1983-1985 Suzuki GSX400 FW FWS Service & Repair Manual

I ' • I l, FOREWORD The SUZUKI GSX400FWS has been developed as a new generation motorcycle to the GSX- models. It is packed with highly advanced design concepts including a liquid cooling system, a new highly efficient combustion system (TSCC), a fully transistorized ignition system, an anti-dive device and a full-floater suspension system. Combined with precise control and easy handling the GSX400FWS provides excellent performance and outstanding riding comfort. This service manual has been produced primarily for experienced mechanics whose job is to inspect, adjust, repair and service SUZUKI motorcycles. Apprentice mechanics and do-it-yourself mechanics, will also find this manual an extremely useful guide. Model GSX400FWS manufactured to standard specificq,tions is the main subject matter of this manual. However, the GSX400FWS machines distributed in your country might differ in minor respects from the standard-specification 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 with the statutory requirements of your country . This manual contains up-to-date information at the time of its issue. Latermade modifications and changes will be explained to each SUZUKI distributor in respective markets, to whom you are kindly requested to make query about updated information, if any.

VIEW OF SUZUKI GSX400FWS RIGHT SIDE LEFT SIDE

GROUP INDEX I GENERAL n------------ f ________________________ - ------------------------------------- --- 1 PERIODIC MAINTENANCE AND I TUNE-UP PROCEDURES l SERVICING ENGINE COOLING SYSTEM FUEL AND LUBRICATION SYSTEM -SYSTEM ------ -- - ----- - ------ ... .. . - ------ --- 1 INFORMATION I l__ ____ ---

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1-1 GENERAL INFORMATION SERIAL NUMBER LOCATIONS The frame serial number or V.I.N. (Vehicle Identi- fication Number) CD is stamped on the steering head pipe. The engine serial number ® is located on the right side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts. FUEL, OIL AND COOLING SOLUTION RECOMMENDATIONS FUEL Gasoline used should de graded 85 - 95 octane or higher. An unleaded or low-lead gasoline type is recommended. ENGINE OIL Be sure that the engine oil you use comes under API classification of SE or SF and that its viscosity rating is SAE 10W/40. If SAE 10W/40 motor oil is not available, select the oil viscosity according to the following chart: SAE 40 30 - I I 20W/50 i 10W/50 \ 10W/30 I 20W \ 10W - : Temp. uc -20-10 0 10 __ 40 oF -4 14 32 50 68 86 1 04 ( BRAKE FLUID Specification and classification: 99000-23021 WARNING: SAE J1703, DOT3 or DOT4 SUZUKI Brake fluid * Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix differ- ent types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. * Do not use any brake fluid taken from old or used or unsealed containers. * Never re-use brake fluid left over from the previous servicing and stored for a long period. FRONT FORK 01 L Mixture of SAE 1OW/30 motor oil and A.T.F. motor oil, the ratio being 50-to-50 percent. Or fork oil # 15.

COOLING SOLUTION Use an anti-freeze & Summer coolant compatible with aluminum radiator, mixed with distilled water only, at the ratio of 50: 50. WATER FOR MIXING Use distilled water only. Water other than distilled water can corrode and clog the aluminum radiator. ANTI-FREEZE & SUMMER COOLANT The coolant performs as corrosion and rust inhibi- tor as well as anti-freeze. Therefore, the coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point. SUZUKI recommends the use of SUZUKI GOLD- EN CRUISER 1 200 anti-freeze & summer coolant. If this is not available, use an equivalent which is compatible with aluminum radiator. REQUIRED AMOUNT OF WATER/COOLANT Solution capacity (total): 2 250 ml Water 1 575 ml 30% f------ - --- 1-------- Coolant 675 ml - ------ ---- ----- 1- I Water 1 350 ml 40% f --- Coolant 900 ml 1--- --- Water 1 125 ml 50% -r--1 Coolant 125 ml CAUTION: Mixing of anti-freeze & summer coolant I should be limited to 60%. Mixing beyond it would reduce its efficiency. If the anti-freeze & summer coolant mixing ratio is below 30%, rust inhibiting performance is greatly reduced. Be sure to mix it above 30% even though the atmospheric temperature does not go down to freezing point. Every new unit is filled with anti-leakage material, Bar's leak. __ _j GENERAL INFORMATION 1-2 BREAKING-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to "B R EAK-1 N" before subject- ing the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows: • Keep to these breaking-in engine speed limits: 80? km l Up to 1 600 km I - -----+--- Over 1 600 km 1 Below 4 000 r/min Below 5 000 r/min Below 11 500 r/min • Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation. However, do not exceed 11 500 r/min at any time. • Do not maintain constant engine speed for an extended time period during any portion of the break-in. Try to vary the throttle position. CYLINDER IDENTIFICATION The four cylinders of this engine are identified as No. 1, No. 2, No. 3 and No. 4 cylinder, as counted from left to right (as viewed by the rider on the seat).

1-3 GENERAL INF0 R MAT I 0 N SPECIAL MATERIALS The materials listed below are needed for maintenance work on the GSX400FWS, 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. Material SUZUKI SUPER GREASE "A" 99000-2 50 10 SUZUKI MOLY PASTE 99000-25140 SUZUKI BOND No. 1207B 99000-31140 SUZUKI BRAKE FLUID 99000-23021 (0.5L) SUZUKI GOLDEN CRUISER 1200 (2L) 99000-24120 Part Page Part • Oil seals 3-50 • Wheel bearings • Throttle grip • Sprocket mounting drum bearing • Speedometer cable • Swing arm bearing and dust seal • Gearshift lever linkage and • Brake pedal shaft mounting boss • Centerstand spacer • Cushion lever bearing 7-53 • Steering stem bearings and races • Cushion rod bearing 7-54 • Clutch lever and release • Side stand • Valve stem 3-28 • Rear shock absorber upper and • Cam shaft journal 3-64 lower bearings • Conrad big end bearing 3-38 • Crankshaft journal bearing 3-52 • Countershaft 3-49 -------------+- -----------+----- • Mating surfaces of upper and lower crankcase • Front fork damper rod bolt • Mating surface of crankcase 1 3-53 7-20 3-56 and clutch cover, generator 3-60 cover • Cylinder head cover gasket 3-68 • Brake fluid ----- t;:,. • Water temperature gauge • Engine thermo-switch Page 7- 6 7-55 7-25 7-53 7-54 5-14 3-68 5-12

Material THREAD LOCK SUPER "13038" 99000-32030 1-d) I I THREAD LOCK cement 99000-32040 --------- THREAD LOCK "1342" 99000-32050 THREAD LOCK SUPER "1305" 99000-321 00 SUZUKI BAR's LEAK 99000-24240 Part • Gearshift arm return spring stopper • Cam sprocket bolt • Starter clutch allen bolt • Cam chain guide screw • Gearshift cam retainer screw • Carburetor bracket screw • Engine sprocket spacer inner surface • Front fork damper rod bolt • Oil filter cap nut • Cylinder stud bolt • Generator stator securing screw • Generator lead wire guide screw • Gearshift cam stopper bolt • Countershaft bearing retainer screw • Starter motor mounting bolt --------- • Generator rotor bolt • To prevent leakage of cooling solution from small hole. GENERAL INFORMATION 1-4 Page Part Page 3-31 3-46 3-32 3-57 4-13 3-50 7-20 2-10 ---------- -· 3-46 • Gearshift fork shaft stopper screw 3-51 • Gearshift cam guide bolt 3-51 3-46 • Oil sump filter screw 3-54 • Throttle valve screw 4-12 3-57 • Starter motor housing screw 6-10 3-57 • Anti-Dive modulator valve fitting 7-20 bolt 3-56 • Anti-Dive modulator plunger 2-16 bolt - -- t - 3-56 I 2-12

1-5 GENERAL INFORMATION PRECAUTIONS AND GENERAL INSTRUCTIONS Observe the following items without fail when servicing, disassembling and reassembling motorcycles. 0 Do not run engine indoors with little or no venti lation. o Be sure to replace packings, gaskets, circlips, 0 rings and cotter pins with new ones. CAUTION: Never reuse a circlip after a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. When installing a new circlip, care must be taken not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always insure that it is completely seated in its groove and securely fitted. o Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter, and from inside to out-side diagonally, to the specified tightening torque. o Use special tools where specified. o Use genuine parts and recommended oils. o When 2 or more persons work together, pay attention to the safety of each other. o After the reassembly, check parts for tightness and operation. o Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use gasoline as cleaning solvent. Warning, Caution and Note are included in this manual occasionally, describing the following contents. WARNING ............ When personal safety of the rider is involved, disregard of the information could result in injury. CAUTION ............ For the protection of the motorcycle, the instruction or rule must be strictly adhered to. NOTE ................ Advice calculated to facilitate the use of the motorcycle is given under this heading. USE OF GENUINE SUZUKI PARTS To replace any part of the machine, use a genuine SUZUKI replacement part. Imitation parts or parts supplied from any other source than SUZUKI, if used to replace SUZUKI parts can reduce the machine's performance and, even worse, could induce costly mechanical troubles.

1983-1985 Suzuki GSX400 FW FWS Service & Repair Manual

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