Suzuki GSXR400 GSX R400 1984-1987 Service Repair Manual

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This manual covers the Suzuki GSX-R400 motorcycle, produced from 1984 to 1987, identified by chassis code GK71B. As part of Suzuki's pioneering efforts in the 400cc sportbike segment, the GSX-R400...

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Taper: Motorcycle

Distributeur:

UGS: 153621

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

Variantes de produits

Description

This manual covers the Suzuki GSX-R400 motorcycle, produced from 1984 to 1987, identified by chassis code GK71B. As part of Suzuki's pioneering efforts in the 400cc sportbike segment, the GSX-R400 offered a blend of performance and handling, setting a precedent for the highly influential GSX-R lineage. This model is characterized by its 398 cc liquid-cooled, 4-cylinder engine, dual front disc brakes, and a steel frame, representing a significant development in sportbike technology for its era. It competed with other notable models of its time, reflecting Suzuki's commitment to engineering quality and rider-focused design. This comprehensive Service Repair Manual provides detailed, step-by-step instructions for the maintenance, troubleshooting, and repair of your Suzuki GSX-R400. It covers all essential systems, including the engine, fuel system, cooling system, electrical components, and chassis. The manual includes procedures for disassembly, assembly, and rebuilding of key components, alongside periodic maintenance schedules and diagnostic guides. With hundreds of illustrations and photos, this English-language manual is an invaluable resource for owners and technicians alike, ensuring the optimal performance and longevity of the GSX-R400.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GSX-R400

Model Designation:

GSXR400 / GSX R400

Production Years Covered:

1984, 1985, 1986, 1987

Codes

Chassis Codes:

GK71B (primary chassis code for early models)

👋 Introduction

Market Position

Segment:

Sportbike / Motorcycle

Target Audience:

Owners of Suzuki GSX-R400 (1984-1987) seeking to perform maintenance, repairs, or restoration. Enthusiasts interested in detailed technical information.

Competitive Analysis

Key Competitors Era:

Yamaha FZ400R, Honda CBR400F, Kawasaki GPZ400.

Key Features

Value Proposition:

Provides comprehensive, step-by-step repair and maintenance guidance to empower owners to maintain their vehicle affordably and effectively.

Uniqueness:

Digital format ensures instant access and portability. Specifically tailored for the 1984-1987 GSX-R400 models.

📋 Manual Details

Coverage Areas

Manual Type:

Service Repair Manual

Language:

English

Format:

Delivery Method:

Instant Download

File Requirements:

Adobe PDF Reader, WinZIP

Compatibility:

All Versions of Windows & Mac

📖 Manual Coverage

Systems Covered

General Information:

Includes an overview of the motorcycle, safety precautions, and general service information.

Periodic Maintenance:

Detailed schedule for routine maintenance tasks, including lubrication, inspections, and adjustments.

Engine:

Comprehensive coverage of the 4-cylinder engine, including disassembly, assembly, inspection, repair of internal components (pistons, cylinders, crankshaft, camshafts), valve timing, and lubrication system.

Fuel System:

In-depth information on the fuel delivery system, including carburetor service (disassembly, cleaning, adjustment, synchronization), fuel pump, fuel lines, and fuel tank.

Cooling System:

Details on the liquid cooling system, including radiator, coolant flow, thermostat operation, water pump, and hoses.

Electrical System:

Extensive coverage of the electrical system, including ignition system, charging system (alternator, regulator/rectifier), starter motor, battery, lighting, instrumentation, and wiring diagrams.

Chassis:

Covers the frame, suspension (front forks, rear shock absorber/monoshock), steering system, wheels, tires, and brakes (front and rear). Includes procedures for fork seal replacement, suspension adjustments, and brake component servicing.

Emission Control Information:

Information related to emission control systems and their maintenance, if applicable to the specific market versions covered.

Procedures Included

Repair Procedures:

Step-by-step instructions for all repair and overhaul procedures, from minor adjustments to complete engine rebuilds and chassis component replacements.

Maintenance Procedures:

Detailed guidance on routine maintenance tasks to ensure optimal performance and longevity.

Troubleshooting:

Diagnostic procedures and common problem-solving techniques for various systems.

Rebuild Instructions:

Comprehensive instructions for rebuilding key components like the engine, transmission, and carburetors.

Disassembly And Assembly:

Detailed guidance on the complete disassembly and reassembly of the motorcycle and its components.

Technical Depth

Depth Of Information:

Highly detailed, suitable for both DIY enthusiasts and professional mechanics. Covers basic maintenance to advanced diagnostics and complete rebuilds.

Illustrations And Photos:

Hundreds of photos and illustrations to visually guide the user through service and repair procedures.

📊 Manual Specifications

File Format

File Type:

Printable:

Fully Printable

Searchability:

Likely text-searchable within the PDF for quick information retrieval.

Zoom Functionality:

Zoom IN/OUT enabled for detailed viewing of diagrams and text.

Binding Type

Binding Type:

Digital (PDF) - No physical binding

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, DOHC, 4-cylinder, 16-valve

Displacement:

398 cc (approximately)

Bore X Stroke:

53.8 mm x 44.5 mm (typical for this era of 400cc Suzuki)

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approx. 53-59 HP (varies by market and specific model year)

Torque:

Approx. 3.6 - 3.9 kgf·m (varies by market and specific model year)

Fuel System

Carburetion:

Mikuni VM or similar multi-carburetor setup (e.g., 4 x Mikuni BDST 32)

Fuel Type:

Unleaded gasoline (RON 91 or higher recommended)

Lubrication

Oil Type:

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

Oil Capacity:

Approx. 3.0 - 3.4 Liters (with filter change, specified in manual)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-plate

Features

Gear Ratios:

Detailed gear ratios provided in the manual for each gear.

Final Drive:

Chain drive

📐 Dimensions

Exterior

Wheelbase:

Approx. 1400 mm (55.1 inches)

Weights

Dry Weight:

Approx. 160-165 kg (353-364 lbs)

Wet Weight:

Approx. 180-185 kg (397-408 lbs)

🛡️ Safety Features

Ratings

Safety Standards:

Adheres to manufacturer safety standards of the era. Manual provides guidance on safe operation and maintenance.

Active Features

Brakes Front:

Dual disc brakes, hydraulic actuated (specific caliper and disc specs in manual).

Brakes Rear:

Single disc brake, hydraulic actuated (specific caliper and disc specs in manual).

Passive Features

Frame Type:

Steel twin-spar or semi-double cradle frame (specific construction details in manual).

💡 Technology Features

Infotainment

Instrumentation:

Analog tachometer, speedometer, fuel gauge, coolant temperature gauge, indicator lights (refer to manual for specific layout and functions).

Driver Assistance

Anti-lock Braking System was not standard on this model.

Connectivity

Electronic Aids:

Minimal to no electronic rider aids typical for the era.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000 - 6,000 km or 6-12 months (refer to manual for exact schedule).

Valve Clearance Check:

Typically every 6,000 - 12,000 km (refer to manual for exact schedule).

Spark Plug Replacement:

Typically every 12,000 - 24,000 km (refer to manual for specific type and interval).

Fluid Specifications

Brake Fluid:

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

Coolant:

Ethylene glycol-based antifreeze with corrosion inhibitor (typically 50/50 mix with distilled water)

Known Issues

Carburetor Issues:

Carburetor synchronization can drift, leading to rough idling or poor throttle response. Diaphragms and jets can degrade over time.

Electrical Gremlins:

Corrosion in connectors, worn wiring, and failing regulator/rectifiers are common on older motorcycles. The manual's wiring diagrams are invaluable.

Suspension Wear:

Fork seals can leak, and rear shock absorbers may lose damping over time, requiring rebuild or replacement.

Cam Chain Tensioner:

Automatic cam chain tensioners can sometimes fail, leading to rattling noises. Manual will cover inspection and replacement.

📚 Vehicle History

Brand Heritage

Brand Focus:

Suzuki is renowned for its performance-oriented motorcycles, particularly in the sportbike segment.

Model Evolution

Gsxr Lineage:

The GSX-R400 was part of Suzuki's early foray into the 400cc sportbike class, a popular segment in Japan and other markets. It laid the groundwork for the iconic GSX-R series.

Production

Manufacturing Location:

Likely Japan

🏆 Awards & Recognition

Recognitions

Sportbike Segment Impact:

While specific awards for this early model are scarce, the GSX-R line became highly influential and a benchmark in the sportbike category.

Ratings

Editorial Reviews Era:

Contemporary reviews would have focused on its nimble handling, strong engine performance for its class, and sharp styling.