Suzuki GSX 400F

To Next Page

To Previous Page

Main Page

View of Suzuki GSX400F4
Group Index5
General Information: Contents7
Serial Number Locations8
Fuel and Oil Recommendations8
Brake Fluid8
Front Fork Oil8
Breaking-In Procedures9
Blowby Gas Recycling9
Cylinder Identification9
Camshaft Drive Chain Tensioner10
Push Rod and Lock Screw10
Lock Shaft10
Twin Swirl Combustion Chamber (TSCC)11
Full-Transistorized Ignition System15
Signal Generator16
Special Materials17
Precautions and General Instructions19
Use of Genuine Suzuki Parts19
Specifications20
Periodic Maintenance and Tune-Up Procedures23
Periodic Maintenance Chart24
Lubrication Chart25
Maintenance and Tune-Up Procedures26
Air Cleaner Element26
Battery27
Cylinder Head Nuts and Exhaust Pipe Bolts28
Valve Clearance29
Compression Check31
Compression Test Procedure31
Spark Plug32
Ignition Timing33
Carburetor33
Idling Adjustment34
Fuel Level Inspection34
Fuel Line35
Engine Oil and Oil Filter35
Oil Pressure36
Necessary Amount of Engine Oil36
Oil Pump Filter36
Oil Pump Pressure Specification36
Clutch37
Brake Fluid Level37
Brake Pads38
Brake Pedal Height38
Brake Light Switches39
Air Bleeding the Brake Fluid Circuit39
Brake Shoe Wear (Drum Type)41
Drive Chain41
Tire Tread Condition42
Tire Pressure43
Steering43
Front Fork44
Tightening Torque44
Servicing Engine: Contents45
Engine Components Removable with Engine in Place46
Engine Removal47
Engine Reinstallation52
Engine Disassembly54
Engine Components Inspection and Servicing65
Cylinder Head Disassembly65
Cylinder Head Distortion66
Valve Face Wear66
Valve Stem Runout66
Valve Head Radial Runout67
Valve Guide - Valve Stem Clearance67
Valve Stem Wear67
Valve Guide Servicing68
Valve Seat Width69
Valve Seat Servicing70
Valve Springs72
Reassembly Valves72
Camshaft73
Cam Wear74
Camshaft Journal Wear74
Camshaft Runout75
Cam Sprocket Reassembly75
Cam Chain Tensioner Disassembly76
Cam Chain Tensioner Reassembling77
Cam Chain 20-Pitch Length79
Cam Chain Guide79
Cylinder Distortion79
Cylinder Bore79
Piston Diameter80
Piston-Cylinder Clearance80
Piston Ring-Groove Clearance80
Piston Ring Free End Gap and Piston Ring End Gap81
Piston Pin and Pin Bore82
Connecting Rod Small End Bore I.D.83
Connecting Rod Big End Thrust Clearance83
Connecting Rod-Crank Pin Bearing Selection83
Bearing Assembly85
Crankcase-Crankshaft Bearing Selection86
Crankshaft Thrust Clearance89
Crankshaft Runout90
Clutch Drive Plates and Driven Plates90
Clutch Spring Free Length91
Clutch Bearings91
Sleeve Hub Wave Washer91
Starter Clutch Removal92
Starter Clutch Assembly92
Oil Pump93
Transmission Gears and Related Parts94
Gear-Shifting Fork Clearance94
Countershaft Disassembly95
Countershaft Reassembly96
Drive Shaft Disassembly96
Drive Shaft Reassembly97
Engine Reassembly98
Fuel and Lubrication System: Contents119
Fuel System120
Fuel Cock121
Carburetor View122
Carburetor Specifications123
Diaphragm and Piston Operation124
Slow System125
Main System126
Starter System127
Float System127
Carburetor Disassembly128
Float Height Adjustment130
Needle Valve131
Balancing Carburetors132
Reassembly Carburetors134
Lubrication System137
Electrical System: Contents139
Charging System: Description140
Charging Output Check142
AC Generator No-Load Performance142
AC Generator Continuity Check143
Regulator/Rectifier143
Ignition System: Description144
Ignition Coils144
Igniter Unit146
Electrical System: Starter System147
Starter Motor Removal and Disassembly147
Starter Motor Inspection148
Starter Motor Reassembly149
Starter Relay Inspection149
Combination Meter150
Combination Meter Inspection151
Fuel Meter152
Fuel Gauge152
Lamps153
Headlight153
Tail/Brake Light153
Turn Signal Light154
Ignition Switch154
Engine Stop and Start Switch154
Lighting Switch155
Front Brake Right Switch155
Dimmer Switch155
Turn Signal Light/Horn and Passing Switches155
Battery Specifications156
Initial Charging156
Battery Charging Time157
Battery Servicing157
Recharging Operation157
Battery Service Life158
Chassis: Contents159
Front Wheel Construction160
Front Wheel Removal and Disassembly160
Wheel Bearing Inspection162
Axle Shaft162
Wheel and Wheel RIM Reassembly162
Front Brake Pad Replacement164
Caliper Removal and Disassembly164
Caliper and Disc Inspection166
Caliper Reassembly167
Master Cylinder Removal and Disassembly168
Master Cylinder Reassembly169
Master Cylinder Inspection169
Chassis Front Fork Removal170
Front Fork Disassembly171
Fork Spring Inspection173
Inner Tube and Outer Tube Inspection173
Damper Rod Ring Inspection173
Chassis Front Fork Reassembly174
Inner Tube Metal174
Damper Rod Bolt174
Outer Tube Metal, Spacer and Oil Seal174
Fork Oil175
Fork Spring175
Steering Stem Construction176
Steering Stem Disassembly176
Steering Stem Reassembly179
Stem Nut179
Rear Wheel Construction180
Rear Wheel Removal180
Rear Wheel Construction (Disc Brake Type) and Removal182
Rear Wheel Disassembly184
Wheel Bearings Inspection184
Brake Shoes185
Brake Drum185
Wheel and Wheel Rim186
Rear Wheel Reassembly186
Brake Panel187
Rear Brake (Disc Brake Type) Pad Replacement188
Rear Brake Caliper Removal and Disassembly188
Rear Brake Caliper and Disc Inspection190
Rear Brake Caliper Reassembly190
Rear Brake Master Cylinder Removal and Disassembly191
Rear Suspension Construction193
Rear Suspension Removal and Disassembly194
Swing Arm Bearing Inspection195
Swing Arm Pivot Shaft Inspection195
Rear Suspension Reassembly196
Servicing Information: Contents197
Engine Troubleshooting198
Carburetor Troubleshooting200
Electrical Troubleshooting201
Battery Troubleshooting202
Chassis Troubleshooting203
Brakes Troubleshooting204
Wiring Diagram205
Wire Routing212
Cable Routing214
Special Tools215
Tightening Torque Engine217
Chassis Tightening Torque218
Tightening Torque Chart219
Service Data220
Contents229
View of Suzuki GSX400FZ230
Specifications Model GSX400FZ231
GSX400FZ Periodic Maintenance Chart233
GSX400FZ Service Data234
Anti-Dive Front Fork243
Anti-Dive Divice244
Anti-Dive System245
The Anti-Dive System Is Inactive While the Front Brake Is Inactive246
When the Anti-Dive System Is Activated246
What Happens When the Motorcycle Receives a Jolt from the Road, While the Anti-Dive Device Is Active247
Modifications248
Valve Rocker Arm Shaft Stopper Screw249
Conrod Big End Bearing251
Part Supply Data for Conrod Big End Bearing251
Crankshaft Journal Bearing252
Part Supply Data for Crankshaft Journal Bearing253
Oil Gallery Plug Stopper254
Coil Type Fuel Gauge255
Fuel Level System255
Model GSX400FZ Fuel Meter256
Fuel Tank Float Assembly256
Model GSX400FZ Oil Pump257
Effective Engine Number258
Amount of Engine Oil258
Engine Modifications258
Servicing259
Primary Driven Gear and Spacer260
Cylinder261
Generator Rotor Bolt262
Generator Rotor Bolt Removal263
Generator Rotor Bolt Installation263
Fuel Level Gauge Attachment264
Front Fork (Wite Anti-Dive Device)265
Air-Bleeding Procedure267
Front Fork Removal267
Anti-Dive Device Inspection268
Front Fork Reassembly268
Model GSX400FZ Wire Routing271
Model GSX400FZ Cable Routing273
Model GSX400FZ Wiring Diagram274
Model GSX400FD: Service Data281

Suzuki GSX 400F - Page 12

Table of Contents

Related product manuals