Suzuki 1980 GSX400 Service Manual Download Page 30

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Summary of Contents for 1980 GSX400

Page 1: ......

Page 2: ...ects from the standard specification GSX400 and if they do it is because some minor modifications which are of no consequence in most cases as far as servicing is concerned had to be made to comply wi...

Page 3: ...CONNECTING ROD 9 COUNTER BALANCER 11 CRANKCASE 13 TRANSMISSION 15 GEARSHIFT CAM AND FORK 18 CLUTCH AND OIL PUMP 19 STARTER CLUTCH AND GENERATOR 22 EXHAUST PIPE AND MUFFLER 23 CARBURETOR 24 LUBRICATIO...

Page 4: ...1 GSX400E GENERAL INFORMATION VIEW OF SUZUI I GSX400E 1 b At I i I RIGHT SIDE LEFT SIDE...

Page 5: ...S twin Air cleaner Polyurethane foam element Starter system Electric Lubrication system Wet sump TRANSMI SSI ON Clutch Wet multi plate type Transmission 6 speed constant mesh Gearshift pattern 1 down...

Page 6: ...anding 3 OOS1B 4PR 3 50S18 4PR 3 75S18 4PR for W Germany and Denmark 140mm 100mm 175 kPa Normal 200 kPa Normal 1 75 kg cm 2 solo riding 2 00 kg cm 2 solo riding ignition for General Fully transistoriz...

Page 7: ...in four pockets of the cylinder head before mounting the head cover on the cylinder head Set two positioning pins at proper position and tighten with long bolts 6 x 35mm Apply small amount of SUZUKI t...

Page 8: ...STE lightly with out break on camshaft journal and valve stem Apply Suzuki thread lock super 13038 to the cam sprocket bolts TIGHTENING TORQUE 15 20 N m 1 5 2 0kg rn 8 10 N m 0 8 1 0 kg rn 9 11 N m 0...

Page 9: ...I ENGINE GSX400E 6 NOTE The timing chain is now riding on all three sprockets Be careful not to disturb the crankshaft until four holders are secured 20th pin 1St...

Page 10: ...EASSEMBLY Be sure to replace cylinder head gasket with new one There are two different washers and for cylinder head nuts so identify each to use in the specified place Camshaft cap bolt has 9 mark on...

Page 11: ...face piston sliding part piston rings and piston pin Use special tools when mounting piston on cylinder Part No Part Name 09916 74520 Piston ring holder 099 16 74540 Band bore 63 75 mrn Confirm that 0...

Page 12: ...age 3 39 CAUTION Bearings should be replaced as a set J7___MoIv_paste Moly pa TIGHTENING TORQUE COLOR Part Number THICKNESS mm Green 12164 44100 010 1 484 1 488 Black 12164 44100 020 1 488 1 492 Brown...

Page 13: ...Part THICKNESS mm I 0 25 Under size 1 12229 44100 025 1 625 0 50 Undersize 1 750 I 12229 44100 050 THRUST BEARING THICKNESS Check the crankshaft thrust bearing thickness for wear If wearing portion ex...

Page 14: ...nkshaft go into place with their oil groove side ID facing the crank webs COUNTER BALANCER DISASSEMBLY Remove the counter balancer setting bolt Pull out the counter balancer drive gear I I 35 45N m I...

Page 15: ...r race by using special tool ID during the punched mark side facing out side 09913 80112 Bearing installer When mounting the balancer drive gear be sure to locate the dent mark right on the radial lin...

Page 16: ...13 GSX400E ENGINE Fix the washer j spacer and washer tighten the counter balancer setting bolt with specified torque Tightening 35 45 N m torque 3 5 4 5 kg m CRANKCASE...

Page 17: ...er and tighten oil pressure regulator with specified torque Tightening 17 20 N m torque 1 7 2 0 kg rn Apply Suzuki Bond No 4 to the mating surface of the upper crankcase Mate the lower crankcase with...

Page 18: ...driven gear 29T Top driven gear 23T 2nd driven gear 32T Driveshaft Engine sprocket 15T Engine sprocket nut Bearing retainer Countershaft 13T 5th drive gear 26T 3rd 4th drive gear 21 24T Top drive gear...

Page 19: ...ntershaft length low to 2nd 114 7mm STD Length 4 52 in 99000 32020 Thread lock super 1303B 114 7 114 8 mm 1 Conft 2nd 6th 3rd 4th 5th 1st NOTE Before mounting 2nd drive gear apply THREAD LOCK SUPER 13...

Page 20: ...ear on the drive shaft insert lock washer No 2 into the drive shaft and turn it to fit it into the groove Then fit the lock washer No 1 c in the lock washer No 2 Install the two drive shaft oil seals...

Page 21: ...GEARSHIFT CAM AND FORK ENGINE GSX400E 18 Thread lock 1 333B T Thread lock 1342 TIGHTENING TORQUE L 18 28N m 1 8 2 Skg m I...

Page 22: ...19 GSX400E ENGINE CLUTCH AND OIL PUMP...

Page 23: ...all primary driven gear and thrust washer After tightening the clutch sleeve hub nut be sure to lock the nut by positively bending the tongue of the washer Tightening torque for the nut is specified 0...

Page 24: ...w gasket to align two holes with oil passage of crankcase Apply grease to oil seal lip of the crankshaft Apply suzuki bond No 4 to oil pressure switch thread 99000 31030 Suzuki Bond No 4 NOTE Using co...

Page 25: ...ENGINE GSX400E 22 t STARTER CLUTCH AND GENERATOR Thread lock 1 332B J Thread lock 1342...

Page 26: ...23 GSX400E ENGINE EXHAUST PIPE AND MUFFLER T model Thread lock 1333B 4 X model Ljad_lock 1333B TIGHTENING TORQUE...

Page 27: ...ng Jet needle Diaphragm and piston Throttle cable bracket Ei Fuel pipe joint J2 Choke shaft Breather hose 3 Vaccum hose fJ Spring f Steel ball Throttle valve shaft 1 Throttle valve shaft I Throttle va...

Page 28: ...25 GSX400E FUEL AND LUBRICATION SYSTEM LUBRICATION SYSTEM CYLINDER WALL CON ROD SMALL END 01 L PAN ROCKER ARM CAM FACE CAM CHAINJ MAIN GALLERY I b4 oh I h I...

Page 29: ...0E 26 SPEEDOMETER AND TACHOMETER f Meter hood Bulb 12V 1 1W Gear position indicator Trip meter knob Speedometer Tachometer Meter case Meter bracket Cushion Cushion Socket Bulb 12V 3 4W Speedometer cab...

Page 30: ...ering stem upper bracket Headlight bracket R Headlight bracket L Steering stem bearing Upper Steering stem bearing Lower Steering stem lower bracket Front fork cover Tightening torque Nm kg rn 12 20 1...

Page 31: ...hometer Headlight Take off turn signal light with headlight bracket and front fork cover Remove ignition tool switch by using special 0991 1 73730 T type hexagon wrench CHASSIS GSX400E 28 Disconnect t...

Page 32: ...y using special tool NOTE Hold the steering stem lower bracket by hand to prevent dropping Steering nut 09940 14910 socket wrench Remove steering stem head bolt and loosen clamp bolt Draw out bearing...

Page 33: ...order of disassembly and removal and also carry the following steps and lower outer races using Draw out bearing outer races upper lower by using special tool and 09941 34511 Steering outer race inst...

Page 34: ...orks right to seat the bearings Turn out the steering stem out 1 2 turn nut by using special and left 5 or 6 times Steering nut 09940 149 10 socket wrench I 40 50N m Tightening torque 4 0 5 0 kg rn Ap...

Page 35: ...REAR WHEEL CHASSIS GSX400E 32 REA TIGHTENING TORQUE Item N m kg rn L 5 8 0 5 0 8 50 80 5 0 8 0 25 40 2 5 4 0...

Page 36: ...WIR W Y Y Bl Y G Brown with Red tracer Green with Blue tracer Green with White tracer Green with Yellow tracer Orange with White tracer Red with Black tracer White with Blue tracer V White with Green...

Page 37: ...blue Light green Orange Red White Yellow Black with White tracer Black with Yellow tracer Br R GIRl GIW GIY O W R B W Bl W G W R WIY Y Bl Y G Brown with Red tracer Green with Blue tracer Green with Wh...

Page 38: ...cer BrIR GIBI G W G Y 01W R B WIBI WIG WIR W Y YIBI Y G Brown with Red tracer Green with Blue tracer Green with White tracer Green with Yellow tracer Orange with White tracer Red with Black tracer Whi...

Page 39: ...Lbl Light blue Light green Orange Red White Yellow Black with White tracer Black with Yellos tracer BrIR GIBI G W G IY 0 W R B W Bl W G W R W Y Y fBI Y G Brown with Red tracer Green with Blue tracer G...

Page 40: ...ad Generator lead T Neutral indicator lead Brake hose ing harness to headlight housing Clamp Tachometer cable Wiring harness j_B rake hose clamp Clamping direction Brake hose Wiring harness cTachomete...

Page 41: ...CDCD CD 0 0 0 CD U U CD U m C C m 0 0 C U 0 m I V h i 3oJ 0 D 0 I 4o c...

Page 42: ...39 GSX400E SERVICING INFORMATION CABLE ROUTING cable Throttle cable Clutch cable...

Page 43: ...SX400E 40 Following special tools are required for servicing the steering head items of the GSX400 Item Part No Part Name c 09941 54911 Steering race remover 09941 74910 Steering bearing installer 099...

Page 44: ...nut 8 10 0 8 1 0 Starter motor bolt 4 7 0 4 0 7 Generator rotor bolt 90 100 9 0 10 0 Starterclutch allen bolt 15 20 1 5 2 0 Primary drive gear nut 90 110 9 0 11 0 Counter balancer center bolt 35 45 3...

Page 45: ...g stem clamp bolt Steering stem head bolt Handlebars clamp bolt Brake hose union bolt Master cylinder clamp bolt Brake pedal arm bolt Swinging arm pivot nut Front footrest bolt 10mm 8mm Muffler bracke...

Page 46: ...5 3 5 0 2 0 4 1 5 3 0 2 4 0 3 0 6 2 0 4 5 3 6 6 0 4 0 7 3 0 5 0 4 7 0 8 1 2 6 0 8 5 8 12 8 1 0 1 6 7 0 11 5 10 16 1 8 2 8 13 0 20 0 18 28 10 2 2 3 5 16 0 25 5 22 35 4 0 6 0 29 0 43 5 40 60 12 3 5 5 5...

Page 47: ...9 Valve guide I D IN EX 5 500 5 512 _0 2165 _0 2170 Valve stem O D 5 460 5 475 IN 0 2150 0 2156 EX 5 445 5 460 0 2144 0 2150 Valve stem runout 0 05 IN EX _____ ___ 0 002 Valvheadthickness lN EX 0 5 0...

Page 48: ...I D IN EX 0 8666 0 8671 21 959 21 980 Camshaft journal O D IN EX 0 8645 0 8654 0 10 Camshaft runout IN EX 0 004 157 80 Cam chain 20 pitch length 6 2 13 20th pin 12 000 12 018 Rocker arm l D IN EX 0 4...

Page 49: ...linder distortion 0 10 0 004 Piston ring free end gap 9 5 7 6 N Approx 0 37 0 30 1 St 9 5 7 6 R Approx 0 37 0 30 10 0 8 0 N Approx 0 39 0 31 2nd 10 0 8 0 R Approx 0 39 0 31 Piston ring end gap 0 10 0...

Page 50: ...1 3386 Crankshaft journal oil clearance 0 020 0 044 0 080 0 0008 0 0017 0 0031 Crankshaft journal O D 31 976 32 000 1 2589 1 2598 Crankshaft thrust bearing thickness 2 95 2 98 2 85 0 116 0 117 0 112 C...

Page 51: ...ch cable play 4 0 0 16 Clutch release screw 1 2 turn back Drive plate thickness 2 9 3 1 2 6 0 11 0 12 0 10 Drive plate claw width 1 5 8 16 0 15 0 0 62 0 63 0 59 Driven plate thickness 1 60 0 06 0 063...

Page 52: ...61 32 13 2nd 1 777 32 18 3rd 1 380 29 21 4th 1 125 27 24 5th 0 961 25 26 Top 0 851 23 27 Shift fork to Groove 0 10 0 30 0 50 clearance 0 004 0 012 0 020 Shift fork groove width 5 5 5 6 0 217 0 220 Shi...

Page 53: ...202 44220 Idle r min 1100 50r min Fuel level 5 0 0 5 0 20 0 02 Float height 22 4 1 0 0 88 0 04 Main jet M J 117 5 Main air jet M A J 0 6 Jet needle J N 5D69 4 Needle jet N J 0 9 P i P 2 Pilot jet P J...

Page 54: ...e KOKUSAN 190 E 28 Condensercapacity KOKUSAN 0 25 0 03 MF E 28 Br B W Except for Signal coil resistance Approx 60 80 G W B W E 28 01W W or BIY Except for Ignition coil resistance Primary Approx 3 5 4...

Page 55: ...0 30 0 012 Master cylinder bore 14 000 14 043 Front 0 5512 0 5529 Master cylinder piston diam 13 957 13 984 Front 0 5495 0 5506 Brake caliper cylinder bore 42 850 42 926 Front 1 6870 1 6900 42 770 42...

Page 56: ...an octane number of 90 or higher Research Method pre ferably unleaded or low lead Fuel tank including reserve 14 5 L 3 8 3 2 US Imp gal reserve 3 0 L 3 2 2 6 US Imp qt Engine oil type SAE 1OW 40 Engi...

Page 57: ...m 2 psi FRONT 175 1 75 25 175 1 75 25 200 2 00 28 200 2 00 28 REAR 200 2 00 j28 225 2 25 32 225 2 25 32 250 2 50 36 WATTAGE W SPECIFICATION ITEM E 02 E O4 E 22 E 28 E 24 E 16 E 26 Headlight HI 35 36 4...

Page 58: ......

Page 59: ...differences from GSX400E are equipped with sporty fairing and steel ball type steering Except for the items in this section p ease refer to the section GSX400E for servicing CONTENTS VIEW OF SUZUKI GS...

Page 60: ...VIEW OF SUZUKI GSX400S RIGHT SIDE LEFT SIDE 57 GSX400S I LI...

Page 61: ...speed constant mesh Gearshift pattern 1 down 5 up Primary reduction 2 7 14 76 28 Final reduction 2 750 44 16 Gear ratios Low 2 46 1 32 13 2nd 1 777 32 18 3rd 1 380 29 21 4th 1 125 27 24 5th 0 96 1 25...

Page 62: ...00S18 4PR Rear tire size 3 50S18 4PR ELECTRICAL Ignition type Transistorized Ignition timing 20 B T D C below 1 650 r min and 40 B T D C above 3 500 r min Spark plug NGK DR8ES L or NIPPON DENSO X24ES...

Page 63: ...r clamp Steering stem upper bracket Headlight bracket R Headlight bracket L Steering stem bearing Upper Steering stem bearing Lower Steering stem lower bracket Tightening torque N m kg rn 12 20 1 2 2...

Page 64: ...ounting the handlebars on the steering stem upper bracket HANDLEBARS Set the handlebars to match its punched mark to the protrusion of the handlebar pad Secure the each handlebars clamp in such a way...

Page 65: ...9 GSX400S 62 I FAIRING REMOVAL Loosen a bolt I located under fairing Loosen two bolts 2 located right and left sides of fairing and remove fairing...

Page 66: ......

Page 67: ...TS VIEW OF SUZUKI GSX400L 65 SPECIFICATIONS 66 FUEL SYSTEM 68 COMBINATION METER 69 LAMPS 72 FRONT WHEEL 74 STEERING STEM 75 FRONT BRAKE 76 WIRING DIAGRAM 80 WIRE ROUTING 83 CABLE ROUTING 86 SERVICE DA...

Page 68: ...65 GSX400L VIEW OF SUZUKI GSX400L J RIGHT SIDE LEFT SIDE...

Page 69: ...twin Air cleaner Polyurethane foam element Starter system Electric Lubrication system Wet sump TRANSMI SSI ON Clutch Wet multi plate type Transmission 6 speed constant mesh Gearshift pattern 1 down 5...

Page 70: ...dampened spring 5 way adjustable 42 right left 600 30 123mm Disc brake Internal expanding 200 kPa 2 00 kg cm 2 Transistorized 20 B T D C below 1 650 r min and 400 B T D C above 3 500 r min NGK DR8ES...

Page 71: ...o the carburetors When the lever is set at the PRI which stands for priming to supply the fuel to the carburetors position the fuel flows to the carburetors not via the diaphragm unit but directly thr...

Page 72: ...EMOVAL Remove seat Set the fuel cock lever ON or RES position and remove fuel and vacuum hoses Take off fuel tank Disconnect combination meter lead wires from main wiring harness Disconnect speedomete...

Page 73: ...GSX400L 70 Remove mounting bolts and take off com bination meter DISASSEMBLY...

Page 74: ...t it is not necessary to remove the combination meter I LLGX4OOL INSPECTION Using pocket tester check the Continuity between lead wires in the above diagram If the continuity measured is incorrect rep...

Page 75: ...GSX400L 72 LAMPS HEADLIGHT Adjust the headlight vertically after reassembling TAIL BRAKE LIGHT CAUTION Do not overtighten the lens fitting screws...

Page 76: ...73 GSX400L TURN SIGNAL LIGHT L CAUTION Do not overtighten the lens fitting screws REAR FRONT...

Page 77: ...NT WHEEL CONSTRUCTI ON iD Axle spacer Cover Bearing spacer Bearing Spacer Bearing Front brake disc Dust seal Speedometer gear box 40 Tightening torque N m kg rn lb ft 36 52 3 6 5 2 26 0 37 5 15 25 1 5...

Page 78: ...ight bracket L Steering stem bearing Upper Steering stem bearing Lower Steering stem lower bracket Front fork cover Tightening torque N rn kg m lb ft 12 20 1 2 2 0 8 5 14 5 36 52 3 6 5 2 26 0 37 5 15...

Page 79: ...GSX400L 76 FRONT BRAKE MASTER CYLINDER...

Page 80: ...er to catch spilled drops of brake fluid Unscrew the union bolt and disconnect the brake hose master cylinder joint CAUTION Completely wipe off any brake fluid adhering to any part of motorcycle The f...

Page 81: ...GSX400L 78 Pull out the reservoir and 0 ring Draw out dust seal boot Remove circlip by using special tool I 09900 06108 Snapringpliers I Pull out piston primary cup and spring L...

Page 82: ...ancilebars first tighten the clamp bolt for upside as shown CAUTION Adjust the front brake light switch after installation Bleeding the air after reassembling master cylinder MASTER CYLINDER INSPECTIO...

Page 83: ...GSX400L 80 WIRING DIAGRAM ZO c z 2 2 I os_n C For ENGLAND 0 2 C 2 2 I C m C 00 o A I I OQQG W 0 C 0 0 0 0 C...

Page 84: ...BI GIW GIY 0 W RIB W Bl WIG W R W Y Y Bl Y G Brown with Red tracer Green with Blue tracer Green with White tracer Green with Yellow tracer Orange with White tracer Red with Black tracer White with Blu...

Page 85: ...WIR W Y V fBI Y G Lbl Light blue Lg Light green 0 Orange R Red W White Y Yellow 8 W BlackwithWhitetracer B Y Black with Yellow tracer Brown with Red tracer Green with Blue tracer Green with White tra...

Page 86: ...D 4 0 0 C z m Cl m Clamp Clamp Gear position indicator light harness Clamp Clamp c J Cl Main wiring harness Left handlebar switch harness grou nd Clamp Transistor unit NTurn signal relay Guide Starter...

Page 87: ...tor lead Brake hose clamp Regulator Rectifier 0 Transistor unit Clamping direction k Ground Clamp Brake light switch lead Neutral Clamp indicator lead Ground Fuse Brake hose Turn signal relay Wiring h...

Page 88: ...J I CD a U a L 0 0 CU 0 4 CU a a U 0 CU 0 0 E CU C LCD EEr...

Page 89: ...J ID CD 0 a o C c C 4 C a 0 a o C c C 4 C 2 I D 0 LU J C a U 0 a...

Page 90: ...5 512 Valve guide I D IN EX 0 2165 0 2170 5 460 5 475 ValvestemO D IN 0 2150 0 2156 5 445 5 460 EX 0 2144 0 2150 0 05 Valve stem runout IN EX 0 002 0 5 Valve head thickness IN EX 0 02 3 6 Valve stem...

Page 91: ...666_ 0 867 1 Camshaft journal O D 21 959 21 980 IN EX _0 8645 0 8654 Camshaft runout 0 10 IN EX 0 004 Cam chain 20 pitch length 157 80 6 213 Cam chain pin at arrow 3 20th pin Rocker arm l D 12 000 12...

Page 92: ...GSX400L PISTON RING CYLINDER...

Page 93: ...rank pin O D 33 976 34 000 1 3376 _1 3386 Crankshaft journal oil clearance 0 020 0 044 0 080 0 0008 0 0017 0 0031 Crankshaft journal O D 31 976 32 000 1 2589 1 2598 Crankshaft thrust bearing thickness...

Page 94: ...ay 4 0 0 16 Clutch release screw 1 2 turn back Drive plate thickness 2 9 3 1 2 6 0 11 0 12 0 10 Drive plate claw width 15 8 16 0 15 0 0 62 0 63 0 59 Driven plate thickness 1 60 0 06 0 063 0 002 Driven...

Page 95: ...777 32 18 3rd 1 380 29 21 4th 1 125 27 24 5th 0 961 25 26 Top 0 851 23 27 Shift fork to Groove 0 10 0 30 0 50 clearance 0 004 0 012 0 020 Shift fork groove width 5 5 5 6 0 217 0 220 Shift fork thickn...

Page 96: ...4 4 Fuel level 5 0 0 5 0 20 0 02 4 4 Float height 22 4 1 0 0 88 0 04 4 4 Main jet M J 117 5 4 4 Main air jet M A J 0 6 Jet needle J N 5D69 4 4 4 Needle jet N J 0 9 P i P 2 Pilot jet P J 42 5 r By pas...

Page 97: ...KOKUSAN_ 0 25 0 03 F E 28 Signal coil resistance Approx 60 80 Br B W Except for G W B W E 28 Ignition doil resistance 01W W or B Y Except for Primary Approx 3 5 4 5 2 E 28 Plug cap W or B Y Except fo...

Page 98: ...hickness Front 0 20 0 004 0 18 0 30 Brakediscrunout 0 012 14 000 14 043 Master cylinder bore Front 0 5512 0 5529 13 957 13 984 Master cylinder piston diam Front 0 5495 0 5506 42 850 42 926 Brake calip...

Page 99: ...ane number of 90 or higher Research Method preferably unleaded or low lead Fuel tank including reserve 1 1 L 2 9 2 4 US Imp gal reserve 2 0 L 2 1 1 8 US Imp gal Engine oil type SAE 1OW 40 Engine oil c...

Page 100: ...175 1 75 25 200 2 00 28 200 2 00 28 REAR 200 2 00 28 225 2 25 32 225 2 25 32 250 2 50 36 WATTAGE W SPECI FICATION ITEM E 28 E O2 E O4 E 22 Headlight HI 45 LO 40 45 40 Parking or city light 3 4 4 Tail...

Page 101: ...CONTENTS VIEW OF SUZUKI GSX400E S 99 SPECIFICATIONS ioo SERVICE DATA 102...

Page 102: ...99 GSX400E S VIEW OF SUZUKI GSX400E S GSX400E GSX400S A...

Page 103: ...ratios Low 2nd 3rd 4th 5th 075 mm E type Model 2 065 mm S type Model mm E type Model 7lOmm Stype Model type Model 1 230 mm S type Model Model 805 mm S type Model 175 kg Four stroke air cooled DOHC 2...

Page 104: ...h 10 Hours Three phase A C generator 15A 12V 35 35W England 12V 36 36W France 12V 45 45W Australia 12V 45 40W The others 12V 8 23W Australia 12V 5 21W The others 12V 23W Australia 12V 21W The others 1...

Page 105: ...0026 0 014 Valve guide I D EX 0 2165 0 2170 5 500 5 512 5 460 5 47 5 Valve stem O D IN 0 2150 0 2156 5 445 5 460 EX 0 2144 0 2150 0 05 Valve stem runout IN EX 0 002 0 5 Valve head thickness IN EX 0 0...

Page 106: ...8666 0 8671 Camshaft journal 0 D r EX 21 959 21 980 _0 8645 0 8654 Camshaft runout 0 10 IN EX 0 004 Cam chain 20 pitch length 1 57 80 6 213 Cam chain pin at arrow 3 20 th pin Rocker arm l D 12 000 12...

Page 107: ...0 0 004 Piston ring free end gap 9 5 7 6 N Approx 0 37 0 30 1st ________________ 9 5 7 6 R Approx 0 37 0 30 10 0 8 0 N Approx 2nd 0 39 0 31 R Approx 10 0 8 0 0 39 0 31 Piston ring end gap 1st 0 10 0 3...

Page 108: ...0031 Crank pin O D 33 976 34 000 1 3376 1 3386 Crankshaft journal oil clearance 0 020 0 044 0 080 0 0008 0 0017 0 0031 Crankshaft journal O D 31 976 32 000 1 2589 1 2598 Crankshaft thrust bearing thic...

Page 109: ...TRANSMISSION DRIVE CHAIN Unit mm in ITEM STANDARD LIMIT Primary reduction ratio 2 714 76 28 Final reduction ratio 2 812 45 16 Gear ratios Low 2 461 32 13 2nd 1 777 32 18 3rd 1 380 29 21 4th 1 125 27...

Page 110: ...mm 1100 50 r min Fuel level 5 0 Q5 0 20 0 02 Float height 22 4 1 0 __0 88 0 04 Main jet M J 117 5 Main air jet M A J 0 6 Jet needle J N 5D 69 4 Needlejet N J P i P 2 Pilotjet P J 42 5 By pass B P 0 9...

Page 111: ...Over 8 0 3 at 1 atm Signal coil resistance Approx 60 80 Br BIW GIW BIW Ignition coil resistance Primary 01W W or B Approx 3 5 2 Plug cap 0 WorW Secondary Approx 21 25 k2 Generator no load voltage More...

Page 112: ...0 012 14 000 14 043 Master cylinder bore Front 0 551 2 0 5529 13 957 1 3 984 Master cylinder piston diam Front 0 5495 0 5506 42 850 42 926 Brake caliper cylinder bore 1 Front 1 6870 1 6900 42 770 42 8...

Page 113: ...24 7 3 Etyie Model 197 E 22 26 E type 7 8 Model Rear wheel travel 100 3 9 Swing arm pivot shaft runout 0 3 0 012 FUEL OIL ITEM SPECIFICATION NOTE Fuel type Use gasoline with an octane number of 85 gOo...

Page 114: ...RESSURE SOLO RIDING DUAL RIDING SOLO RIDING DUAL RIDING kPa kg cm 2 psi kPa kg cm 2 psi kPa kg cm 2 Psi kPa kg cm 2 Psi FRONT 175 1 75 25 175 1 75 25 200 2 00 28 200 2 00 28 REAR 200 2 00 28 225 2 25...

Page 115: ...CONTENTS VIEW OF SUZUKI GSX400T 113 SPECIFICATIONS 114 COMBINATION METER 116 WIRING DIAGRAM 117 WIRE ROUTING 121 CABLE ROUTING 122 SERVICE DATA 123...

Page 116: ...113 GSX400T VIEW OF SUZUKI GSX400T RIGHT SIDE LEFT SIDE...

Page 117: ...SMI SSI ON Clutch Transmission Gearshift pattern Primary reduction Final reduction Gear ratios Low 2nd 3rd 4th 5th Top 2 100mm 845 mm 1145 mm 1 375 mm 140mm 175 kg Four stroke air cooled DOHC 2 67 0 m...

Page 118: ...arkets 12V 5 21W England 8 23W General market 12V 21W England 23W General market 12V 3 4W England 12V 4W France and West Germany 12V 3 4W 12V 3 4W 12V 3 4W 12V 3 4W 12V 3 4W 12V 3 4W 12 L 2 6 Imp gal...

Page 119: ...GSX400T 116 COMBINATION METER...

Page 120: ...Lg Light green 0 Orange R Red W White Y Yellow B W Black with White tracer B Y Black with Yellow tracer SPEEDOMETER FRONT TURN SIGNAL LIGHT HI Brown with Red tracer Green with Blue tracer Green with...

Page 121: ...W R White with Red tracer W White W Y White with Yellow tracer Y Yellow Y Bl Yellow with Blue tracer B W Black with White tracer Y G Yellow with Green tracer B Y Black with Yellow tracer l oI AAWlGIW...

Page 122: ...ith Red tracer Green with Blue tracer Green with White tracer Green with Yellow tracer Orange with White tracer Red with Black tracer White with Blue tracer White with Green tracer White with Red trac...

Page 123: ...er Br Brown G W Green with White tracer G Green G Y Green with Yellow tracer Gr Gray 0 W Orange with White tracer LbI Light blue R B Red with Black tracer Lg Light green W Bl White with Blue tracer 0...

Page 124: ...r Ground Fuse Electric parts holder ground Brake hose to Starter relay to Battery to Fuse holder bolt Ignitor to Crankcase bolt harness M Turn signal relay Brake hose Battery Secure with crank case bo...

Page 125: ...C I D 7 c e z I CD C I I xJ 0 C CD C C C C 0 CD 6 o C 0 Cn C 0 0 3 CD CD 0 0 0 CD 0 CD V CD C C N t J...

Page 126: ...lve guide I D IN EX 5 500 5 512 _0 2165 0 2170 Valve stem O D 5 460 5 475 I N _0 2150 0 2156 5 445 5 460 EX _0 2144 0 2150 Valve stem runout 0 05 IN EX _0 002 Valve head thickness 0 5 IN EX __0 02 Val...

Page 127: ..._____________ 21 959 21 980 Camshaft journal O D IN EX 0 8645 0 8654 0 10 Camshaft runout IN EX 0 004 157 80 Cam chain 20 pitch length 6 213 20 th pin Cam chain pin at arrow 3 12 000 12 018 Rocker arm...

Page 128: ...ortion 0 10 _0 004 Piston ring free end gap N Approx 95 7 6 0 37 0 30 1st 9 5 7 6 R Approx 0 37 0 30 10 0 8 0 N Approx 0 39 0 31 2nd 10 0 8 0 R Approx 0 39 0 31 Piston ring end gap 1st 0 10 0 30 0 7 0...

Page 129: ...3 1 Crank pin O D 33 976 34 000 1 3376 1 3386 Crankshaft journal oil clearance 0 020 0 044 0 080 0 0008 0 0017 0 0031 Crankshaft journal O D 31 976 32 000 1 2589 1 2598 Crankshaft thrust bearing thick...

Page 130: ...RANSMISSION DRIVE CHAIN Unit mm in ITEM STANDARD LIMIT Primary reduction ratio 2 7 14 76 28 Final reduction ratio 2 687 43 16 Gear ratios Low 2 46 1 32 13 2nd 1 777 32 18 3rd 1 380 29 21 4th 1 125 27...

Page 131: ...1100 50 r min Fuel level 5 0 0 5 0 20 0 02 Float height 22 4 1 0 0 88 0 04 Main jet M J 1 1 7 5 Main air jet M A J 0 6 Jet needle J N 5D69 4 Needle jet N J P i P 2 Pilotjet P J 42 5 C By pass B P 0 9...

Page 132: ...DENSO X24ESR U The others 0 6 0 7 Gap 0 024 0 028 Spark performance Over 8 0 3 at 1 atm Signal coil resistance Approx 60 80 2 Br B W GIW B W Ignition coil resistance Primary O W W or B Approx 3 5 Plug...

Page 133: ...04 0 18 0 30 Brake disc runout 0 012 14 000 14 043 Master cylinder bore Front 0 5512 0 5529 13 957 13 984 Master cylinder piston diam Front 0 5495 0 5506 42 850 42 926 Brake caliper cylinder bore Fron...

Page 134: ...mber of 85 90 or higher Research Method preferably unleaded or low lead Fuel tank including reserve 12 L __3 2 2 6 US Imp_gal reserve 4 0 L 4 2 3 5 US Imp_qt Engine oil type SAE 1OW 40 Engine oil capa...

Page 135: ...175 1 75 25 200 2 00 28 REAR 175 1 75 25 225 2 25 32 175 1 75 25 250 2 50 36 WATTAGE W SPEC I FICATION ITEM E 01 E 02 E21 22 25 Headlight HI 45 35 LO 45 35 40 Parking or city light 3 4 4 Tail Brake l...

Page 136: ...Prepared by SUZUKI MOTOR CO LTD Service Department Overseas Operations Division 3rd Ed August 1981 1st Ed November 1980 Manual No 99500 34000 OlE Printed in Japan...

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