Etiquetas: GSX Series GSX-R400 Motorcycle Motorcycles Suzuki

Variantes de producto

Descripción

The Suzuki GSX-R400, produced between 1984 and 1987 for models GK71B and GK73A, represents an early and significant entry in Suzuki's renowned GSX-R sportbike lineage. This air-cooled inline-four motorcycle, displacing 398cc, was engineered to deliver a potent sportbike experience within the 400cc class, a segment popular in its primary market of Japan. Known for its sporty handling, responsive engine, and robust build quality, the GSX-R400 embodies Suzuki's commitment to performance and rider engagement, making it a sought-after machine for enthusiasts and collectors. This comprehensive English Service Repair Manual is designed as an essential resource for owners, mechanics, and technicians working on the Suzuki GSX-R400 (GK71B / GK73A) models from 1984-1987. It meticulously details all aspects of maintenance, repair, and troubleshooting, covering engine mechanicals, fuel and ignition systems, transmission, clutch, brakes, suspension, and electrical systems. With abundant diagrams, illustrations, critical torque specifications, and detailed step-by-step procedures for routine maintenance, adjustments, and complete rebuilds, this manual serves to simplify complex tasks, ensure proper servicing, and help maintain the optimal performance and longevity of your motorcycle.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GSX-R400

Model Generation:

GK71B / GK73A

Applicable Years:

1984-1987

👋 Introduction

Market Position

Target Audience:

Suzuki GSX-R400 owners, enthusiasts, mechanics, and repair shops.

Value Proposition:

Essential resource for parts ordering, maintenance, and repairs, saving time and money on professional servicing.

Competitive Analysis

Competitor Manuals:

Provides more in-depth technical detail and coverage than generic online guides.

Key Features

Completeness:

Covers the complete tear down and rebuild, making it a comprehensive reference.

Visual Aid:

Extensive use of pictures and diagrams enhances understanding and procedural accuracy.

Practicality:

Printable pages offer flexibility for use in any workshop environment, avoiding damage to original manuals.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Manual

Language:

English

Format:

Page Count:

Download Type:

Instant Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full disassembly, inspection, repair, and reassembly of all engine components including cylinder head, valves, pistons, crankshaft, connecting rods, oil pump, and timing chain.

Fuel System:

Carburetor service, cleaning, adjustment, fuel tank, fuel pump, and fuel lines.

Ignition System:

CDI unit, ignition coils, spark plugs, wiring, and timing.

Cooling System:

Radiator, cooling fan, water pump, thermostat, hoses, and coolant specifications.

Transmission:

Gearbox disassembly, inspection, repair, gear shift mechanism, and clutch operation.

Clutch:

Clutch operation, adjustment, wear limits, and replacement of friction plates and springs.

Frame And Suspension:

Frame inspection, front fork disassembly, seal replacement, rear shock absorber service, and swingarm maintenance.

Brakes:

Front and rear brake caliper service, master cylinder overhaul, brake pad replacement, fluid specifications, and bleeding procedures.

Electrical System:

Wiring diagrams, battery maintenance, starter motor, alternator, lighting system, horn, and instrumentation.

Wheels And Tires:

Wheel bearing inspection and replacement, tire pressure recommendations, and rim specifications.

Bodywork And Fittings:

Fairing removal and installation, seat, fuel tank, and minor body panel adjustments.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, brake checks, and general inspection procedures.

Troubleshooting:

Diagnostic procedures for common starting problems, engine performance issues, electrical faults, and braking system anomalies.

Rebuilds:

Complete engine and transmission rebuild procedures, including step-by-step instructions and critical tolerances.

Adjustments:

Carburetor synchronization, valve clearance adjustment, clutch lever free play, and brake lever free play.

Replacement:

Detailed instructions for replacing wear items such as brake pads, spark plugs, fork seals, and chain and sprockets.

Cleaning And Lubrication:

Specific instructions for cleaning and lubricating various components of the motorcycle.

Technical Depth

Detail Level:

Comprehensive; covers complete tear down and rebuild procedures with detailed steps.

Diagrams Illustrations:

Abundant pictures and part diagrams for visual guidance throughout repair processes.

Torque Specifications:

Includes critical torque specifications for all fasteners and engine components.

Service Data:

Provides essential service data, including clearances, measurements, and wear limits.

Diagnostic Charts:

Likely includes diagnostic charts or flowcharts for troubleshooting.

📊 Manual Specifications

File Format

File Type:

Adobe PDF

Compatibility:

Windows and Mac

Searchability:

Likely text-searchable for quick information retrieval.

Print Quality

Printable:

All pages are printable for convenient use in the workshop.

Binding Type

Digital Format:

No physical binding; digital document.

Paper Type

Digital Format:

N/A (digital document)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, DOHC, 4-valve per cylinder, air-cooled inline-four

Displacement:

398 cc

Bore X Stroke:

56.0 mm x 40.4 mm

Compression Ratio:

11.3:1 (approximate, may vary by specific model year)

Power Output:

53 HP @ 11,000 RPM (approximate, varies by market and specific model year)

Torque:

3.8 kgf·m @ 9,000 RPM (approximate, varies by market and specific model year)

Fuel System

Carburetors:

Mikuni BS29 (typically 4 x CV carbs)

Fuel Capacity:

16 Liters (approximate)

Oil System

Oil Capacity:

2.6 Liters (with filter change)

Oil Type:

API SE or SF, SAE 10W-40 (refer to manual for exact Suzuki recommendations)

🔧 Transmission

Standard

Transmission Type:

Constant mesh 6-speed sequential

Optional

Automatic Transmission:

Features

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Length:

Approx. 2000 mm (varies by model year)

Width:

Approx. 700 mm (varies by model year)

Height:

Approx. 1150 mm (varies by model year)

Weights

Dry Weight:

Approx. 150-153 kg (varies by model year)

Wet Weight:

Approx. 170-173 kg (varies by model year)

🛡️ Safety Features

Ratings

Crash Safety Ratings:

N/A (Motorcycle, not subject to automotive crash ratings)

Active Features

Braking System:

Dual front disc brakes, single rear disc brake.

Suspension:

Telescopic front forks, Monoshock rear suspension with adjustable preload.

Passive Features

Lighting:

Halogen headlamp, tail lamp, and turn signals.

💡 Technology Features

Infotainment

Infotainment System:

N/A (This is a motorcycle from the mid-1980s, no advanced infotainment systems)

Driver Assistance

N/A (ABS was not a standard or widely available option on motorcycles of this era)

Connectivity

Bluetooth Connectivity:

Instrumentation

Dashboard:

Analog speedometer, tachometer, fuel gauge, odometer, trip meter, and indicator lights.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km or 6 months (refer to manual for precise Suzuki interval).

Oil Filter Interval:

Every oil change (or as specified by Suzuki, often with every oil change).

Valve Clearance Check:

Every 12,000 km or 1 year (refer to manual for precise Suzuki interval).

Chain Lubrication Adjustment:

Regularly, every 500-1000 km, and adjust as needed.

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for specific Suzuki recommendation)

Coolant Type:

Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio recommended).

Known Issues

Carburetor Issues:

Common for Mikuni carbs of this era to require regular cleaning and synchronization due to fuel deposits and aging diaphragms.

Electrical Connections:

Corrosion or looseness in electrical connectors can lead to intermittent faults. Regular inspection and cleaning are recommended.

Fork Seals:

Older fork seals can degrade over time, leading to oil leaks. Replacement is a common maintenance item.

Engine Vibrations:

While inherently a characteristic of inline-fours, excessive vibrations might indicate out-of-balance components or worn engine mounts.

📚 Vehicle History

Brand Heritage

Suzuki Legacy:

Suzuki has a long-standing reputation for producing high-performance motorcycles, particularly in the sportbike segment with the GSX-R lineage.

Model Evolution

Gsx R Lineage:

The GSX-R400 was an early iteration of Suzuki's popular GSX-R series, which began with the GSX-R750 in 1985. It offered a sportbike experience in a more accessible 400cc package.

Generations:

The 1984-1987 models represent the initial generations of the GSX-R400, evolving through chassis and engine refinements during this period.

Production

Manufacturing Location:

Japan

Key Markets:

Primarily Japan, with limited availability in other markets.

🏆 Awards & Recognition

Recognitions

Motorcycle Awards:

While specific awards for the GSX-R400 might be scarce, the GSX-R line in general received critical acclaim for its performance and handling.

Ratings

Performance Reviews:

Contemporary reviews praised its sporty handling and competitive performance within the 400cc class.

Certifications

Emissions Certification:

Met the emissions standards of its time, specific certifications would be in official Suzuki documentation.