Suzuki GSX 400F Manuals

Manuals and User Guides for Suzuki GSX 400F. We have 1 Suzuki GSX 400F manual available for free PDF download: Service Manual

Suzuki GSX 400F Service Manual (293 pages)

Brand: Suzuki | Category: Motorcycle | Size: 41.83 MB

View of Suzuki GSX400F
4
Group Index
5
General Information: Contents
7
Serial Number Locations
8
Fuel and Oil Recommendations
8
Brake Fluid
8
Front Fork Oil
8
Breaking-In Procedures
9
Blowby Gas Recycling
9
Cylinder Identification
9
Camshaft Drive Chain Tensioner
10
Push Rod and Lock Screw
10
Lock Shaft
10
Twin Swirl Combustion Chamber (TSCC)
11
Full-Transistorized Ignition System
15
Signal Generator
16
Special Materials
17
Precautions and General Instructions
19
Use of Genuine Suzuki Parts
19
Specifications
20
Periodic Maintenance and Tune-Up Procedures
23
Periodic Maintenance Chart
24
Lubrication Chart
25
Maintenance and Tune-Up Procedures
26
Air Cleaner Element
26
Battery
27
Cylinder Head Nuts and Exhaust Pipe Bolts
28
Valve Clearance
29
Compression Check
31
Compression Test Procedure
31
Spark Plug
32
Ignition Timing
33
Carburetor
33
Idling Adjustment
34
Fuel Level Inspection
34
Fuel Line
35
Engine Oil and Oil Filter
35
Oil Pressure
36
Necessary Amount of Engine Oil
36
Oil Pump Filter
36
Oil Pump Pressure Specification
36
Clutch
37
Brake Fluid Level
37
Brake Pads
38
Brake Pedal Height
38
Brake Light Switches
39
Air Bleeding the Brake Fluid Circuit
39
Brake Shoe Wear (Drum Type)
41
Drive Chain
41
Tire Tread Condition
42
Tire Pressure
43
Steering
43
Front Fork
44
Tightening Torque
44
Servicing Engine: Contents
45
Engine Components Removable with Engine in Place
46
Engine Removal
47
Engine Reinstallation
52
Engine Disassembly
54
Engine Components Inspection and Servicing
65
Cylinder Head Disassembly
65
Cylinder Head Distortion
66
Valve Face Wear
66
Valve Stem Runout
66
Valve Head Radial Runout
67
Valve Guide - Valve Stem Clearance
67
Valve Stem Wear
67
Valve Guide Servicing
68
Valve Seat Width
69
Valve Seat Servicing
70
Valve Springs
72
Reassembly Valves
72
Camshaft
73
Cam Wear
74
Camshaft Journal Wear
74
Camshaft Runout
75
Cam Sprocket Reassembly
75
Cam Chain Tensioner Disassembly
76
Cam Chain Tensioner Reassembling
77
Cam Chain 20-Pitch Length
79
Cam Chain Guide
79
Cylinder Distortion
79
Cylinder Bore
79
Piston Diameter
80
Piston-Cylinder Clearance
80
Piston Ring-Groove Clearance
80
Piston Ring Free End Gap and Piston Ring End Gap
81
Piston Pin and Pin Bore
82
Connecting Rod Small End Bore I.D.
83
Connecting Rod Big End Thrust Clearance
83
Connecting Rod-Crank Pin Bearing Selection
83
Bearing Assembly
85
Crankcase-Crankshaft Bearing Selection
86
Crankshaft Thrust Clearance
89
Crankshaft Runout
90
Clutch Drive Plates and Driven Plates
90
Clutch Spring Free Length
91
Clutch Bearings
91
Sleeve Hub Wave Washer
91
Starter Clutch Removal
92
Starter Clutch Assembly
92
Oil Pump
93
Transmission Gears and Related Parts
94
Gear-Shifting Fork Clearance
94
Countershaft Disassembly
95
Countershaft Reassembly
96
Drive Shaft Disassembly
96
Drive Shaft Reassembly
97
Engine Reassembly
98
Fuel and Lubrication System: Contents
119
Fuel System
120
Fuel Cock
121
Carburetor View
122
Carburetor Specifications
123
Diaphragm and Piston Operation
124
Slow System
125
Main System
126
Starter System
127
Float System
127
Carburetor Disassembly
128
Float Height Adjustment
130
Needle Valve
131
Balancing Carburetors
132
Reassembly Carburetors
134
Lubrication System
137
Electrical System: Contents
139
Charging System: Description
140
Charging Output Check
142
AC Generator No-Load Performance
142
AC Generator Continuity Check
143
Regulator/Rectifier
143
Ignition System: Description
144
Ignition Coils
144
Igniter Unit
146
Electrical System: Starter System
147
Starter Motor Removal and Disassembly
147
Starter Motor Inspection
148
Starter Motor Reassembly
149
Starter Relay Inspection
149
Combination Meter
150
Combination Meter Inspection
151
Fuel Meter
152
Fuel Gauge
152
Lamps
153
Headlight
153
Tail/Brake Light
153
Turn Signal Light
154
Ignition Switch
154
Engine Stop and Start Switch
154
Lighting Switch
155
Front Brake Right Switch
155
Dimmer Switch
155
Turn Signal Light/Horn and Passing Switches
155
Battery Specifications
156
Initial Charging
156
Battery Charging Time
157
Battery Servicing
157
Recharging Operation
157
Battery Service Life
158
Chassis: Contents
159
Front Wheel Construction
160
Front Wheel Removal and Disassembly
160
Wheel Bearing Inspection
162
Axle Shaft
162
Wheel and Wheel RIM Reassembly
162
Front Brake Pad Replacement
164
Caliper Removal and Disassembly
164
Caliper and Disc Inspection
166
Caliper Reassembly
167
Master Cylinder Removal and Disassembly
168
Master Cylinder Reassembly
169
Master Cylinder Inspection
169
Chassis Front Fork Removal
170
Front Fork Disassembly
171
Fork Spring Inspection
173
Inner Tube and Outer Tube Inspection
173
Damper Rod Ring Inspection
173
Chassis Front Fork Reassembly
174
Inner Tube Metal
174
Damper Rod Bolt
174
Outer Tube Metal, Spacer and Oil Seal
174
Fork Oil
175
Fork Spring
175
Steering Stem Construction
176
Steering Stem Disassembly
176
Steering Stem Reassembly
179
Stem Nut
179
Rear Wheel Construction
180
Rear Wheel Removal
180
Rear Wheel Construction (Disc Brake Type) and Removal
182
Rear Wheel Disassembly
184
Wheel Bearings Inspection
184
Brake Shoes
185
Brake Drum
185
Wheel and Wheel Rim
186
Rear Wheel Reassembly
186
Brake Panel
187
Rear Brake (Disc Brake Type) Pad Replacement
188
Rear Brake Caliper Removal and Disassembly
188
Rear Brake Caliper and Disc Inspection
190
Rear Brake Caliper Reassembly
190
Rear Brake Master Cylinder Removal and Disassembly
191
Rear Suspension Construction
193
Rear Suspension Removal and Disassembly
194
Swing Arm Bearing Inspection
195
Swing Arm Pivot Shaft Inspection
195
Rear Suspension Reassembly
196
Servicing Information: Contents
197
Engine Troubleshooting
198
Carburetor Troubleshooting
200
Electrical Troubleshooting
201
Battery Troubleshooting
202
Chassis Troubleshooting
203
Brakes Troubleshooting
204
Wiring Diagram
205
Wire Routing
212
Cable Routing
214
Special Tools
215
Tightening Torque Engine
217
Chassis Tightening Torque
218
Tightening Torque Chart
219
Service Data
220
Contents
229
View of Suzuki GSX400FZ
230
Specifications Model GSX400FZ
231
GSX400FZ Periodic Maintenance Chart
233
GSX400FZ Service Data
234
Anti-Dive Front Fork
243
Anti-Dive Divice
244
Anti-Dive System
245
The Anti-Dive System Is Inactive While the Front Brake Is Inactive
246
When the Anti-Dive System Is Activated
246
What Happens When the Motorcycle Receives a Jolt from the Road, While the Anti-Dive Device Is Active
247
Modifications
248
Valve Rocker Arm Shaft Stopper Screw
249
Conrod Big End Bearing
251
Part Supply Data for Conrod Big End Bearing
251
Crankshaft Journal Bearing
252
Part Supply Data for Crankshaft Journal Bearing
253
Oil Gallery Plug Stopper
254
Coil Type Fuel Gauge
255
Fuel Level System
255
Model GSX400FZ Fuel Meter
256
Fuel Tank Float Assembly
256
Model GSX400FZ Oil Pump
257
Effective Engine Number
258
Amount of Engine Oil
258
Engine Modifications
258
Servicing
259
Primary Driven Gear and Spacer
260
Cylinder
261
Generator Rotor Bolt
262
Generator Rotor Bolt Removal
263
Generator Rotor Bolt Installation
263
Fuel Level Gauge Attachment
264
Front Fork (Wite Anti-Dive Device)
265
Air-Bleeding Procedure
267
Front Fork Removal
267
Anti-Dive Device Inspection
268
Front Fork Reassembly
268
Model GSX400FZ Wire Routing
271
Model GSX400FZ Cable Routing
273
Model GSX400FZ Wiring Diagram
274
Model GSX400FD: Service Data
281

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Suzuki GSX 400F Service Manual (293 pages)

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