Target Audience:
Designed for both amateur DIY mechanics and seasoned professional technicians seeking in-depth information.
Value Proposition:
Provides an inexpensive alternative to dealership service and expensive physical manuals, offering instant access and comprehensive repair guidance.
Instruction Format:
Clear, numbered step-by-step instructions with detailed substeps, notes, cautions, and warnings.
Illustration Integration:
Bold figure numbers facilitate quick matching of illustrations to corresponding repair procedures.
Navigability:
Numbered table of contents for efficient information retrieval.
Applicable Years:
1980, 1981, 1982, 1983, 1984, 1985, 1986
Covered Styles:
All GSX400 variants including E, F, L, S, FW (Impulse)
Estimated Pages:
Approximately 300
Type:
Factory Service Manual (FSM)
Subtype:
Repair Manual, Workshop Manual, Maintenance Manual
Delivery Method:
Instant Digital Download
Engine:
Complete engine disassembly, assembly, tuning, and troubleshooting for all GSX400 engine variants.
Fuel System:
Carburetor overhaul, adjustment, troubleshooting, fuel tank, fuel lines, and fuel pump (if applicable).
Ignition System:
CDI system, ignition timing, spark plugs, coils, and troubleshooting.
Transmission:
Gearbox inspection, repair, clutch operation, and adjustment.
Electrical System:
Detailed wiring diagrams, charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), lighting, instrumentation, and troubleshooting.
Suspension:
Front fork service (oil change, seal replacement), rear shock absorber inspection and adjustment.
Brakes:
Front and rear brake system maintenance, caliper overhaul, brake fluid replacement, and bleeding procedures.
Cooling System:
Air-cooling system maintenance, fin cleaning.
Chassis And Frame:
Frame inspection, steering head bearing service, swingarm maintenance.
Bodywork And Trim:
Fairing removal/installation, seat, fuel tank, fenders.
Maintenance:
Regular scheduled maintenance, lubrication, filter changes, fluid checks and changes.
Troubleshooting:
Comprehensive guides for diagnosing and resolving common and uncommon issues across all systems.
Repair:
Step-by-step instructions for component repair, replacement, and rebuilding.
Overhaul:
Detailed procedures for complete engine and major component overhauls.
Adjustment:
Carburetor synchronization, valve clearance adjustment, clutch and brake lever adjustments, suspension adjustments.
Diagnostics:
Systematic diagnostic procedures for electrical and mechanical issues.
Level Of Detail:
Complete factory-level detail, suitable for both novice DIY enthusiasts and experienced professional mechanics.
Diagnostic Aid:
Includes detailed troubleshooting flowcharts and symptom-based diagnostics.
Illustration Quality:
Hundreds of clear, step-by-step illustrations, drawings, and photos, with enlarged inset views for critical components.
Data Specificity:
Precise torque specifications, measurements, clearances, and fluid capacities.
Type:
Air-cooled, 4-stroke, DOHC, Inline-4 Cylinder
Bore X Stroke:
Approx. 57.0 mm x 77.0 mm (varies slightly by specific model variant)
Compression Ratio:
Typically around 9.7:1 to 10.0:1 (depending on variant)
Horsepower:
Approximately 40-48 PS (29-35 kW) at 9,500-10,000 rpm (varies by market and variant)
Torque:
Approximately 3.2-3.5 kgf·m (31-34 Nm) at 7,500-8,000 rpm (varies by market and variant)
Carburetion:
Mikuni VM or BS series carburetors (e.g., VM22 or BS26, typically 4x carburetors)
Fuel Type:
Unleaded gasoline (Octane rating to be confirmed in manual)
Length:
Varies slightly by model (e.g., GSX400F: approx. 2130 mm)
Width:
Varies slightly by model (e.g., GSX400F: approx. 745 mm)
Height:
Varies slightly by model (e.g., GSX400F: approx. 1165 mm)
Dry Weight:
Approximately 174-183 kg (varies by model variant)
Wet Weight:
Approximately 190-199 kg (varies by model variant)
Dashboard Features:
Analog speedometer, tachometer, odometer, fuel gauge (on some variants), neutral indicator, turn signal indicators, oil pressure warning light, high beam indicator.
ABS:
N/A (Anti-lock Braking System was not available on this model).
Connectivity Features:
N/A (Basic mechanical and electrical systems).
Oil Change:
Every 3,000 - 5,000 km or 6-12 months (refer to manual for exact interval based on usage).
Valve Clearance:
Every 10,000 - 15,000 km (critical for engine performance and longevity).
Spark Plugs:
Inspection every 5,000 km, replacement as needed or at recommended intervals (e.g., 10,000-20,000 km).
Engine Oil:
API SE/SF classification, SAE 10W-40 or 10W-50 (refer to manual for specific viscosity based on ambient temperature).
Engine Oil Capacity:
Approx. 2.6 - 2.8 liters with filter change (refer to manual).
Brake Fluid:
DOT 3 or DOT 4 recommended (refer to manual for specific type and replacement interval).
Fork Oil:
Suzuki Fork Oil SS-06 or equivalent SAE 10W fork oil (volume specified per fork leg in manual).
Carburetor Issues:
Carburetor synchronization drift, fuel flow restrictions due to aging rubber components, and general wear and tear on jets and needles.
Electrical Gremlins:
Corroded electrical connectors, failing voltage regulators/rectifiers, and worn wiring insulation are common in older vehicles.
Engine Wear:
With age, potential for valve guide wear, piston ring wear, and cam chain tensioner issues may arise.
Suspension Wear:
Front fork seals can degrade over time, leading to leaks. Rear shock absorbers may lose damping effectiveness.
Suzuki Motorcycles:
Suzuki has a long-standing reputation for producing reliable and performance-oriented motorcycles, particularly in the sportbike and naked bike segments.
Gsx Series Introduction:
The GSX designation was introduced by Suzuki in the early 1980s to signify their foray into multi-valve, high-performance motorcycles.
Production Period:
1980-1986 covers the initial production run of the GSX400 line, encompassing various sub-models.
Manufacturing Location:
Japan (Suzuki Motor Corporation)
