Suzuki 1980 GSX400 Manual de usuario

FOREWORD

The

SUZUKI

GSX400

has

been

developed

new

generation

motorcycle

the

models.

packed

with

highly

advanced

design

concepts

including

forged

one

piece

crankshaft

assembly

and

new

highly

efficient

combustion

system

(TSCC).

Combined

with

precise

control

and

easy

handling,

the

GSX400

provides

excellent performance

and

outstanding

riding

comfort.

This

service

manual

has

been

produced

primarily

for

experienced

mechanics

whose

job

inspect, adjust,

repair

and

service

SUZUKI

motorcycles.

Apprentice

mechanics

and

do-it-yourself

mechanics,

will

also

find

this

manual

extremely

useful

guide.

Model

GSX400

manufactured

standard

specifications

the

main

subject

matter

this

manual.

However,

the

GSX400 machines

distributed

your

country

might differ

minor

respects

from the

standard-specification

GSX400

and,

they

do,

because

some

minor

modifications

(which

are

consequence

most

cases

far

servicing

concerned)

had

made

comply

with

the

statutory

requirements

your

country.

This

manual

contains

up-to-date

formation

the

time

its

issue.

Latermade

modifi

cations

and

changes

will

explained

each

SUZUKI

distributor

respective

markets,

whom

you

are

kindly

requested

make

query

about

updated

information,

any.

NOTE:

This

service

manual

gives

only

servicing

procedures

which

differ

from

those

the

GSX25O

and

describes

the

new

features

the

GSX4OU

Before

performing

any

servicing,

please

read

thoroughly

GSX25O

service

manual

SUZUKI

MOTOR

CO.,LTD.

Administration

Department

Overseas

Service

Division

Quoting,

copying

otherwise

using any

part

this manual

without

plicit

authorization

from

Suzuki

Motor

Co.,

Ltd.

not

permitted

all

rights

the

publication

are

reserved

under

law.

CONTENTS

VIEW

SUZUKI

GSX400E

BREAKING-IN

RIMIN

SPECIFICATIONS

ENG1NE

CYLINDER HEAD

COVER

VALVE

AND

CAMSHAFT

CYLINDER HEAD

CYLINDER,

PISTON

AND RING

CRANKSHAFT

AND

CONNECTING

ROD

COUNTER

BALANCER

CRANKCASE

TRANSMISSION..

GEARSHIFT

CAM

AND

FORK

CLUTCH

AND

OIL

PUMP

STARTER

CLUTCH

AND GENERA

TOR

EXHAUST

PIPE

AND

MUFFLER

CARBURETOR

LUBRICATION

SYSTEM

SPEEDOMETER

AND

TACHOMETER

STEERING

STEM

REAR

WHEEL

WIRING

DIAGRAM

WIRE

ROUTING

CABLE

ROUTING

SPECIAL

TOOLS

TIGHTENING

TORQUE

SERVICE

DATA

BREAKING-IN

R/MIN

Keep

these

breaking-in engine

speed limits:

SPECI

CATI

ONS

DIMENSIONS

AND

DRY

MASS

Overall

length

075

Overall

width

755

Overall

height

075

Wheelbase

385

Ground

clearance

155

Seat

height 815

Dry

mass

175

ENGINE

Type

Four-stroke,

air-cooled,

DOHC

Number

cylinders

Bore

67.0

Stroke

56.6

Piston

displacement 399

Compression

ratio

10.0

Carburetor

MIKUNI

BS34SS,

twin

Air

cleaner

Polyurethane

foam

element

Starter

system Electric

Lubrication

system

Wet

sump

TRANSMI

SSI

Clutch

Wet

multi-plate

type

Transmission

6-speed

constant

mesh

Gearshift

pattern

1-down,

5-up

Primary

reduction 2.714

(76/28)

**Final

reudction

2.750

(44/16)

Gear

ratios,

Low

2.46

(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)

Drive

chain

DAIDO

DID5OUB,

104

links

**Modification

Rear

sprocket

for

manufactured

and

after

June,

1981

[2.812

(45/16)1

GSX400E GENERAL INFORMATION

VIEW

SUZUI(I

GSX400E

GSX400E GENERAL INFORMATION

Initial

800

Below

4,000

r/min

1,600

Below

6,000

r/min

Over

1,600

Below

9,500

r/min

RIGHT

SIDE

LEFT

SIDE

BREAKING-IN

R/MIN

Keep

these

breaking-in engine

speed limits:

SPECI

CATI

ONS

DIMENSIONS

AND

DRY

MASS

Overall

length

075

Overall

width

755

Overall

height

075

Wheelbase

385

Ground

clearance

155

Seat

height 815

Dry

mass

175

ENGINE

Type

Four-stroke,

air-cooled,

DOHC

Number

cylinders

Bore

67.0

Stroke

56.6

Piston

displacement 399

Compression

ratio

10.0

Carburetor

MIKUNI

BS34SS,

twin

Air

cleaner

Polyurethane

foam

element

Starter

system Electric

Lubrication

system

Wet

sump

TRANSMI

SSI

Clutch

Wet

multi-plate

type

Transmission

6-speed

constant

mesh

Gearshift

pattern

1-down,

5-up

Primary

reduction 2.714

(76/28)

**Final

reudction

2.750

(44/16)

Gear

ratios,

Low

2.46

(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)

Drive

chain

DAIDO

DID5OUB,

104

links

**Modification

Rear

sprocket

for

manufactured

and

after

June,

1981

[2.812

(45/16)1

GSX400E GENERAL INFORMATION

VIEW

SUZUI(I

GSX400E

GSX400E GENERAL INFORMATION

Initial

800

Below

4,000

r/min

1,600

Below

6,000

r/min

Over

1,600

Below

9,500

r/min

RIGHT

SIDE

LEFT

SIDE

GSX400E GENERAL INFORMATION

ENGINE

GSX400E

ENGINE

CHASSIS

Front

suspension

Rear

suspension

Steering

angle

Caster

Trail

Turning

radius

Front

brake

Rear

brake

Front

tire

size.

Rear

tire

size

Front

fork

stroke

Rear wheel

travel

Front

tire

pressure

Rear

tire pressure

Spark

plug

Battery

Generator

Fuse

CAPACITI

Fuel

tank

including

reserve.

Reserve

Engine

oil

Front

fork

oil

(each

leg)

Telescopic,

oil

dampened

•

Swing

arm,

oil

dampened

spring

5-way

adjustable

42°

(right

left)

62° 00’

.2.4m

Disc

brake

Internal

expanding

3.OOS1B

4PR

3.50S18

4PR

3.75S18

4PR

(for

Germany

and

Denmark)

.140mm

.100mm

175

kPa

(Normal

200

kPa

(Normal

(1.75

kg/cm

solo

riding)

(2.00

kg/cm

solo

riding)

Battery

ignition

(for General)

Fully

transistorized

(for

the

others)

Contact

point

type

20°

B.T.D.C.

below

650

r/min

and

35°

B.T.D.C.

above

500 r/min

Fully

transistorized

type

20°

B.T.D.C.

below

650

r/min

and

40°

B.T.D.C.

above

500

r/min

NGK

DBEA/DR8ES-Lor

NIPPON

DENSO

X24ES-U/X24ESR-U

12V

43.2

(12

Ah)/10

Three-phase

A.C.

generator

14.5

(3.2

Imp

gal)

3.0

(2.6

Imp

qt)

2.6

(2.3

Imp

qt)

..145

(5.11

lmpoz)

CYLINDER

HEAD

COVER

REMOVAL

•

unnecessary

remove

four

cover

cap

bolts

before

removing

cylinder

head

cover

®.

Four

bolts

cannot

remove

unless

camshaft

end

caps

are

not

removed.

NSTALLATI

•

sure

replace

gaskets

and

with

new

ones.

•

Fill

approx.

engine

oil

four

pockets

the

cylinder

head

before

mounting

the

head

cover

the

cylinder

head.

•

Set

two

positioning

pins

proper

position

and

tighten

with

long

bolts

35mm).

•

Apply

small

amount

SUZUKI

thread

lock

cement

screw

which

clamps

camshaft

end

cap

®.

•

Install

tachometer

drive gear

after

cylinder

head

cover

fitted

the

cylinder

head.

•

Gasket

should

fit

that

breather

hole

side

faces

toward

front.

105mm

ELECTRI

CAL

Ignition

type

Ignition

timing

15A

These

specifications

are

subject

change

without

notice.

99000-32040

Suzuki

Thread

lock

]

cement

TIGHTENING TORQUE

Bolt(j,®and®

9—

N.m

(0.9—1.0kg-rn)

GSX400E GENERAL INFORMATION

ENGINE

GSX400E

ENGINE

CHASSIS

Front

suspension

Rear

suspension

Steering

angle

Caster

Trail

Turning

radius

Front

brake

Rear

brake

Front

tire

size.

Rear

tire

size

Front

fork

stroke

Rear wheel

travel

Front

tire

pressure

Rear

tire pressure

Spark

plug

Battery

Generator

Fuse

CAPACITI

Fuel

tank

including

reserve.

Reserve

Engine

oil

Front

fork

oil

(each

leg)

Telescopic,

oil

dampened

•

Swing

arm,

oil

dampened

spring

5-way

adjustable

42°

(right

left)

62° 00’

.2.4m

Disc

brake

Internal

expanding

3.OOS1B

4PR

3.50S18

4PR

3.75S18

4PR

(for

Germany

and

Denmark)

.140mm

.100mm

175

kPa

(Normal

200

kPa

(Normal

(1.75

kg/cm

solo

riding)

(2.00

kg/cm

solo

riding)

Battery

ignition

(for General)

Fully

transistorized

(for

the

others)

Contact

point

type

20°

B.T.D.C.

below

650

r/min

and

35°

B.T.D.C.

above

500 r/min

Fully

transistorized

type

20°

B.T.D.C.

below

650

r/min

and

40°

B.T.D.C.

above

500

r/min

NGK

DBEA/DR8ES-Lor

NIPPON

DENSO

X24ES-U/X24ESR-U

12V

43.2

(12

Ah)/10

Three-phase

A.C.

generator

14.5

(3.2

Imp

gal)

3.0

(2.6

Imp

qt)

2.6

(2.3

Imp

qt)

..145

(5.11

lmpoz)

CYLINDER

HEAD

COVER

REMOVAL

•

unnecessary

remove

four

cover

cap

bolts

before

removing

cylinder

head

cover

®.

Four

bolts

cannot

remove

unless

camshaft

end

caps

are

not

removed.

NSTALLATI

•

sure

replace

gaskets

and

with

new

ones.

•

Fill

approx.

engine

oil

four

pockets

the

cylinder

head

before

mounting

the

head

cover

the

cylinder

head.

•

Set

two

positioning

pins

proper

position

and

tighten

with

long

bolts

35mm).

•

Apply

small

amount

SUZUKI

thread

lock

cement

screw

which

clamps

camshaft

end

cap

®.

•

Install

tachometer

drive gear

after

cylinder

head

cover

fitted

the

cylinder

head.

•

Gasket

should

fit

that

breather

hole

side

faces

toward

front.

105mm

ELECTRI

CAL

Ignition

type

Ignition

timing

15A

These

specifications

are

subject

change

without

notice.

99000-32040

Suzuki

Thread

lock

]

cement

TIGHTENING TORQUE

Bolt(j,®and®

9—

N.m

(0.9—1.0kg-rn)

GSX400E

ENGINE

VALVE

AND

CAMSHAFT

VALVE

TIMING

REASSEMBLY

•

Apply

SUZUKI

MOLY

PASTE

lightly

with

out

break

camshaft

journal and

valve

stem.

•

Apply

Suzuki

thread

lock

super

“13038”

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

(0.9—1.1

kg-m)

ENGINE

GSX400E

IN.open

Ex.

N.close

Moly

paste

NOTE:

The

timing

chain

now

riding

all

three

sprockets.

careful

not to

disturb

the

crankshaft

until

four

holders

are

secured.

IN.

open

Ex.

Moly

paste

20th

1St

GSX400E

ENGINE

VALVE

AND

CAMSHAFT

VALVE

TIMING

REASSEMBLY

•

Apply

SUZUKI

MOLY

PASTE

lightly

with

out

break

camshaft

journal and

valve

stem.

•

Apply

Suzuki

thread

lock

super

“13038”

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

(0.9—1.1

kg-m)

ENGINE

GSX400E

IN.open

Ex.

N.close

Moly

paste

NOTE:

The

timing

chain

now

riding

all

three

sprockets.

careful

not to

disturb

the

crankshaft

until

four

holders

are

secured.

IN.

open

Ex.

Moly

paste

20th

1St

ENGINE

GSX400E

ENGINE

CYLINDER

HEAD

CYLINDER,

PISTON

AND

RING

VALVE

GUIDE

Part

No.

Part

Name

15-49290

Valve

guide

09289-05003

Oil

seal

REASSEMBLY

•

sure

replace

cylinder

head

gasket

with

new

one.

•

There

are

two

different

washers

)

and

)

for

cylinder

head

nuts,

identify

each

use

the

specified

place.

•

Camshaft

cap

bolt

has

“9”

mark

crown

part,

not

use

other

bolt.

TIGHTENING

TORQUE

N.m

kg-rn

)

35—40

3.5—4.0

8—12

0.8—1.2

(

7—11

0.7—1.1

REASSEMBLY

•

Mount

new

0-ring

ID,

gasket

()

and circlips

•

sure

apply

oil

cylinder

surface,

piston

sliding

part,

piston

rings

()

and

piston

®.

•

Use

special

tools

when

mounting

piston

cylinder.

Part

No.

Part

Name

09916-74520

Piston

ring

holder

099 16-74540

Band

(bore

—

mrn)

•

Confirm

that

0-ring

properly

installed

groove

the

lower

cylinder,

and

then

install

piston

into

the

cylinder.

OVERSIZE

OIL

RING

SIZE

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