Service Data

Valve spring free length (IN. & EX.) Valve spring tension (IN. & EX.) * Asterisk indicates the new GSX400FZ specification. * Asterisk indicates the new GSX400FZ specification. CAMSHAFT + CYLINDER HEAD Unit mm Cam chain pin (at arrow 3) CYLINDER + PISTON + PISTON RING Unit mm 52.960-52.975 Measure at 14 from the skirt end. * Asterisk indicates the new GSX400FZ specification. * Asterisk indicates the new GSX400FZ specification. Above 2.5 kg cm2 Below 5.5 kg cm2 at 3000 r min. * Asterisk...

Antidive Divice

When a speeding motorcycle is stopped, it is impossible to prevent the front fork dive because the momentum of the machine's center of gravity continues forward. The front fork is compressed and extended, as it is braked before cornering and full throttle applied coming out of the corner, which naturally changes its cornering clearance (motorcycle-to-ground clearance and balance). In order to minimize this change of the front fork length on a racing motorcycle, the spring of the front fork has...

For Austria

RIGHT HANDLEBAR SWITCH A ENGINE KILL SWITCH B STARTER BUTTON FUEL GAUGE TURN SIGNAL INDICATOR LIGHT H GH BEAM INDICATOR LiGHT OIL PRESSURE INDICATOR LIGHT NEUTRAL, INDiCATOR LIGHT SWITCH GEAR POSITION INDICATOR SPEEDOMETER TACHOMETER RIGHT HANDLEBAR SWITCH A ENGINE KILL SWITCH B STARTER BUTTON FUEL GAUGE TURN SIGNAL INDICATOR LIGHT H GH BEAM INDICATOR LiGHT OIL PRESSURE INDICATOR LIGHT NEUTRAL, INDiCATOR LIGHT SWITCH GEAR POSITION INDICATOR SPEEDOMETER TACHOMETER I TAIL BRAKE LIGHT LICENSE...

Front Wheel Construction

Remove caliper mounting bolts and dismount the caliper. Do not operate the brake lever while dismounting the caliper. Pull off cotter pin and remove axle nut. Remove axle holder. Draw out axle shaft and take off front wheel. Remove the securing bolts and separate the disc from wheel (Right and Left). Draw out the right and left wheel bearings. If drawing out the left side bearing first, it makes the job easier. The removed bearing should be replaced.

Cylinder Bore

Measure the cylinder bore diameter at six places. If any one of the measurements exceeds the limit, overhaul the cylinder and replace the piston with an oversize, or replace the cylinder. Once the reboring is done on any one cylinder which measurements is beyond the limit, the remaining cylinders must be also rebored accordingly. Otherwise the imbalance might causes excess vibration.

Part Supply Data For Crankshaft Journal Bearing

Four different sizes of bearing are provided as a standard size to each of above mentioned journal bearings, and also two sizes, 0.25 mm and 0.50 mm, are available as an under-size. When replacing the journal bearings, refer to the page 3-43 of GSX400F service manual to select the bearing properly. * When changing any conrod big end bearing, and crankshaft journal bearing to new one, make it a rule to check the I.D. code number printed or stamped on the crank web, conrod, and crankcase. Select...

Master Cylinder Reassembly

Reassemble the master cylinder in the reverse orders of disassembly and by taking the following steps Wash the master cylinder components with fresh brake fluid before reassembly. Never use cleaning solvent or gasoline to wash them. Apply brake fluid to the cylinder bore and all the internals to be inserted into the bore. When remount the master cylinder to the handlebars, first tighten the clamp bolt for upside as shown. Bleed the air after reassembling master cylinder. (See page 2-16). Adjust...

Wire Routing

Body ground tighten with horn bracket Body ground tighten with horn bracket when tightening engine mounting nut, do not bite this lead wire between chassis and engine. Route the each bent hose at the recess of air chamber body Route the each bent hose at the recess of air chamber body

Brake Fluid Level

Support the motorcycle body on the center stand, and place the handlebars straight. Remove the right frame cover. Check the brake fluid level by observing the upper and lower limit lines on the brake fluid reservoirs, both front and rear. When the level is below the lower limit line, replenish with brake fluid that meets the following specification. The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based...

What Happens When The Motorcycle Receives A Jolt From The Road While The Antidive Device Is Active

While the anti-dive device is restricting fluid flow, any road shock could be directly transmitted to the chassis because the front fork would react as if it were equipped with very stiff springs. However, the road shock is reduced by the following mechanism The relief valve, mounted on a spring, is compressed and opened in direct proportion to the pressure on the front-fork oil,permitting the oil to progressively flow through the clearance between the valve and valve seat. Hence the pressure...

Special Materials

The materials listed below are needed for maintenance work on the GSX400F, and should be kept on hand for ready use. They supplement such standard materials as cleaning fluids, lubricants, emery cloth and the like. How to use them and where to use them are described in the text of this manual. Cables (speedometer and tachometer) Gearshift lever linkage and shaft Sprocket mounting drum bearing Swinging arm bearing and dust seal Mating surfaces of upper and lower crankcase Mating surface of...

Cylinder Head Disassembly

Using special tools, compress valve springs and take off two cotter halves from valve stem. Take out the spring retainer, inner and outer springs. From the other side, pull out the valve. Be sure to identify each removed part as to its location, and lay the parts out in groups designated as No. 1 cylinder, No. 2 cylinder, Exhaust, Inlet, R and L, so that each will be restored to the original location during assembly. * Removal of valves completes ordinary disassembling work. If valve guides...

Lock Shaft

The cam drive chain tension tries to vary during engine operation. The spring controlled push rod is designed so as to only move in, towards the chain guide preventing slack from occurring if the spring pressure on the push rod were overcome. A steel ball is jammed against a angled surface preventing backwards movement of the push rod. The lock shaft is preloaded with a light spring which keeps the ball in contact with the push rod and angled surface . TSCC (TWIN SWIRL COMBUSTION CHAMBER)...

Engine Reassembly

This engine is reassembled by carrying out the steps of disassembly in the reversed order, but there are a number of steps which demand special descriptions or precautionary measures. Apply engine oil to each running and sliding part before reassembling. Refer to the following figure in regard to the correct positions and orientations of the forks when installing these parts. Gearshift fork for 5th driven gear. (D Gearshift fork for 3rd 4th drive gears. (D Gearshift fork for 6th driven gear....

Caliper Removal And Disassembly

Disconnect brake hose and catch the brake fluid in a suitable receptacle. Never re-use the brake fluid left over from the last servicing and stored for long periods. Brake fluid, if it leaks, will interfere with safe running and discolor painted surfaces. Check the brake hose for cracks and hose joint for leakage before riding. Separate the caliper arid caliper holder. Place a rag over the piston to prevent popping up. Force out the piston by using air gun. Do not use high pressure air to...

Battery

Inspect Initial 1 OOO km and Every 5 000 km The battery must be removed to check the electrolyte level and specific gravity. Remove battery lead at the battery terminal. Check electrolyte for level and specific gravity. Add distilled water, as necessary, to keep the surface of the electrolyte above the LOWER level line but not above the UPPER level line. For checking specific gravity, use a hydrometer to determine the charged condition. An S.G. reading of 1.22 (at 20 C) or under means that the...

Amount Of Engine

The engine oil amount of the GSX400F model has been increased to improve the engine productability. The above new specification could also be applied to machines produced before following modifications, without any trouble. 2. Accompanied with the above changes in oil capacity, the following modifications have been made. A) The engine oil pressure regulator has been changed in form and washer is eliminated. And instead of a washer, a new guide has been adopted to the oil pressure regulator. B)...

Oil Gallery Plug Stopper

All oil stopper plugs in the lubrication compartment of the crankcases of model GSX400F are to be covered by locking plates. This modification have been carried out on and after the E. No. 112260 . Please take notice of the following remarks on each respective position, when reinstalling each locking plate together with its bolt. Below are the illustration of the modified area. Below are the illustration of the modified area. Tigtening torque for 6 mm bolt is 8 - 12 N-m (0.8 - 1.2 kg-m). After...

Change oil Initial 1 000 km and Every 5 000 km

The oil should be changed while the engine is hot. Oil filter replacement at the above intervals should be done together with engine oil change. Keep the motorcycle upright, supported on the center stand. Place an oil pan below the engine and drain the oil by removing the drain plug ( ) and filler cap Remove three nuts (3) and remove the filter cover. Pull out old filter and replace with new one. Replace O-ring and filter cover, and secure nuts (D with applying thread lock cement. Fit drain...

Starter Motor Inspection Carbon Brushes

When the brushes are worn, the motor will be unable to produce sufficient torque, and the engine will be difficult to turn over. To prevent this, periodically, inspect the length of the brushes, replacing them when they are too short or chipping. If the commutator surface is dirty, starting performance decrease. Polish the commutator with 400 or similar fine emery paper when it is dirty. After polishing wipe the commutator with a clean dry cloth. Using a pocket tester, check the coil for open...

Starter Motor Reassembly Brush Holder

When fixing brush holder to starter motor case, align the protrusion of the starter motor case with the notch of the brush holder. When installing housing end, fix the protrusion (3) of the starter motor case to the notch on the housing end. Apply Thread Lock 1342 to starter motor securing screws. Disconnect lead wire of the starter motor at starter relay. Turn on the ignition switch, inspect the continuity between the terminals, positive and negative, when pushing the starter button. If the...

Cam Wear

Worn-down cams are often the cause of mistiming valve operation resulting in reduced power output. The limit of cam wear is specified for both intake and exhaust cams in terms of cam height (0), which is to be measured with a micrometer. Replace camshafts if found worn down to the limit. CAMSHAFT JOURNAL WEAR Determine whether or not each journal is worn down to the limit by measuring the running clearance with the camshaft installed in place. Use plastigauge to read the clearance at the...

Cylinder Head Nuts And Exhaust Pipe Bolts

Retighten Initial 1 000 km and Every 5 000 km Remove the cylinder head cover. Tighten the twelve 8 mm nuts (12 mm wrench) to the specified torque with a torque wrench sequentially in ascending numerical order with the engine cold. After firmly tightening the 12 nuts, tighten the 6 mm bolt (indicated as ) to the torque value below Tighten the exhaust pipe bolts and coupler tube bolts to the specified torque with a torque wrench. The valve clearance specification is the same for both intake and...

Balancing Carburetors

Check the four carburetors for balance according As the first step, calibrate the carburetor balancer Start up the engine and run it in idling condition for warming up. Stop the warmed-up engine. Remove the vacuum inspection plug for No. 1 or No. 4 cylinder and install the hose of the carbaretor balancer gauge. * Turn the air screw (3) of the gauge so that the vacuum acting on the tube of that hose will bring the steel ball ( ) in the tube to the center line After making sure that the steel...

Inspection

IGNITION COILS (Checking with Electro Tester) Using the electro tester, test each ignition coil for sparking performance. The test connection is as indicated. Make sure that the three-needle sparking distance is at least 8 mm. If no sparking or orange color sparking occures with this much gap, then it is defective and must be replaced. Test for 5 minutes. IGNITION COILS (Checking with Pocket Tester) A SUZUKI pocket tester or an ohm meter may be used, instead of the electro tester. In either...

Tire Tread Condition

Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace the tire when the remaining depth of tire tread reaches the following specifications. If the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Therefore, maintain the correct tire pressure for good readability or shorter tire life will result. Cold inflation tire pressure is as...

Replace the head cover gasked with new one

Check Initial 1 000 km and Every 5 000 km The compression of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinders is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service. Low compression pressure can indicate any of the * Excessively worn cylinder wall * Worn-down piston or piston rings * Piston rings stuck in the grooves * Leaking or...

Fuel Meter

With the ignition switch turned on, remove two lead wires going into the fuel gauge, and connect the resistor between the main wiring harness side, and check the fuel meter. Remove the lead wires coming out of the fuel gauge and check resistance of each of them. If the resistance measured is incorrect, replace the fuel gauge assembly with new one.

Troubleshooting

Valve clearance out of adjustment. 2. Worn valve guides or poor seating of valves. 4. Piston rings excessively worn. 6. Starter motor cranks but too slowly. Replace, or rebore. Consult electrical complaints. 3. Ignition timing out of adjustment. 5. Open or short in high-tension cords. 6. Defective signal generator or transistor unit. 1. Clogged hole in the fuel tank cap. 2. Clogged or defective fuel cock. 3. Defective carburetor float valve. 4. Clogged fuel pipe or suction cock pipe. 5....

Front Fork

Change oil Initial 1 000 km and Every 10 000 km Remove four handlebar clamp bolts CO and take down the handlebar from the upper bracket. Loosen two front fork upper bracket bolts (2) and remove front fork top caps, both right and left. Unscrew front fork oil drain bolts (3), right and left, and drain oil in the fork tube completely by moving the front fork outer tube up and down some times. Mount the drain screw and washer onto the outer tube and pour specified amount of oil from the top of the...

Generator Rotor Bolt

Suzuki Gsx1100e Rotor Removal Tool

To improve efficiency, the Generator rotor bolt has been changed from A to B and the specified securing torque is as follows. This new tightening torque is applicable to the A type bolt, too. When replacing generator rotor or bolt, use new type bolt and tighten it with specified torque. Below are the special tools necessary for tightening B type flange bolt. As illustrated above, the new rotor holder has been arranged to tighten the flange bolt. This tool is applicable to both A and B type...

Oil Sump Filter

Check to be sure that the strainer screen is free from any sign of rupture and wash the strainer clean periodically. When installing oil sump filter, be sure to face the arrow mark (oil inlet) to the front. Replace oil pan gasket with new one to prevent oil leakage. Below 550 kPa (5.5 kg cm2) at 3 000 r min If the pressure is too low, it means that the oil pump is internally worn or otherwise defective and needs to be replace with new one.

Wiring Diagram

1981 Suzuki Gs850l Wiring Diagram

A ENGINE KILL SWITCH B STARTER BUTTON TURN SIGNAL INDICATOR LIGHT HIGH BEAM INDICATOR UGHT OIL PRESSURE INDICATOR LIGHT .NEUTRAL iNDiCATOR LIGHT SWITCH GEAR POSITION INDICATOR SPEEDOMETER TACHOMETER A ENGINE KILL SWITCH B STARTER BUTTON TURN SIGNAL INDICATOR LIGHT HIGH BEAM INDICATOR UGHT OIL PRESSURE INDICATOR LIGHT .NEUTRAL iNDiCATOR LIGHT SWITCH GEAR POSITION INDICATOR SPEEDOMETER TACHOMETER I TAIL BRAKE LIGHT LICENSE PLATE LIGHT SIGNAL GENERATOR OIL PRESSURE SWITCH STARTER MOTOR STARTER...

Disassembly

When taking off fuel tank, disconnect fuel hose, vacuum hose and fuel gauge lead wires. Fuel cock must be in ON position. Remove headlight by removing three fitting screws. Dismount the headlight housing, turn signal light and headlight bracket for same time. Disconnect speedometer and tachometer cables. Remove meter mounting nuts and take off meter. Remove ignition switch by using special tool. Remove clamp bolts and take off handlebars. Loosen the steering stem clamp bolt. Remove steering...

Reassembly

Reassemble and remount the steering stem in the reverse order of disassembly and removal, and also carry out the following steps. Press in the upper and lower outer races using special tool. Press in the lower bearing by using special tool. Apply grease upper and lower bearing before remounting the steering stem. Tighten the steering stem nut by using special tool with specified torque. Turn the front fork right and left 5 or 6 times to seat the bearings. Turn out the steering stem nut 1 4...

Coil Type Fuel Gauge

As shown in Fig. 1, coils Nif N2, N3 and N4 are set in the fuel gauge. When the ignition switch is ON, the float in the tank is displaced in proportion to the change in the amount of gasoline, the resistance of the fuel gauge sending unit varies, currents and l2 vary, strength of the magnetic field generated by the coils vary, compound vector H Fig. 2 varies, and the magnet of the fuel gauge rotates to deflect the pointer. Even when the ignition is turned off, the pointer remains in the...

Lubrication Chart

The maintenance schedule, which follows, is based on this philosophy. It is timed by odometer indication, and is calculated to achieve the ultimate goal of motorcycle maintenance in the most economical manner. Be careful not to apply too much grease to the brake cam shafts. If grease gets on the linings, brake slippage will result. Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the motorcycle has been operated under wet or rainy conditions. Before...

Special Tools

T type hexagon wrench 5 mm T type hexagon wrench 6 mm L type hexagon wrench 8 mm Cylinder head nut and spark plug wrench set 09914-24510 T handle D 09911-74510 Long socket 14 mm 09911-74520 12 mm 09930-14530 Universal joint 09930-14520 Spark plug wrench 21 mm Front fork assembling T handle NOTE mark shows newly applied for GSX400F. NOTE mark shows newly applied for GSX400F.

Valve Stem Wear

If the valve stem is worn down to the limit, as measured with a micrometer, where the clearance is found to be in excess of the limit indicated replace the valve, if the stem is within the limit, then replace the guide. After replacing valve or guide, be sure to recheck the clearance.

Suzuki Gsx400f Fork Springs

09940 34520

Remove fork cap and take off color, springs and Invert the fork and stroke it several times to let out the oil inside. Under the condition inverted condition , hold the fork for a few minutes. Remove damper rod securing bolt by using special tools. Draw out damper rod and rebound spring. While holding the caliper mounting portion of the outer tube by vise, separate the inner tube from the outer tube as shown. The outer tube and inner tube anti-friction rings or metal slide rings must be...

Connecting Rodcrank Pin Bearing Selection

Loosen bearing cap nuts and tap the bolt end lightly with plastic hammer to remove bearing cap. Remove rods and mark them to identify the cylinder position. Inspect bearing surfaces for any sign of fusion, pitting, burn or flaws. If any, replace them with specified set of bearings. Never try to remove or loosen the connecting rod big end stud, otherwise, it will displace the stud and will not fit the bearing cap properly. Place plastigauge axially on the crank pin, avoiding the oil hole and at...

Crankshaft Thrust Clearance

Check the crankshaft thrust bearing thickness for wear. If most wearing portion exceeds the following limit, replace it with new one. If bearing thickness exceeds the limit, measure the crankshaft width and crankcase width . Calculate the difference between and b , and select the proper size thrust bearing in the following table. Lower crankcase bearing Upper crankcase bearing Lower crankcase bearing Upper crankcase bearing Clearance is 3.07 mm so, select the Brown color bearing. CRANKSHAFT...

Bearing Selection

Inspect each bearing of upper and lower crank cases for any damage. Place plastigauge on each crankshaft journal in the usual manner. Do not place the plastigauge on the oil hole, and do not rotate the shaft when plastigauge is in place. Mate the lower crankcase with the upper crank-case, and tighten the crankcase securing bolts with specified torque value in the indicated order. Remove the lower crankcase, and measure the width of compressed plastigauge in the usual manner. If the width at...

Valve Guide Servicing

Using valve guide remover CD, drive the valve guide out toward intake or exhaust camshaft side. Discard the removed valve guide subassemblies. Only oversized valve guide is available. Re-finish the valve guide holes in cylinder head with a 10.8 mm reamer. Fit a ring to each valve guide. Be sure to use new rings and valve guides. Use of rings and valve guides removed during disassembly is prohibited. Remember that both valve guides for intake and exhaust and both oil seals are identical in...

Valve Stem Runout

Support the valve with V blocks, as shown, and check its runout with a dial gauge. The valve must be replaced if the runout exceeds the limit. VALVE HEAD RADIAL RUNOUT Place the dial gauge at right angles to the valve head face, and measure the valve head radial runout. If it measures more than limit, replace the valve. VALVE GUIDE VALVE STEM CLEARANCE Measure the clearance in two directions X and Y, perpendicular to each other, by rigging up the dial gauge as shown. If the clearance measured...

Rear Suspension Construction

Remove torque link bolts after pulling off cotter Remove brake hose union bolt and remove rear brake caliper with brake hose Only for DISC Remove rear shock absorbers, right and left. Draw out pivot shaft and take off swing arm. Remove dust cover, washer, bearing inner race and spacer. Remove the bearing outer race by using special tool. The removed bearing should be replaced. Inspect the play of swing arm bearing inner spacer by hand while fixing it in the swing arm. Rotate the spacer by hand...

Engine Reinstallation

For remounting, reverse the order of engine removal. Temporarily fasten the engine mounting bracket before inserting the engine mounting bolts. After inserting the engine mounting bolts, tighten engine mounting bracket bolts and engine mounting bolts. Insert all three long bolts from the left side and insert the rear upper bolt through the spacer l on the left side of the engine. Tightening torque for engine mounting bolts Tightening torque for engine mounting bolts The nut 2 takes its position...

Antidive Device Inspection

As shown in the figure, the anti-dive device can be disassembled into the modulator plunger and modulator valve and for these two sections, no individual replacement parts are provided. If the moving parts should be marked or scratched or if the brake fluid or front fork oil is leaking from the sliding parts, replace the modulator plunger or valve as a unit. The modulator valve is attached to the front fork by 4 mm alien bolts. Two O-rings are provided between the modulator valve and front...

Front Fork Removal

Refer to P6-11 in the GSX400F Service Manual for details on the procedure involved in removing and disassembling the front fork. In view of the fact that the anti-dive device is provided on the left front fork, the following steps differ. When removing the front fender, remove the hose guide connected between the caliper and anti-dive device. The anti-dive device can be divided into two large sections the first is included in the brake fluid circuit and the second is the front fork oil circuit....

Fuel Level Gauge Attachment

To facilitate the fuel level inspection, following attachment is newly established. To facilitate the fuel level inspection, following attachment is newly established. Remove the carburetor drain plug. Install the attachment to the body of the fuel level gauge. This attachment is used by pressing the top of it toward the surface. The attachment is supplied individually. In accordance with this change, fuel level gauge set is also renewd as follows. Place the small diameter end of the spring in...

Valve Seat Servicing

The valve seats for both the intake and exhaust valves are machined to two different angles. The seat contact surface is cut 45 and the area above the contact service closest to the combustion chamber is cut to 15 . The valve seat contact area must be inspected after each cut. Insert the solid pilot CD with a slight rotation. Seat the pilot snugly. Install the 45 cutter, attachment and T handle. Using the 45 cutter, descale and cleanup the seat with one or two turns. Inspect the seat by the...

Engine Disassembly

Remove cylinder head cover and its gasket. Loosen the. lock nut CD and tighten the stop screw 2 and then remove two cam chain tensioner mounting bolts 3 . Screw CD locks the spring loaded tensioner push rod inside. Remove the eight camshaft holders. Remove the two camshafts, intake and exhaust. Be sure to loosen camshaft holder bolts evenly by shifting the wrench diagonally. The cylinder head becomes free for removal when its one 6-mm bolt and twelve 8-mm nuts are removed. Be sure to use the...

Piston Ring Free End Gap

PISTON RING END GAP Before installing piston rings, measure the free end gap of each ring using vernier calipers. Next, fit the ring in the cylinder, and measure each ring end gap using a thickness gauge. If any ring has an excess end gap, replace the ring. Piston ring free end gap_ If any ring has an excess end gap, replace the ring. Piston ring free end gap_ The following two types of oversize piston rings are used. They bear the following identification numbers. The following two types of...