Segment:
Mid-size sport motorcycle, popular in its era for performance and versatility
Target Audience:
Enthusiasts and owners seeking to perform their own maintenance and repairs
Competitors:
Honda CB400 series, Kawasaki GPZ400, Yamaha XJ400
Manual Advantage:
Directly provides the same information used by authorized Suzuki service centers, enabling DIY repairs and cost savings.
Coverage Scope:
Extensive coverage, implying no significant system is omitted for the specific model.
Engine:
Complete engine overhaul, disassembly, assembly, tuning, troubleshooting
Fuel System:
Carburetor system, fuel delivery, fuel tank, fuel lines, troubleshooting and adjustment
Lubrication System:
Oil pump, oil filter, oil passages, oil pressure checks, lubrication system maintenance
Electrical System:
Complete wiring diagrams, lighting system, ignition system, charging system (alternator, regulator/rectifier), starter system, troubleshooting electrical faults
Transmission Drivetrain:
Gearbox overhaul, clutch operation, final drive (chain maintenance, sprocket replacement)
Suspension:
Front fork (disassembly, seal replacement, oil level and type), rear shock absorber(s) (adjustment, potential rebuild if applicable)
Brakes:
Front and rear brake systems (drum or disc depending on variant), brake fluid replacement, caliper/master cylinder overhaul, bleeding procedures
Cooling System:
Air-cooled engine specific maintenance (fin cleaning, inspection)
Chassis Frame:
Frame inspection, steering head bearing maintenance, swingarm maintenance
Bodywork Fittings:
Fairings, fuel tank, seat, fenders, control levers, cables
Maintenance:
Scheduled maintenance tasks, lubrication points, cleaning procedures
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based fault finding
Repair:
Step-by-step repair instructions for all major components and systems
Overhaul:
Complete engine, transmission, and other major system overhauls
Adjustment:
Carburetor synchronization, valve clearance adjustment, ignition timing (if applicable), cable adjustments
Diagnosis:
Systematic identification of problems and their causes
Depth:
Comprehensive from basic owner maintenance to full engine rebuilds and advanced electrical diagnostics
Diagnostic Tools:
Details on necessary tools, though proprietary diagnostic equipment for this era is minimal
Special Tools:
Identification of any specific Suzuki special tools required for certain procedures
Type:
Air-cooled, 4-stroke, DOHC, Inline-4 Cylinder
Displacement:
Approx. 398 cc
Bore X Stroke:
Likely around 53.4 mm x 46.2 mm (typical for 400cc inline-4s of the era)
Compression Ratio:
Typically in the range of 9.0:1 to 9.5:1
Horsepower:
Estimated 40-45 HP (at crankshaft, depending on specific market tune)
Torque:
Estimated 35-40 Nm (at crankshaft)
Carburetion:
Likely multi-carburetor setup, e.g., Mikuni VM or similar, possibly 4x 26mm or 28mm carbs
Fuel Type:
Unleaded Gasoline
Crash Safety:
N/A (Motorcycle safety ratings are not standardized like cars; manual covers safe operating procedures)
Braking System:
Front disc brake, Rear drum or disc brake (variant dependent)
Lighting:
Halogen headlight, tail light, brake light, turn signals
Frame Construction:
Steel frame, designed for rigidity and handling
Oil Change:
Typically every 3,000 - 5,000 km or annually
Spark Plug Service:
Inspection every 6,000 km, replacement as needed
Valve Clearance:
Initial check at 1,000 km, then every 6,000 - 10,000 km
Engine Oil Type:
API SE or SF, SAE 10W-40 or 20W-40 (refer to manual for exact specification)
Engine Oil Capacity:
Approx. 2.5 - 3.0 liters with filter change
Brake Fluid Type:
DOT 3 or DOT 4
Fork Oil Type:
Specific fork oil viscosity (e.g., Showa SS-8 or equivalent), quantity per leg to be specified in manual
Carburetor Sync:
Carburetors can go out of sync, requiring periodic adjustment for smooth running.
Electrical Connections:
Corrosion or looseness in electrical connectors can lead to intermittent faults.
Cam Chain Tensioner:
May require adjustment or replacement over time to prevent rattling.
Clutch Wear:
Clutch plates may wear over time, requiring replacement.
Brand Focus:
Suzuki is a well-established Japanese manufacturer with a strong history in motorcycles, particularly performance-oriented models.
Gsx Lineage:
The GSX designation represents Suzuki's line of sport-oriented motorcycles, often featuring multi-cylinder engines.
Production Years:
1982-1983 (as specified by product name)
Manufacturing Location:
Japan (presumed for Suzuki motorcycles of this era)
