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Manuals
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Suzuki Manuals
Motorcycle
GSX 400F
Service manual
Suzuki GSX 400F Service Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
View of Suzuki GSX400F
Group Index
General Information: Contents
Serial Number Locations
Fuel and Oil Recommendations
Brake Fluid
Front Fork Oil
Breaking-In Procedures
Blowby Gas Recycling
Cylinder Identification
Camshaft Drive Chain Tensioner
Push Rod and Lock Screw
Lock Shaft
Twin Swirl Combustion Chamber (TSCC)
Full-Transistorized Ignition System
Signal Generator
Special Materials
Precautions and General Instructions
Use of Genuine Suzuki Parts
Specifications
Periodic Maintenance and Tune-Up Procedures
Periodic Maintenance Chart
Lubrication Chart
Maintenance and Tune-Up Procedures
Air Cleaner Element
Battery
Cylinder Head Nuts and Exhaust Pipe Bolts
Valve Clearance
Compression Check
Compression Test Procedure
Spark Plug
Ignition Timing
Carburetor
Idling Adjustment
Fuel Level Inspection
Fuel Line
Engine Oil and Oil Filter
Oil Pressure
Necessary Amount of Engine Oil
Oil Pump Filter
Oil Pump Pressure Specification
Clutch
Brake Fluid Level
Brake Pads
Brake Pedal Height
Brake Light Switches
Air Bleeding the Brake Fluid Circuit
Brake Shoe Wear (Drum Type)
Drive Chain
Tire Tread Condition
Tire Pressure
Steering
Front Fork
Tightening Torque
Servicing Engine: Contents
Engine Components Removable with Engine in Place
Engine Removal
Engine Reinstallation
Engine Disassembly
Engine Components Inspection and Servicing
Cylinder Head Disassembly
Cylinder Head Distortion
Valve Face Wear
Valve Stem Runout
Valve Head Radial Runout
Valve Guide - Valve Stem Clearance
Valve Stem Wear
Valve Guide Servicing
Valve Seat Width
Valve Seat Servicing
Valve Springs
Reassembly Valves
Camshaft
Cam Wear
Camshaft Journal Wear
Camshaft Runout
Cam Sprocket Reassembly
Cam Chain Tensioner Disassembly
Cam Chain Tensioner Reassembling
Cam Chain 20-Pitch Length
Cam Chain Guide
Cylinder Distortion
Cylinder Bore
Piston Diameter
Piston-Cylinder Clearance
Piston Ring-Groove Clearance
Piston Ring Free End Gap and Piston Ring End Gap
Piston Pin and Pin Bore
Connecting Rod Small End Bore I.D.
Connecting Rod Big End Thrust Clearance
Connecting Rod-Crank Pin Bearing Selection
Bearing Assembly
Crankcase-Crankshaft Bearing Selection
Crankshaft Thrust Clearance
Crankshaft Runout
Clutch Drive Plates and Driven Plates
Clutch Spring Free Length
Clutch Bearings
Sleeve Hub Wave Washer
Starter Clutch Removal
Starter Clutch Assembly
Oil Pump
Transmission Gears and Related Parts
Gear-Shifting Fork Clearance
Countershaft Disassembly
Countershaft Reassembly
Drive Shaft Disassembly
Drive Shaft Reassembly
Engine Reassembly
Fuel and Lubrication System: Contents
Fuel System
Fuel Cock
Carburetor View
Carburetor Specifications
Diaphragm and Piston Operation
Slow System
Main System
Starter System
Float System
Carburetor Disassembly
Float Height Adjustment
Needle Valve
Balancing Carburetors
Reassembly Carburetors
Lubrication System
Electrical System: Contents
Charging System: Description
Charging Output Check
AC Generator No-Load Performance
AC Generator Continuity Check
Regulator/Rectifier
Ignition System: Description
Ignition Coils
Igniter Unit
Electrical System: Starter System
Starter Motor Removal and Disassembly
Starter Motor Inspection
Starter Motor Reassembly
Starter Relay Inspection
Combination Meter
Combination Meter Inspection
Fuel Meter
Fuel Gauge
Lamps
Headlight
Tail/Brake Light
Turn Signal Light
Ignition Switch
Engine Stop and Start Switch
Lighting Switch
Front Brake Right Switch
Dimmer Switch
Turn Signal Light/Horn and Passing Switches
Battery Specifications
Initial Charging
Battery Charging Time
Battery Servicing
Recharging Operation
Battery Service Life
Chassis: Contents
Front Wheel Construction
Front Wheel Removal and Disassembly
Wheel Bearing Inspection
Axle Shaft
Wheel and Wheel RIM Reassembly
Front Brake Pad Replacement
Caliper Removal and Disassembly
Caliper and Disc Inspection
Caliper Reassembly
Master Cylinder Removal and Disassembly
Master Cylinder Reassembly
Master Cylinder Inspection
Chassis Front Fork Removal
Front Fork Disassembly
Fork Spring Inspection
Inner Tube and Outer Tube Inspection
Damper Rod Ring Inspection
Chassis Front Fork Reassembly
Inner Tube Metal
Damper Rod Bolt
Outer Tube Metal, Spacer and Oil Seal
Fork Oil
Fork Spring
Steering Stem Construction
Steering Stem Disassembly
Steering Stem Reassembly
Stem Nut
Rear Wheel Construction
Rear Wheel Removal
Rear Wheel Construction (Disc Brake Type) and Removal
Rear Wheel Disassembly
Wheel Bearings Inspection
Brake Shoes
Brake Drum
Wheel and Wheel Rim
Rear Wheel Reassembly
Brake Panel
Rear Brake (Disc Brake Type) Pad Replacement
Rear Brake Caliper Removal and Disassembly
Rear Brake Caliper and Disc Inspection
Rear Brake Caliper Reassembly
Rear Brake Master Cylinder Removal and Disassembly
Rear Suspension Construction
Rear Suspension Removal and Disassembly
Swing Arm Bearing Inspection
Swing Arm Pivot Shaft Inspection
Rear Suspension Reassembly
Servicing Information: Contents
Engine Troubleshooting
Carburetor Troubleshooting
Electrical Troubleshooting
Battery Troubleshooting
Chassis Troubleshooting
Brakes Troubleshooting
Wiring Diagram
Wire Routing
Cable Routing
Special Tools
Tightening Torque Engine
Chassis Tightening Torque
Tightening Torque Chart
Service Data
Contents
View of Suzuki GSX400FZ
Specifications Model GSX400FZ
GSX400FZ Periodic Maintenance Chart
GSX400FZ Service Data
Anti-Dive Front Fork
Anti-Dive Divice
Anti-Dive System
The Anti-Dive System Is Inactive While the Front Brake Is Inactive
When the Anti-Dive System Is Activated
What Happens When the Motorcycle Receives a Jolt from the Road, While the Anti-Dive Device Is Active
Modifications
Valve Rocker Arm Shaft Stopper Screw
Conrod Big End Bearing
Part Supply Data for Conrod Big End Bearing
Crankshaft Journal Bearing
Part Supply Data for Crankshaft Journal Bearing
Oil Gallery Plug Stopper
Coil Type Fuel Gauge
Fuel Level System
Model GSX400FZ Fuel Meter
Fuel Tank Float Assembly
Model GSX400FZ Oil Pump
Effective Engine Number
Amount of Engine Oil
Engine Modifications
Servicing
Primary Driven Gear and Spacer
Cylinder
Generator Rotor Bolt
Generator Rotor Bolt Removal
Generator Rotor Bolt Installation
Fuel Level Gauge Attachment
Front Fork (Wite Anti-Dive Device)
Air-Bleeding Procedure
Front Fork Removal
Anti-Dive Device Inspection
Front Fork Reassembly
Model GSX400FZ Wire Routing
Model GSX400FZ Cable Routing
Model GSX400FZ Wiring Diagram
Model GSX400FD: Service Data
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Table of Contents
Troubleshooting
Engine Troubleshooting
198
Carburetor Troubleshooting
200
Electrical Troubleshooting
201
Battery Troubleshooting
202
Chassis Troubleshooting
203
Brakes Troubleshooting
204
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