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.
Competitor Manuals:
Provides more in-depth technical detail and coverage than generic online guides.
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.
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.
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.
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.
Engine Type:
4-stroke, DOHC, 4-valve per cylinder, air-cooled inline-four
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)
Carburetors:
Mikuni BS29 (typically 4 x CV carbs)
Fuel Capacity:
16 Liters (approximate)
Oil Capacity:
2.6 Liters (with filter change)
Oil Type:
API SE or SF, SAE 10W-40 (refer to manual for exact Suzuki recommendations)
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.
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).
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.
