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Suzuki GSX 400 F Service Manual WWW - Manualedereparatie.info PDF

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Jose Antonio Espinoza Villegas
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1K views292 pages

Suzuki GSX 400 F Service Manual WWW - Manualedereparatie.info PDF

Uploaded by

Jose Antonio Espinoza Villegas
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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SERVICE MANUAL FOREWORD The SUZUKI GSX400F tas Been developed a 2 new generation motorcyele to the GS- ‘models It packed with highly advanced design concepts including a forged ane piece crankshoft assembly and @ new highly efficient combustion system (TSC. Combined With precise control and easy handling tho GSXAODF provides excllent erformence and utstanling riding comfort. This service manual has boon produced primarily fr expereneed mechanics whe jb it 10 inspect, adjust, repoir and service SUZUKI motorcycles Apprentice mechanics ad foeyousalf mechanics, wil alo find this manual an extremely useful gue Mode! GSX400F manufactured to standerd specications is te main subject mater ofthis ‘manual. However, the GSX400F machines distributed jn your country might differ in ‘minor respects trom the standardspecitiation and, if they do, It becuse ome minor ‘modifications (which ae of no conssquonce in mast cases a¢ far as servicing is concerned) ‘had tobe made to comply with the statutory requirements of your county hie manual contains up-to-date information at the time of its fase, Letermade modi: ‘ations are changes willbe explsined to each SUZUKI dlatrbutor in respective markets, {© whom you are kindly requested to make query about Undated infermation. f any. SUZUKI MOTOR €0.LTD. ‘Service Publications Department Oversee Service Divison Quoting. copying or otherwise using any part of this manual without ox- plicit authorization from Suzuki Motor Co. Ltd. is not permitted as all rights to the publication are reserved under copyright law. VIEW OF SUZUKI GSX400F RIGHT SIDE LEFT SIDE GROUP INDE} GENERAL INFORMATION —~=s PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES SERVICING ENGINE FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION GSX400FZ ('82-model) GSX400FD (’83-model) GENERAL INFORMATION | CONTENTS: [SERIAL NUMBER LOCATIONS xeon nonn | FUEL AND Oll. RECOMMENDATIONS... BREAKING-IN PROCEDURES nn CYLINDER IDENTIFICATION nnn (SPECIAL FEATURES no BLOWBY GAS RECYCLING t 4 it TENOR sy ener sight GENERATOR igaeON are oary WONTON y SPECIAL MATERIALS GENERAL INFORMATION 110 “The materials listed below are needed for maintenence work on the GSX400F, and should be ket on hand for ready use. They supplement sich standard materials a cleaning fluid, lubricants, emery cloth and the Tk Howto use them and where to use them are described in the text of tis manta suzuki S SUZUKI siLIcone ite penta sod tachemete ‘Gear es kage ond aaron sat 38 358 416 Sprocet mounting um being Brake pds sat 62 ‘coo 25140 am sat urna Cone igend bang Countett 37 380 oH 355 SUZUKI BOND No.4 sion0310 ‘500075021 (081) 4 Fronteneamperrod bot | 618 © Otpresureseh 396 Maingsuace oferinkcae | 3.50 = ake aa ae | GENERAL INFORMATION We Par Paw Par = Geant cam ei scew | 361 Cameningucescew | 338 utr coe sew au Rocarsrmststop | 320 + Cotuatr serrate | 416 “THREAD LOCK SUPER | ‘2000 2070 Cam oroka bot aa Oitpumphautngscrew | Ba Serarcluthslentat | 348 ‘TuReao Lock suPER © canstatendeapscen | 328 | & an:Die cane bot © Eroresprcketscr | 352 =o ser eros 1 Fronttoksmpe roa bolt | 615 ud 2 cities ru 22 2 Shiner sma bate 0000 32040, = + Gwwatorsnorwauing | 247 | © Stee mator cringe sere Geant ton stat seper # Genwatorindwreguide | 347 |” see come Gest cam ie 38 © Guunnttcam toppertoe | 261 | © Oitsama tite sem 3s 1 Count tering 300 | © Thote ere “5 ~[ Genertarrororbor | 388 | “THREAD Lock SUPER GENERAL INFORMATION 112 PRECAUTIONS AND GENERAL INSTRUCTIONS ‘Observe the following itoms without fil when dsesembling and resembling motoreyeles 18 Be sure to replace packing, gaskets, cin, O rings and cotter pine with new ons ‘caUTiON ~] Never ruse a erlp after crip he been removed from a shat, t shouldbe dicarded and 3 now ‘irl must be installed, | ‘Won insalng 3 now ciectp, ere must be taken not to expand the nd gp bre than required to slip the eelip over he sat. |_ After instaing & crip, always insure tha tis complataly sated in ts grove and secure ed. © Tighten cylinder heed and ease bolts and nuts beginning with larger dlameter snd ending with smaller ameter, and from inside to outside aiagonlly, tothe specified tightening torque, © Use special tools whore specified parts and recommended ot, © Use gnu '© When 2 or more persons work topether, pay attntion tothe safety ofeach other © Aftor the reassembly check parts for tightness and operation, © Treat gasoline, which is extremly flammable and highly explosive, with grntet cae, Never use (asoline cleaning solvent. Warning, Caution and Wote are ineiucea in thie manual ocasionally, deseribing te folowing contents WARNING Wen personal safety of the rider is involved, dscegrd of the information ‘ould esl in injury, caution For the protection of the motoreyee, the instruction or rule must be strictly adhered to, Note ‘Advice calculated to faclitate the use of the motoreyele is given under this heading. USE OF GENUINE SUZUKI PARTS “To replace any part of the machine, use 9 genuine SUZUKI replacement part. Imitation parts o¢ arts supolied trom any other source than SUZUKI, if used to replace SUZUKI parts ean reduce the machine's performane and, even wore, ‘oul induce costly mechanical troubles. 1.13_GENERAL INEORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS ‘Overall length ‘Overall width ‘Overl height Wneabaee : Ground clearance ‘Seat height Dry mass. ENGINE Type. Number of evindars Bore. Stroke vessels Piston diplacament (Compression ratio Carburetor» Air cleaner Starr systor Lbristion system ‘TRANSMISSION ‘tuteh Transmission Gearshit pattern Primary eduction Fiaslreduetion Gear ratios, Low 20d ard “ah 5th Top Drive cain 2.105 mm 750mm 2 1136mm 2 1415mm 185 mm 720mm 1799 - Fourstroke,aireooled, DOHC 4 53.0mm 452mm 398em* 02:1 IMIKUNI 852655, four Polyurethane foam element Eleeie Wet sump Wet muttiplte type Speed constant mesh ‘oun, 5p 2.300 (82/40) 2.586 (43/15) + 166 (38/12) 2.125 (34/16) 1.631 (31/18) 1.333 28/20) 1173 (27/23) 1 09s (26/28) DAIDO DIDSOUB, 104 links CHASSIS Front suspension Rear suspension Steering andle aster Trail “Turing radius Front brake ear brake Front tr size ear tre size Front for stroke ear wheel trove Front tr pressure Rear tice presure ELECTRICAL, Ignition type Ignition timing -- Soark plug «| Battery Generator CAPACITIES, Fuel tank including reserve Reserve Engine ose eeesscscee Front fork ol (ese leah GENERAL INFORMATION 1-18 ‘Telescope oll dampened ‘Swinging sm, ol eampenee, soring Sway adjustable 4F (ight & let) ra 100m “2am Diz brake, twin Internal expanding Dise brake (fr England and Wet Germany) 3.2551047R 3758184°R 110/80-18 61S (only for West Germany) 160mm 107 mm 175 kPa (1.78 kalem*) {Normal soo ring) 200 kPa (2.00 kale) (Wocmal solo eding) Folly trandstorized 15" B.T.0.C below t 1650 r/min and 38° BT.D.C shove at 3500 r/min NGK DBEA or NIPPON DENSO x24ES.U INGK DRGES-L or NIPPON DENSO X24ESR-U 12 43.2 kC (12 AnI/I0 HR, ‘Throephase AC. generator 15a 151133 Imp gat £35181 Imp at £20 (1.8 Imp at) 169 ml (5.95 Imp o2) * These soecitications are subject to change without notice. PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES —- — CONTENTS: — PERIODIC MAINTENANCE SCHEDULE. 2 MAINTENANCE AND TUNE-UP PROCEDURES nnn | ait CLEANER ELEMENT... 1 3 : 3 | BATTERY enn ea. | CYLINDER HEAD NUTS AND EXHAUST PIPE BOLTSo-2- 5 | VALVE CLEARANCE : - 6 COMPRESSION CHECK nce ~ 8 ‘SPARK PLUG ° IGNITION TMING | carsuneTor | FUEL UNES .. ENGINE OIL AND FILTER. OL. PRESSURE nen (OIL SUMP FILTER, cLuTcH. BRAKES.. DRIVE CHAIN TIRES... STEERING noon FRONT FORK... 21 PERIODIC MAINTENANCE ANO TUNE.UP PROCEDURES: PERIODIC MAINTENANCE SCHEDULE ‘The chert below lists the recommended intervals for all the required periodic sevice work necessary to keep the motoreyele operating at peak performance and economy. Mileages are exressd in toms of kilometers. Nore: 7 More frequent servicing maybe performed on motoreycles that reused under ever sondtons PERIODIC MAINTENANCE CHART ENGINE ira Tt 1 008 omy 100008 | Poe [aie - 2_| [ese Tet 5 24 | Eng batande | eet a 25 “Vereen inet = 26 Gonpreion rset = 28 Sok 1 eae 28 taion rina rset a 210 inc = 20 ‘mo fer aa = Ga 213 ‘eh ist iets [aoe [Dae ry 5000 very 10080 | Pan 7 [= 2 Deven Test and een ey 1 000 28 "Seeing [eet = Frontera Gino ae PERIODIC MAINTENANCE AND TUNEUP PROCEDURES _22 LUBRICATION CHART ‘The maintenance schedule, which follows, f based on this philosophy. It timed by odometer indication, snd is eaeulated to achieve theultimate goal of motorcycle maintenance in the most economics! manner. ria a vr 50004 fry 10008 Conon 7 come 1 Troi bs Nowra = cence - Toor ot oa Gueniew Mer = Secret ce 5 Gee Tahanaw ete = oy Baeecam ew = con ‘Sting Being ‘Swinging am bts ras vry 2 yur oF 20000 arelul not to spply too much grease to the brake cam shafts. I ge ippage wll result. 8 gets onthe linings, brake Lubricate exposed parts which are subject to rust, with ether motor il or grease whenever the matoreyele has beon operated under wet oF rainy conditions Before lubricating each pat, clan off any rusty spots and wipe off any grease ol, itor aime, 23_ PERIODIC MAINTENANCE AND TUNE.UP PROCEDURES MAINTENANCE AND TUNE-UP PROCEDURES ‘This stetion describes the servicing procedures for each items of the Periodic Maintenance require AIR CLEANER ELEMENT Clean Every 3.000 km If the air cleaner is clogoed with dust, intake re sistance wil be incrased witha resultant decrease in output end sn increase in fuel consumption. Check and clean the element in the following Take out air cleanec element from the air cleaner case by removing two guides Fill » washing pan of a proper size with non flammable cleaning solvent. Immerse the oe ment inthe cleaning solvent and wash i lean, Squeeze the cleaning solvent out of the wash clement by presting it between the palns of both hanes: do not twist or wring he olomant or twill develop teas. ‘+ Immerse tho clement in motor ol, nd squeeze ‘the oll out of the element laving it sightly wet with ot ‘+ Fiche cleaner element to frame properly [ caution | + Betore and during the cleaning operation, inspact the element for tear. A torn ol ‘ment must be rplaced. Be sure to postion the element snugly and correctly, 0 that no Incoming ai will Dbypss it) Remember, rapid weer of piston Tings and cylinder bore i often caused by @ | detective or poorly fitted clement connect InconnecT PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 24 BATTERY Inspect Iii 1/000 km Every 5000 km '¢ The battry must be removed 10 check the electrolyte level and specific rvity Femove left frame cover, Remove batery lead atthe battery terminal Remove battery © lead wire Femove battery rom the fame. (hack electrolyte for lovel and specie erat ‘Add distilled vate, ab necesary, to Koop the surface of the electrolyte above the LOWER lov line but not above the UPPER lve line, For checking specifi gravity, use a hydrometer to termine the charged contin, ss00z8403 | Hydrometer Standard spect 1.289 20°C (68°F) [An SG. reading of 1.22 (at 20°C) or under means ‘that the battery navds recharging of the machine: . take ito and charge it fom a recharge. Charging the battery in place can lead to failure of the regulator esti, To install the battery, reverse the procedure orribe above [wars ~ 4 | Mine iting she bat tad wi, fc || the) od antand hd tt | © Moke sure that the breather pipe is tightly secured and undamaged, and is routed as shown in the fig. | entre nba 25 _Penonie main ANO_TUNE-UP PROCEDU CYLINDER HEAD NUTS AND EXHAUST PIPE BOLTS. Fetighten initial 1 000 km and Every 5000 km CYLINDER HEAD 1 Remove the fuel tank ' Remove the elinder headcover {© Tighten the twelve 8 mm nuts {12mm wrench) to the recited torqe with 2 torque weonch sequentially in sending numerical ordor with the engine cold i 20.Nan ovlinder ese od mut After firmly tightening the 12 nuts, tighton ‘the 6 mm bolt (indicate st) to the torque value below 0-1 Naw eae (0.91.1 kgm) NOTE: Install a new gasket to prevent ll ekage, EXHAUST PIPE ‘© Tighten the exhaust pipe bolts and coupler tbe bolts to the specified torque with © torque wren, aust pipe bole 10— 16Nm Exhaust pipe bol noe ist Sioustvine [8-14 connector bot (09 = 14 kgm) PERIODIC MAINTENANCE AND TUNEUP PAOCEOURES 25 VALVE CLEARANCE | Inspect tit 1000 em ad I Every 5000 km ‘The valve clearance specification is the same for both intake and exhaust valves Valve clgarance adjustment must be checked and adjusted 1) at the time of perieae inspection, 2) when the valve mechani ie serviced, and’ 3) when the camshafts are disturbed by removing thom for servicing ‘Valve clearance (when eal 0.98 = 0.13 mm [Nore ] | The eam must beat postion ® or @ in || order to check the valve clearance or to ‘adjust valve clearance, Clearance readings fhould not be taken with the eam in ny ‘ther postion than these wo postions ‘The clearance specification is for COLD To turn the crankshaft for clearance checking, be sure to use a 19:mm wrench land to rotate in normal running dere ton. Allspark plugs should be removed Turn cranksheft to bring the “"T" mark on Nos. 1 and 4 sie (of sdvanee governer) tothe timing mark and leo to ring the notches in the both camshaft (Ex and ln) of the right ‘ends to the position at shown, In this cond tion, read the valve clearance atthe valves | (in and Ex of No, 1 evlinder, Ex of No. 2 and Inof No. 3h. 27 PERIODIC MAINTENANCE AND TUNE.UP PROCEOURES ‘+ Uso thickness gouge between tappet and vale. If clearance i& off the specification, tring it Ingo the specied range by using the tappet adjusting driver 2 (0800020808 | Thickness snuge (0901714910 “Tappet adjust driver ‘= Turn crankshaft by 360° (one rotstion) to bring the “7 mark on Nos. 1 and 4 side to the timing mark and algo to bring the notches 1 t0 the position shown, ‘© Read clearance atthe vive ©) and adjust the clearance If necesay. ‘Tighten the eylindbr head cover propery NOTE: epee the heed cover gasked with new one PERIODIC MAINTENANCE a COMPRESSION CHECK ‘Check init 1 000 km and Every 5000 km ‘The compression of # cylinder is 2 good indicator of ie internal condition. The decision to overhaul the cylinders is often based on the results of a compres test. Poriogie maintenance recorce kept at your deleship should inlude compeesion readings for each maintenance sve COMPRESSION ‘Standard Limit | Difference [1 100-1 500s” 700KPa | 200 KPa (111 kglem®) | (7 kglem?) | (2kglem®) Low compression pressure an indieate any of the following conditions * Excosivaly woeneylindr wal * Worm down piston oF pat rnge * Piston rings stuck inthe grooves + Poor ling of valves ssket Overhaul the engine in the following ese: * Difference in compression presue between the two i more than 200 KPa (2 kg/er * All compression pressure are below 1 100 KPa (11 kalem?) (standard) even whan they mess: ure more than 700 KPa (7 kglem) WO TUNE-UP PROCEDURES 28 COMPRESSION TEST PROCEDURE NOTE: * Before tasting the compression of the engine, make ture tht the eylinder heod tuts and bots are torqued to speciation, + arm up the engine before testing, Remove al spark plugs. Ground al plug lead * Fi the compression snue (in one of the plug holes, while taking ear thatthe connection Is th 1 Twist the throttle grip fll pan. {Crank the engine a few cance with the starter, and record the maximum gauge reading a the ‘compression of tet evn, ‘© Repost this procedure with the other eylinders (915 64510 cvots63210 | Comprosion gauge ‘Adaptor 29 PERIODIC MAINTENANCE AN TUNEUP PROCEDURES SPARK PLUG (Clean and Adjust Initia 1 000 km and i Every 5000 em Replace Every 10.000 km ‘The plug gp is edusted to 0.6 —0.7 mm. The gap is correctly agusted using a thickness gauge (epecal tool). When carbon i deposited on the spark plug. remove te carbon with a spark ps9 leaning machine or carefully using tool with 3 pointed end, If electrodes are extremly worn oF burnt, place the plug. Also replace the plug if it has 9 broken insulator, damaged thread, etc oomR0 13210 Socket wrench FF c2ea0-14590 Univeral jit | 0901424510 Thandle 3 Thee oe GK DBEA or NIPPON DENSO X24ESU listed inthe table should be use at he standard plu.” However, the heat range of the plug should be selected to meet the requirements of speed, actual food, Wel, et. If ve pidge need to be repised, {ti recommended tht te standard plug listed in the tale be selected, Remove theplugr and inpect the insulators. Prope heat range would be ineat- 4 if both insulators wore light brown in color. If they are Blackened by carbon, they should be teplaced by 2 hot type NGK D7EA or NIPPON DENSO X22ESU and if baked white, by NGK [D9EA or NIPPON DENSO X27ESU, Plugs with high hat range number are used for high speed running. These plugs are designed to be sufficiently cooled to prevent overhesting and ae called cold type pugs [wore “RY sypa sparkplug is fitted under some of specifications and it means that the resistor is located at the center electrode to prevent | redionoise NOTE: To check the spark plugs, fst make sure that ‘the fuel tank contains unletded gone, and aftr atest ride, if the pls are ether sooty ‘with carbon or burnt white, raplace them together. | | | Emsam | | NOTE: Confirm the thread size and reach when replacing the plug. tthe teach is 90 short, carbon wil be deposited on the srew portion ff the plug hole and engine damage may raul —— 61908-07 mm = REMARKS. 1th standard plug is apt to ec race wih Bus Hatt. von7es) | oazesRv) Daca | xaaesu rorsesyy ocwesry | Smee ig Calpe Deca) xz7esu vonaes) | cz7esnuy PERIODIC WAINTENANCE AND TUNE-UP PROCEDURES 240 IGNITION TIMING Inspect Initia 1000 kr and Every 5000 km IGNITION TIMING SPECIFICATIONS | 15 8T.0.c. baow 11650 + 100 r/min ana The poco a Soho torko® opan alee = «Rn Ue oie ese ec naeg 1500 | ann timin, Under this condition, "F" mark on | “No. 1 and No. 4” eylinder side advance gover: ror and timing mark should be in perfect ligament: If not, loon two stator securing Serews 1) and adjust the ignition timing by turing stator bate a shown alow 1 500i 0900027311 | Timinglight CARBURETOR "Inspect Initial 1 000 km ant Every 5000 kn [aes THROTTLE CABLE PLAY ‘There should be 05 mm play (A) on the throttle cable. To adjust the throttle cable play ‘© Tug on the throtte cable to check the amount of play ‘= Looten the two lock nuts 2) and tum the ad juster &) in or out until the spacifed play is ‘obtained «Secure the lock ruts while lding the adustr in ple. Tottecatepiay ® | aSmm AND TU IDLING ADJUSTMENT [nore |_ Make this adjustment when the engines hot ‘Star up the engine and st its sped at anywhere ‘between 1050 and 1160 r/min by turing ‘throttle stp serew Engine idle speed | 11002 S0+/min FUEL LEVEL INSPECTION * Place machine on canter ston, 1 Remove esrburetor drain plug and install the ful lve gauge 2) oegra145t7 Fuel gouge body ‘ag13-14560 ‘Attachment 1 Run the engine at the dling speed (1 050 — 1150 r/min), and measure the distance withthe riddle fine ofthe level gouge aligned with the Tower surface of carburetor body a8 shown Ia jhoto. shouldbe within te specified ange, Distance 40 = 1.0mm ‘Repeat the procedure on each carburetor. NoTE: When refitting the serew, be sure to use the "0" ring 1 fel level readjustment is necesary, se page 4-11 for adjusting float height 2) _ PERIODIC WAINTENANE uP PROCEDURES. PERIODIC MAINTENANCE AND TUNEUP PROCEOURES 212 FUEL LINE [_ Rene or 2 ve ENGINE OIL AND OIL FILTER {Change ot initial 1 000 km and | Every 5000 km | seery The oil shouldbe changed while the engine ishot. Olt iter eeplcement at the above intervals should be done together with engine ol chan. *# Keep the motoryele upright, supported on the conte stand + Place an ol pen below the engine and drain the il by removing the dein plug? and filer e9p + Remove three nuts Wt remove the fier Pull ut od itr @, and replace with new one ‘Replace Oring and filter cover, and secure nuts 3) with applying thread lock coment. 20000-32040 ‘Taved lek cement Fit dealin plug 1) securely, and add tes ol trough the filler, The engine wil hold about 2.4L (2.1 Imp qt) of ol, Use API claification of SE or SF oil with SAE 1OW/40 viscsiy 1 Stor up the engine and allow it to run for several seconds at ling speed. 1 Turm off the engine and wait sbout one minute, then check the ol level through the inspect window (5). UF the level is below mark ‘ppl ol t0 that level 219 PERIODIC MAINTENANCE NECESSARY AMOUNT OF ENGINE OIL (it chang Filter change (Overs engine NOTE: Be sure to take care of Orring to provent ‘any damage and be sure thet filter sping |s property in pace OIL PRESSURE Ingpeet Every 5 000 km ‘Start the engine and check ifthe ol pump presture Indicator light is turned on. 1 keeps on lighting, heck the oll pump pressure indiator ight ecu If it & In goed condition, check the oil pump Brestur in the fllowing manner ‘lost the el pease gouge © In the position shows in the figure, Summer 10 min $0 at 2.000 e/nin Winter 20 min. or 0 at 2000 r/min ‘+ After warming up operation, increase the ‘engine speed t0 3.000 r/min, snd reed the oll pressure gone O1L SUMP FILTER ‘Clean Every 1.000 km [At the same time wash th el pan. Chock to be tare thatthe strainer sree i fee from say sign of rupture and wash the strainer cleen periodically ‘When installing oll sump filter, be sure to face the row mark (i ile) tothe front. [ nore: Replace oi! pan gasket with new one to prevent ll lace. a {AND TUNE.UP PROCEDURES OL PUMP PRESSURE SPECIFICATION ‘Above 260 KPa (2.5 Kalen?) 7 Below 560 KPa (55 kaon? a 3.000 r/min (0001574510 (000157330 Oil pressure gage {Gauge (0 10 kglem*) 1 the pressure is too low, It means that the oil ‘ump is internally worn or oterwise defective and ‘eds tobe replace with new ove PERIODIC MAINTENANCE AND TUNEUP PROCEQURES 214 CLUTCH Inspect Into 1000 km ane =| Every 6000 km | Loosen lock nut () on the lever side of the clutch eable and agjusting nut fully in on the ‘teh lever see # Loosen the cable lock nut >, tighten the acjusting stew to provide play in the outer cable. Adjur the play of the cable with adjuster ‘© until play of the clutch lever is 2 — 3 rm. Next Firmly scure lock nt 3 Cable pley 2-amm TF the specified play ean not be obtsned with acjuster |), cary out the adjustmant using the justin aut 200 thecluteh lever side BRAKES Inspect Initial 1/000 km and Every 5 000 km i Replce hoses Every 2 years (Chango fuid Every 7 year BRAKE FLUID LEVEL * Support the motoreyele body on the center ‘and, and place the handlebars svaight + Remove the right frame cover, hack the brake Fuld level by observing the Uuper and lower limit lines on the Brake Mid resirvoirs, bot front and ret 4 When the lve is below the lower limit tine replenish with brake fuid that meets the fl lowing specification, “Specification AE S17 and Clastieation | SAE 1708 q 99000-23021 SUZUKI Brake ia 2.15 PERIODIC MAINTENANCE AND TUNE.UP PaUEEDURES 4 WARNING: The brake syst of this motoreyele i filled with @ glycoLbased brake fuld, Do not use or mix diffrent typos of fluid such as silicone- based and petrolaum-based fu for refiling | the system, oxhorwis serious damage wil be ‘eausid, Do not use any brake fluid taken ‘rom old or used oF untened container [Nevor rouse the brake id ltt ove from the last servicing and stored for long paods. WARNING: Brake fluid, if oaks, wil intrfre with safe running snd dacolor painted surfaces, (Check the brake hoses for erecks and hose Joint for eskage before riding BRAKE PADS Wearing condition of brake pads can be checked by observing the red limit line) marked on the ad, Wihen the wear exceeds the limit in, replace ‘the ads with new ones. (08 papes 65 and 6-20) * Looten lock nut 2, and turn stopper bolt say from the stopper. # Looten lock nut 8, and rotate push rod (8) to locate brake pedal 20 min ® below the top face of the footrest. ‘= Turn th stopper bolt in so that theclearance between the stopper bolt and stopper is zero, ‘+ Retighten both lock nuts 2) and Brake pedal height 20mm BRAKE LIGHT SWITCHES Adjust both brake light switches, front and rer, 30 that brake light wil come on just before a pressure is fete whon the brake lover ie squeezed, oF the brake pedals depressed AIR BLEEDING THE BRAKE FLUID CIRCUIT ‘ie trapped inthe Suid cicult sts like a cushion to absorb a lsg# proportion af the pressure devel: ‘ped by the master evlindor and thus interferes with the full braking performance of the caliper brake, The presnce of aii indeated by “spans: nese" ofthe brake lever and alo by lak of braking force, Consiering the danger to which sich tap: pd sie exposes the machine and rider, it sexe {al that, after eemounting the beske ad restocing the brake system to. the normal condition, the brake fuid cheat be purge of arin te following # Fill_up the mester eyinder resavoir to the “HIGH lve line. Replace the reservoir cap to prevent entry of dir, = Attach a pipe © the caliper blender valve, and Insert the fee end of the pine ino receptacle, Bleeder vive 790m tightening torque | (0.7 0.9 ks) 0 MAINTENANCE AND TUNE-UP PROCEDURE 247 PERIODIC WAINTENANCE AND TUNE.UP PROCEDURES + Bed the ee calier fst and thn the ight ea: Squeeze and releaie the brake lever several times in rapid secession, and squeeze the lever fully ythout lensing it. Loosen the blesdor vave by turing ta quarter of a tuen so ‘hat the brake fluid rune into the recaptecl; this will remove the tension of the brake lever ‘causing it 0 touch the hanclbar grip. Then, ‘lose the valve, pump and squeeze the lve, and ‘open the valve Repeat this process until the fluid flowing into the recoptacle no longer contains air bubbles. NOTE: Replansh the brake fluid reservoir a¢ noes sary wile bleaing the brake system, Make sure that there is always some fluid Visible in the resent, 1 Close the bleaer valve, and disconnect the poe. Fl he reservoir tothe "HIGH" level ine. ‘CAUTION: Handle the brake Muid with care: the fluid reacts chemically with paint, plastics, rubber materials, te, * Differences between front and rear are that the raster cylinders stusted by 8 pedal REAR (ORUM TYPE) Bring the brake pedal to a position about 20 mm blow the foots. This effected by turning the ajuting bolt, Beaute to tighten the lock nut 2 good and hard after seting the bot. By repositioning the adjusting nut (3) on brake rod, st the pedal pay to 20 mm , install the washer In the groove properly, then engage the woshor 3) to the washer 2 353 _ SERVICING ENGINE ENGINE REASSEMBLY “This engine ie reasembied by carrying out the steps of dsasembly in the reversed over, but thee ae a ‘numberof steps which demand special deserption or precationary meesutes, [ wore: | Ape engin oto ech running and siting part befor ressembing, | Rete to the following figure in regard to the correct positions and orientations ofthe forks hen instaling these parts. 1 + Goarshift fork for Sth driven gear, D : Gearshift fork for Sr drive gar, 1): Gearshift fork for 6th driven gear * Before driving in fork shaft stopper screw © and cm guide bolt, apply THREAD LOCK. 1342" to thar threaa, 9800032050 | Thread lock "1942" * lnstall the gearshiting cam withthe dent forthe neutral stopper directed downward, and meet ‘the neural stopper (3) with this dent SERVICING ENGINE _ 354 —— Tighten the neutral stopper housing a8 the following torque value Tightening 18—28Nm torque [_ tra-28 kom ‘= Apply grease to tho driveshaft ll seal T .99000:25010 | SUZUKI Super grease A Pace two regs 1) and 0 knock pln ‘nd instal drive ond counter sats, «+ tnstall the countershaft and drive shaft ll sel, positioning as shown. SERVICING ENGINE ‘Place cam chain guide) propesy, and fx 190 dampers 2) s0 that the iron side faces t0 the chain guide pin inside) ‘© Identify the two kinds of erenkshat jours ‘earings, one hat anol groove ‘and the other has no il groove on its surface. Grooved ‘one shouldbe fx tothe lower erankcase and the ‘other tothe upper crankcase. 6) + for lower erankease © + for upper erankease ‘When fitting the bearings tothe erenkease, be the stopper part) st ana prs TION: ‘Do not touch the bearing surfaces with your hands. Grasp by the edge ofthe bearing shall ‘= Apply SUZUKI Moly Paste to each journal bearing ight ‘9000026140 | SUZUKI Moly Pate e ‘Thrust bearing for erankshat go into place with Its ol groove side fecing the crank web, Mount the crankshaft with cam drive chain to the upper crankcase. Apply SUZUKI super grease “A tothe lip of ‘he cranks ol sa. When fitting the oi pressure switch, apply SUZUKI Bond No, 4 to its thread lightly to rove oll eke. comoarme | _aveUKi aa 4 Tatenng | 18= 17m tome | thao Clean the mating suraces of the crankcases before matching the unper and ower ones. [Apply SUZUKI BOND No, 4 to the mating su face of the lower crankcase in the following procedure. SERVICING ENGINE _ 95 ‘9900031030 | SUZUKI Bond No.4 257 _ SERVICING ENGINE fi ‘NOTE: ‘| ‘Use of SUZUKI BOND No. 4 i a follows Make surfaces fre from moist and other foreign materi, * Spread on surfaces thinly to form an even layer, and wait for around 10 minutes before asembing. * Take extreme care not t0 apply any bond No, 4 tothe bearing surfaces * Apply to distorted surface as it forms a comparativo tic fm, il dost | ‘Locate the two allen bolts at petition @® and ten 8 mmoles ‘© When securing the lower crankcase, tight the ‘8 mam bolts and the 6 mm Bolin the azending ‘ofder of numbers assigned to these bolts, tight ening each bolt a litle ata time to equalize the pressure. Tighten all the securing bolts t0 the ecified torque values, (09914-25811 | 6 mm T-type hexagon wrench Talon Fi ein 1 Seat washer and tighten cil pressure equator 1D with specitiad torque. 17 = 20Nm (1.7 = 2.0 kgm) ‘Install the il simp filter t foe the ail niet to the tront. ‘+ Apply thrad lock "1942" tothe thre sores T 9900032060 | Thread Lock "1342" SERVICING ENGINE 358 * Locate @ new gisket and oil pan, and tighten ‘5 mm bolts with specified toraut ‘Tightening torque | 10Nm (1.0 kp) | Nore: Install the four clamps for signal generator lead! 2 shown + lnstall the engine ground wite ), and eronkeste securing bolt 2 Tightening] torave (1.3 kom) ‘= Degrease the tpared portion of the rotor nd ako the crankshaft. Uso nonflammabl cleaning Solvent to wipe off the oly oF greasy matter 19 ‘make thes surfaces completly dry ‘= Riter mounting the rotor, sseure the rotor by ‘tightening the canter bolt othe pected torque value Tightening 110-130 'um torque (110-130 kom) 09930-44510 Rotor holder ‘99000-32100 | Thread Lock Super "1305" 250 _SEAVICING ENGINE Mount starter motor, and route the lesd wire property 190000:32050 | Thread Lock "1342" ‘© Coat SUZUKI Bond No.4 lightly to the portion around mating surface between upper an lower crankcame a shown T ‘9800031030 | SUZUKI Bond No. 4 1s Pass the ginerator stator lead wire through gasket and upper crankcase. Route its ead wire “NOTE: — 1 Always use new gasket, and install two | positioning pis * Instal the gear position ineator suitch [ nore: || When installing gear poston indicator switch, be sure to locate spring, switch contact, and ‘ll sel holder vety bend the lock portion of th ‘Install the counteshaft bearing retainer with to (16 mm length) rons. T 9900022050 | Thread Lock "1342" «+ lnstal it pump aseembly without fal to install Oring ‘99000:2050 | Thread Lock "1342" ‘= Install the washer 2, dive pin (and driven gear © by using cielip opener 4 lostll the gearshift shaft and fix washer and clip &) tothe gearshift shat SERVICING ENGINE 1 Intl he cam stopper with bot 19000032050 Three lock "1942" NOTE: [Aftar tightening the cam stopper bolt, move the stopper back and forth with finger to be sure that its movement i¢narmal _| * Bring gear shifting cam to “NEUTRAL” postion «Insert the neutral cam pin (half end cree pin) 1 into the closest pin ole to cam stopper Install pia retainer >) in such a way that the rocess 4) of pin retainer will mit the smi ree end of pin ‘© Tiahten pin retainer securing screw with apply ing thread lock super 19338" 12900032020 | Thread lock supper "1338 + tnstal the two washers on the countershat SEIVICING ENGINE sez ‘Install the large washer “) and oil pump drive or ‘+ Fix the oil pump drive gear @ to face the provusions @ uti, ‘© Assmble the primary driven goar so that the protrusions align with the notch @ behind the primary driven goa. ‘Install the spacer so that the screw hole faces outside 1 Intl he washer 1 Check t0 be sure thet the plano wire, wave washer and driv plate are properly installed ‘+ After tightening the clutch sleeve hub nut, be sure to lock the nut by firmly bending the tongue of the washer. Tightening torque for the ‘uti specified ‘hutch sleeve hub net | 60 70Nm tightening torque |_(50— 7.0kgmm) 0992088710 | Clutch sleeve holder 385 _ SERVICING ENGINE ‘Insert clutch driven plate and dive plate one by one into sleeve hub in the preseribed order, co plate firs. 4 lnsert cluteh- release rock bearing, washer pd wave wather 3) into presure pate in order a shown in the figure ‘Fit he pressure plate into the sloeve hub Tight clutch spring bolts in the onder shown in the photo. NOTE: “Tighten the clutch spring set bolts in the ‘manner indicat, tghtaning them by dearoes unt they attain wiform tightness Clutch springbolk | 17-13 Nm tightening torque (.1= 1.3 kom (Coat SUZUKI Bond No, 4 ight t th portion ‘round mating surface between crankeaes 19900031030 | SUZUKI Bond No. 4 ‘© Replace clutch cover gasket with new one to ‘brevet oi! leakage. ‘© Engage the teeth of cluteh release rack with ‘those of pinion gear at the clutch cover side, and replace clutch cover. Make sure that the tack end pinion gear engage positively. To Install cover, tap lightly with plastic hammer, and tighten screws Install the signal generator rotor tothe advance ‘governor property Make sire to fit the slot) on the back surface fof the automatic advance governor over the locating pin 2) at the end of crankshat Fit the groove of the crankshaft turning nut ‘on protrusion «of th advance governor body. Hole the crankshaft turning mut an tighten the severnor center bolt with specified torque Tightening 13—23Nm (13-23 kgm) Install the signal generator so thet tha index ine 5 aligne with hecantor ofthe iting see. Insal the leed wire tothe ol presure ate, Route the signal generator laa wire as shown, Seaview ENGINE 368 305 _ SERVICING ENGINE ‘+ Moure the piston ring in the order of oil ring, 2nd rng, and top ring, ‘= Top ving and 2nd (middle) ring lffer in the shape of ring face, and the face of top ring it chrome plated wfseeas that of 2nd ring isnot ‘The color of 2nd ving appears darker than that of the top one. '# Top and 2nd midate) rings have letter "A" marked on the side, Be sure to bring the maked ‘Side to top when fitting them tothe piston ‘+ The fist member to 90 into the ring groove is spacer 1). Alter placing space, fit the S00 ‘side alls 2. Sidedsignations top and bottom, ‘se not splied to the spacer and side rails: you ‘an poston each ether way. * Poston the gaps of the three rings es shown. Before inserting each piston into the eylinde check thet the gaps are so located A» ‘+ The piston isin correct position when its arrow (on the crown) points forward Be sure to install the pistons In the eylinder from which they wore taken out in disassembly, refer tothe lator mark, "1" through “4, sib ‘don the piston, 1 Have each piston olled lightly before installing 1 Place 2 rag beneath the piston, and install the cial, 1 Be.sure to use now clos. ‘© Check to be sure two cil jt orifices ©) are not logue «Install the new O-ring ‘+ Make sure thatthe conrod oil hole) is located rear + ace the new cylinder gasket onthe crankcase. «+ tnstal piston tng holders inthe indicted man net. Some light resistance must be overcome to Tower the cylinder block, ‘With No.2 and No, pistons on place, mnstat No. 1 and No. 4 pistons, and insert them into the eylinder. (0991674620 | Holder body (0001674530 | Band (bore 85 — 65 mim) ‘NOTE: * Do not overtighten the specil tol bands for the eylinders wil resist to. admit the pistons * Each band has @ number punchmarked on it.The number refers toa perticular ange of piston sizes. SEAVICING ENGINE 265 AVICING ENGINE 1 Be sure to replace cylinder head gasket with ‘ew one to prevent gs leakage NOTE: Be sure 0 iontify the "HEAD" surface of the cylinder has gasket a shown + Fix two knock pins property + Tighten the ‘welve @mm nuts to specification with a torque wrench sequentially inthe ascond Ing order of numbers 09917-74520] Long socket 12mm 09914.28510 | Thandie Cylinder head ut : Tieng torque 20m (20 kom) ‘After firmly tightening the 12-nus, inset one 6 ‘mem bolt and tighten it with specified tora, Tightening | 8— 11 New torque (09-11 kom + race chain guide) propery G SERVICING ENGINE 368 + Wile holaing down th timing chain, rotate the crankshaft in normal alection to bring the “7” mark (on Nos.1. and 4 cylinder side of the ‘advance governor) t0 the timing mark ‘CAUTION: To tum over crankshaft, torque nut with 9 Buss 49 mm wronch. Never try to rotate eankshett by puting a 12 mm wrench to bole. 4 The exhaust camshaft can be lstingushed {rom that of the imake by the embossed letters za "EX" (for exhaust) as aginst letters “IN” (for Intake). The right end ean be distinguished by the notch [ Note: ust before placing the camshaft on the ey: Inder head, apply high quality molybdenum sulfide lubricant to. its journals, fully | ‘coating each journal withthe parte taking care ot to leave any ery spot. Apply engine oil tothe journal basing. | ‘99000-25140 SUZUKI Moly Paste © With "7" mark accurately fined up with the timing mark, hold the erankshatt steady 2nd lightly pull up the chain to remove the slack between the eran sprocket and exhaust sprock ‘= Exhaust srocket bears an ortow marked 1" ingicated as 1). Tur ove the exhaust camshaft 0 that the arrow points flush withthe gasketed surface of the evlider head. Engage the timing chain with this sprocket. 269 _SERVICING ENGINE ‘© The other arrow marked "2" is now pointing stright upward. Count the chain roller pins toward the intake camshat, starting from the roller pin directly above this arow marked?” fend ending with the 23ed roller pin. Engage the chain with intake sprocket, locating the 231d pin at and above the arrow marked "3" ‘on the intake sprocket. | wore: ‘The timing chain ie now siding on ll three sprockets, Be careful not to disturb the crankshaft until the four holders and chain tensioner adjuster are secured 234d pin ‘Each camshaft hola i inti witha east on letter with» triangle. A. matehing carton symbol sppesrson the head, Intl och oder 2 ies matching letter, with trlangle symbols pointing forward. Secure the eight camshat journal holders evenly by tightening the camshaft journal holder bolts sequentially. Try to equalize the presure by ‘moving the wrench dlagonally from one bott to {nother and from one camshaft journal holder to another, to push shafts down evenly NOTE: Damage to ead or cam journal holder thrust surfaces mey retult inthe situation that cam journal holders are nat drawn down evenly Tighten the camshaft journal holder bolts to the fellowing torque value ‘CAUTUION The camshat journal holder bolt are mad of special mati! and much superior in strength campared with other type of high strenahth bolts | “Toke special care not to use other types of bolts instead of these spacial bolts. To dent fy these bolts, each of them has figure “S| con its hed, ‘Gamsha journal holder bolt tightening torque 10Nm (1.0 kom) ‘While turning tock sof handle countrciock ‘wise, pushin the pushrod al the way. Keep on turing thehandle unt tretuss to ten further Tighten the lock serew to lock the pushrod, so ‘thatthe pushrod il not plunge out, + Secure the adjuster tothe eylinder block SEAVICING ENGINE a0 I tensioner adjuster is not going in, turn the crankshaft slowly clockwige to get chain play a init sce. ‘Withdraw the lock sew by one-quarter to halt 1 tum: this separates the tp ofthe serew from the pushrod, thereby allowing the pushred to svanee under spring force and 10 press the tensioner against the camshat chain, Tighten the tock nut Note: When tightening the lock nut, tke cae to prevent the lock screw from tring, Slowly rotate the erankshat in everse direction {chus causing the chain to push back the tension on. ‘¢ Release the handle and slowly turn back the crankshaft n-normal running ection (to flacken that portion of the chain extending slong the tensioner. Se ifthe handle rotates by itself asthe chain bacomes progressively slack ened; i it does, then the pushrod inside is tbvioutly moving forward under spring free a it should, thor signifying thatthe tensioner is in good opersle’ condition. IF the handle rotates, but sluggishly, t means that the pustrod fF lock shaft is sticking and, in such a cas, remove the tensioner and service the pushrod tnd ook shaft to make them mave smooth cauTion: [Attar installing the tensioner and checking it In initially set condition for operation, do not attempt to turn the handle in sither | direction unt the next overt | ‘Adjust the valve clearance, (ee page 26) ‘= Install he cl jet as shown, * In fiting the sel cing tothe oll filter chamber cap lightly coat grease on theses ring groove 1) to oid any chance of dropping oF mis: locating the ving during the installation work + Tighton engine ol dra pug, ‘+ Pour 50 ml of engine ol in the oil pockets of the head, Install a new gesket and cylinder head cover NOTE: Place the two longer bolts a the knock pin positions Install anew gosket an cylinder head cover cap. Tightening 9—10Nm torque (09- 10k) SERVICING ENGINE an 79 _SERVICING ENGINE + lnstall the tachometer drive gear with a new 0: «Install new O-ring to the intake pipe groove as cAUTION: [Always use new O-ings to provent sucking st from the joint part. ‘ tnstall each intake pipe tothe cylinder head pro ‘Install te signal generator cover and gasket with thre screws. ie) i-\\ oe Re) =/, (erie) A103) ruet sysTEM FUEL COCK | CARBURETOR SPECIFICATION | sassematy. INSPECTION wo | peasseMety weicaTION SYSTEM 431 FUEL AND LUBRICATION SYSTEM FUEL SYSTEM ‘When engaging starter motor, negative pressure is generated in the combustion charter. This negative Dreseure works on the dlaphragm of fuel cock through pessomay provided In the carburetor main bore and vacuum pipe, diaphragm bulls up 4 negative presi whieh is higher than che spring presse Fuel vale is forced to open due to ciaphraym operation, and thus allow Fue Yo flow into carburetor float chamber. or FUEL COCK When the engin is not running and the ove in the (ON oF RES postion, the ful vl is kept in the flosed postion by epplving presure utilizing a pring £0 that no fel wil lotto the carburetor. When the engine Is engaged, a negative pressure g2nerated in the diaphragm chamber “" through ‘the vacuum (negative pressure) pipe which is con rected to the No. 2 carburetor, and builds up 2 ‘egatve preture which is higher than the spring presure so thatthe diaphragm is foeed to open ‘the ful valve and thur allow the felt flow tothe cxrburetors ‘When the lever is sat to PRI poston, the prosru sion (@ located on the lever end putes back the fuel valve mechanically agsinst the spring Force end {allows fuel to flow to the carvuretor direct, laether the engin ix running or nt, though the FES side fut filter and ful valve clearance. FUEL AND LUBRICATION SYSTEM 42 = @Fusivane @ Org @ Diaphragm @ Soring "(One ay vahe ‘Vacuum Fuel ow — - A | | : | | | “RES” LU 43 FUEL AND LUBRICATION sysTeM CARBURETOR FUEL ANO LUBRICATION SYSI eu as SPECIFICATIONS ‘SPECIFICATIONS Tee TMIKUNT BEDESS = 18. =200 301 oe 26 mm ile in 1100 = 6 nin Fuel level ~ ~ 7 Float height 2142 1.0 mm Maint 2975 seal tom “kindle SSSS™S*~*~SCS~CS~SL Needle jet Po - Thro valve #125 Pilotiet 240 By pass - 08, 0.8, 0.8mm Pilot outlee (0.8 mm Valve st - - Starr jet Pilot serew Palo ai ie T Throttle cable play it Esch carburetor hes .0, Number (D printed on the carburetor body according to it specifications. 25__FUEL AWD LUBRICATION sysTEM DIAPHRAGM AND PISTON OPERATION ‘The carburetor is of a voribleventuri type, whose venturl cross section area i inerased or decreased automatically by the piston according to the vacuum present on the downstream side of the vent acum is admitted into the diaphragm ehamber through an ortce provided in the pion Fising vacuum overcomes the spring fore, causing the pston to rise to increase the sid aren and thus to Drovent the air velocity from increasing. Therefore, air velocity in the venturi patae is kept relatively Constant for Improved fuel atomization and fo secuting an optimum ratio of fuel oat the mixture, FUEL AND LUBRICATION SYSTEM _48 ‘SLOW SYSTEM “Thisystom supplies fuel uring engine opection with thrate valve closd o light opened “The fel from float chamber is metered by pilot jet where it mixes with air coming in through pilot air “This minture, rich with fuel, then goes up through pilot pipe to plot screw. A part ofthe mixture i di charged into the main bore out af Bypass port. The remainder is then metered by pilot srew and speayed ‘ut into the main bore through pilot outlet. ee ee Remove the carburetor, float chamber ad oats, and cleen the float chamber and fost parts with ‘line. Ifthe nocd is wor as shown below, replace it together with avalve seat. Clan the fuel passage of the mixing chamber with compressed ‘© Check following items for any damage or clog: ‘ing. Pilot jet + Main jet Main air ot Pilot ait Nectar bleeding holes | hen g Nee et Ova omen Gasket and O-ring Le 413 FUEL AND L BALANCING CARBURETORS {check the four carburetors for balance according to the following procedures ‘As the fist ste, calibrate the carburetor balancer (auge a follows 09013.13121 | Carburetor balancer Start up the engine and run tin ing condition * Stop the warmedup engine, Remove the vacuum inspection plug @ for No. 1orNo. 4 ‘eylinder and install the hose of the earberetor blancer gous. Start up the engine, ana kee it running at 1 750 ‘iin by turing heat stop sexew 2 ‘© Turn the sir serew (2 ofthe gauge so that th vscuum acting on the tube of thet hore wil bring the see ball 4) in the tube to the center line After making sure that the ste! ball stays steady at the centr ine, disconnect the hose from the vacuum inspection pipe and connect the next hose o the pipe. Turn air screw to bring the other sto ball 1) tothe center fine ‘Repeat the process on the third and fourth tubes. The balancer suge is now ready for use In bolancing the eotburetars Remove the respective vacuum inspection caps and the hose tothe pipe respectively. Belance the four carburetors a follow! | nore: | * Remove the vacuum hove ofthe fuel cock. | from the No.2 carburetor and connect the | | howe to tis pipe. | || + Wen ‘balancing the carburetors, remove | the fuel take and fel should be spptod | _br sopra fel tank, | 1750 min. A correcty adjusted carburetor has the ste! ball in te Nos. 1 trough 4 tubes tthe same owl a shown, 1 1f te set bals ae not in correc positions just the trot vale adjusting serew correctly ‘by using trot valve asst wrench, (09013-14010 | Theotte valve adjust wrench Adjusting order: 1 (for No.2 Cab) + (for No. 1) > © (tor No. a) ‘+ After balancing carburetors, set i speed be tween 1 050 and 1 150 e/min by turing trot tle stop srew, cAUTION: | De not distor the pilot srew 2). This com- ponent is preset at the factory by the very Specialized equipment | FUEL AND LUBRICATION SYSTEM 4.14 415 FUEL awo LuaRicaTiON syste REASSEMBLY Align the groove (1) of the nocd et with the in 2) and replace 4 Place tongue @) of dlaphragm to carburetor boey properly 1 Wen fitting tote valve shaft ol sas, roo¥e shouldbe faced outside Aoply SUZUKI SUPER Grease “A lightly to the ip of oil seal ‘© Sot the throttle vole shaft and install the washer) a shown, '* Aoply SUZUKI thread lock “1942” to these ‘oo sre and install the rote valve ‘+ Propery position the spacor ‘nthe cil sa. 1 Hook one end of spring to the boss), turn the other end 2) clockwise by one tur, end hook it to the eable que propel. Tighton lock nut and bend up lock washer ‘Apply thread lack "1342" to two serews for securing throtue valve + when engaging four carburetor, be sure to fix fuel pipe @ with four Orrings and breather eonaeetor 5) properly, ‘+ Postion throttle valve control lover ( corety * Aoply thread leck coment to lower bracket «Apply thread lock cement 10 the upper 99000:22040 | Thread lock coment ‘+ Wen mounting starter sha, align starter valve serew with dent mark (on starter shaft nd reas siding portions 1 Aply thread lock super "13838" to starter shaft securing serous. ‘Install the Iron washer between carburetor body and starter lve. ‘+ Tighten the starter lever guiding serow with plait spacer @ and spring 18 chet FUFL_AND LUBRICATION S¥STEM ag E17 FUEL AND LUBRICATION sysTEML 16 Set each ehrottle valve In such @ way th top ond () meats the foremost bypass 2 Is accomplished by tweming trate valve stop Seow (3) and balance serew NoTE: When adjusting the throtle balance serews, adjusting order i as fll: @ Wor No. 2Carb) > 1 (forNo. 1) | > © (Hoe No.4) Alter each job i competed, mount the carburetor fn the engine, and the following adjustments are Page + Throttle cable play 2-10 * Engine di mn 21 * Balancing carburetor 4n13 AND LUBRICATION SYSTEM 418 LUBRICATION SYSTEM = air wee) Of i ‘CYLINDER Re i CaS SOIRM 7 + rams — | Sar amas | | clic aes SOMA EG ro eet Suir St wire ¥ ¥ (Coowrensiaet cave start | ‘comrensiarT | mL POMP eas am Sov Fi] 419 FUEL awa LUBRICATION sysTEN ELECTRICAL SYSTEM ——— CONTENTS CHARGING SYSTEM ... IGNITION SYSTEM. STARTER SYSTEM COMBINATION METER LAMPS ‘SWITCHES: E1_ ELECTRICAL 55 CHARGING SYSTEM DESCRIPTION “This motoreyete, the circuit ofits charging sytem is indleated in the figure, is composed of AC generator, regulator/ecfer unit and battery. ‘The AC current generate from AC generator is rectified by rectifier and is tuned inte DC curent, then it charges the battery | Lair iter L_ Function of Regulator iit the engine r/min is low and the generated voltage of AC generator is lower than the adjusted voltage ‘of Regulator, the regulator doesnot function incidentally the generated current charger the battery direc. Wy Lovins sin | f OF tone ra ELECTRICAL SYSTEM 62 When the engine n/min becomes higher, the generated voltage of AC gonerator also becomes higher and the ‘voltage between points & and of regulator becomes high accordingly, and when it reaches the adjusted ‘voltage of regulator, 2D (Zener diag snds signal to the gate of SCR (Thyristor). Than the SCR becomes Conductive to the direction from point © to point © . Namely a the state ofthis the current generated fom the AC generator get through SCR without charging the battery and returns to AC generator again, [At the end ofthis state, since the AG current generated from AC genestor flows into the point, re ‘erse current tends to flow to SCR, then the circuit of SCR turns to OFF mode and begins to charge the battery again, Thus the repetitions msintain charging voltage to the battery consant an protect i from overcharging. ‘AC. Genestor _— Lngevtch Rego Recie 16. Sitch Ling ion 5 ‘oad iv 6a syste INSPECTION, CHARGING OUTPUT CHECK Remove the left frame cover, Start the engine an keep It running at 000 r/min ‘with lighting switch tured ON (Hl position. Using pocket tester, massure the DC voltage be ‘een the battery terminal and If the tstor reads under 14V or over I5V, check the AC ganerator no-load performance and regul toriectifier, NTE: Wien making this ost, be sure t tery is fully charge condition. ‘STO charging output ] AC GENERATOR NO-LOAD PERFORMANCE Disconnect the three lead wires from the AC generator terminal Stat theengineand keep i runing at § 000 ein Using the pocket tester, measure the AC voltage between the thee lead wires, Uf the tester reads under 8OV, the AC generator is faulty, [i Wont poomane [to it vet 001 tev Ocitsom rn] drt conc | rete | | ELECTRICAL SYSTEM 54 [AC GENERATOR CONTINUITY CHECK Using the pocket tester, check the continuity Dbtween the lead wires ofthe stator. ‘Also check tht the stator cor is insulated Note: When making this tert, ie not necessary to remove the AC generator, ‘0990026002 Pocket tester REGULATOR/RECTIFIER Using the pocket tester (X10 rangel, measure the resistance between the lead wires in te fllowing table, If the resistance checked is incorect, replace the regulaoreociir. coonzeont | Poca : a rk iwer| wr!) ¥ | sw Boa lore) - [ore & |i] san) ore = [ore Btwn sen! = [| = [ore EY Ten | = lore [Storr ero 55 ELECTAICAL svSreW IGNITION SYSTEM DESCRIPTION ‘The fully tansistorized ignition system consists of a sana! generator, transistor ignite, ignition cols, and spark plugs. The signal generator comprisr one rotor and two pickup col ‘The signal generator is mounted atthe right end of the erankshft, The output of the signal generator ‘90¢s to the transistor ignitor unit, wheee It tens ON and OFF the transistor aiterataly. As the Wansitor {is tuned ON and OFF, the current passing through the primary winding ofthe ignition coi i ago turned OFF and ON secordingly, thus it induces the secandary current on the igition col secondary windings and produce the spark betwoen spark lug gps ENGINE KILL wc wobefighe* bea, : dire pe ct Fuse INSPECTION rT | IGNITION COIS Cheng wi Ee Ten) | ting te tt ath in a for ‘etna oom The ar cometan TE tear te erecing Saar hee | i peng or tect tig eae wisi tect mn roel ert (Sees | ‘STD Spark performence | Bim | IGNITION COILS (Checking with Pocket Tester) ‘A'SUZUKI pocket tester or an ohm meter may be ied, stead ofthe eletro tester. In ether case, the ignition cai eto be checked for coatinulty in both primary and secondary windings, Exact ohmic readings are not necessary, but, if the ‘winding are in sound condition, thelr continuity ‘ill be noted with these approximate ohmic value ee (09900-26002 Pocket tester Tanition col resitance Terminal — Terminal | Approx. 3= 58 Plugeam—Plugeap | Approx. 35 — 45 ka SIGNAL GENERATOR Measure the resistance between lead wires Ii the resistance noted to show infinity or too low ‘redstance vlue,it must be replaced {v9s00.25002 Pocket tester ‘STO resistance er — 8/81 | cw 6/81 co-a00 2 evecray iL SYSTEM IGNITER UNIT Remove each spark plug of Nos. 3 and 4 cylinders tt to respective plug cap and place it onthe cylinder hea Remove the frame cover on the ight side and gisconnect the leadwire from the signal generator. Connect the © pin of the pocket testr (x12. range) to B/B|, and then connect the.) pin to Brand GGIW alternately, Ifthe No. plug sparks, withthe ‘pin connected to Br, andi the No.3 sparks, with ‘the ©) pin to GAW, the igniter s good Nore: ] ‘This checking presupposes tht the ignition coll used for checking isa good one, ee ELICTRNCAL SYSTEM 54 STARTER SYSTEM DESCRIPTION “The starter system is shown in the lagram below: namely, the starter motor, slay, starter switch and battery. Depresing the starter button (on the right handlebar switch box} enerales the relay, causing the Contact points to close which connects the starter motor to the battery, The motor draws about {0 amperes to start the engine, STARTER MOTOR ‘STARTER MOTOR REMOVAL AND DISASSEMBLY Remove the starter motor (Se page 3-15). Disessambly the starter motor a follows ELECTRICAL SYSTEM. ‘STARTER MOTOR INSPECTION CARBON BRUSHES When the brushes are worn, the motor will be tunable to produce aufcinttorgue, andthe engine will be dificult to tum over. To prevent this, Periodically, inpect the length of the brushes, replacing them when they ae too shor or chipping. Serves Limit 6mm CcOMMUTATOR If the commutator surface is dirty, starting pe formance decrease. Polish the commutator with #400 or similar fine emery paper when i is dry [ter palishing wie the commutator sith a clean ary cloth Measure the comutator under cut ‘Service Limit (0.2mm ARMATURE COIL Using pocket tester, check the eal for open and ‘round by placing prabe pins on each commutator “zgment and rotor core (to test fr gfound) end on fy two segments at various placer (to test for open), with the brash ited of the commutator surfoce, If the col is found tobe open circuited or ground fd, relace the armature, Continuous use of 2 elective armature will cause the starter motor to suddenly fai, (0900025002 | Pocket tester ELECTRICAL SYSTEM 5:10 STARTER MOTOR REASSEMBLY BRUSH HOLDER When fixing brth holder to starter motor ease, align the protrusion

3200 wm Front fork oil type Fork ol! 215, | Front fork oil capacity leach leg) Reside 169 ml —_ Tt [esi “etm amano | Brake fluid type SAE J1703 I * Asterisk indicates the new GSX40OFZ specification, 813 _Gsxaourz TIRE PRESSURE cao waren |~Secomowe | ouarmona | sow none | vA. REAR 200 | 200 | 28 | 280 | 2.80 1 6 | 225 | 226 | 32 | 260 | 250] 36 WATTAGE wn mew T ‘SPECIFICATION [Hormezsae] ema eonsernmiaeae] —ea8 Toon w]e = = = ope =a = Peng clio a 2 = Tae aa | san = “Turn signal light [3s a tT —_] | Speedometer figh i 34 —_— — | a4 _— — — Tern dal neato ht a = = Hite new tgt [aa Pe = = Newel at bt = = = Ot prev eB a = LUcense ght I 8 s — 10 Fuel meter ight - 7 = =e ‘Gear position indicator light 1 = — — ssxao0ez ‘SPECIAL FEATURE ANTI-DIVE FRONT FORK ‘THE PHENOMENON OF DIVING ats _osxamnr2 ANTI-DIVE DIVICE When 2 speeding motorcycle is stopped, iti Impossible to prevent the front fork cve because the mo: mentum of the machine's center of pravity continues forward. The front fork is compressed ond extended, 2 itis braked before comering and fll trot applied coming out of the corer, whieh naturally changes Its comering clearance (motoreycleto-ground clearance and balsnce). In order to minimize this change of the front fork length on a racing motoreyce, the spring ofthe frat fark has to be sifend, while the arming force of the rear shock absorber must be strengthened, However te susinsion eystam of the street motorycte is generally set soft for absorbing the bump and shock of the road to ensure riding comfort. However, when the bike's cornering performance requires improvement, the suspension system must be reinforced, ‘Suzuki's hydraulic ant-lve fork was developed to provide exceptional handling performance and a maoth ride. It ensures the bike's ability during high-speed cornering by preventing the cater angle from being ‘hanged during braking and preventing los of comerng clearence, while assuring ring comfort on the rose. sxag0e? 18 ANTI-DIVE SYSTEM Suzuki's antialve system, developed from the feedback of cacing technology, is now equipped on many of Suzuk's 1982 modal. The new aystem i attached to the outer tube ofthe fant fork. The brake line of the front brake's mastr cylinder leading to the caliper is connected by a hose to tho antiive deve When the mater eylinder's hydraulic line functions to brake the front whee, it simultaneously operates ‘the anti-dive device's plunger, whieh regulates and limits the flow of olin the front fork. This reduces the compreston of the front fork, which alo reduces the extension of the rear shock absorber, Hance, the [ew New Tinton ore 30=100ism | 110 130%9m sec ment 13008 ‘05 ieee (99000-32090) (99000-32100) Bai or107-1468 p13 2008 Lock washer caeai ane) [nore ‘When replacing genertor rotor or bolt, se new type bolt and tighten it with specified torque. Below aro the special tools necessary for tightening B type flange bolt __ouw (09990-44610 NEW 09830.44611 ‘Asillusrated above, the new rotor holder has bean eranged a tighten the flange bolt, “This toot is applicable to both /\ snd 6 type bolts. TOOL SUPPLY DATA Only the new type wil be supplies. EFFECTIVE ENGINE NO. This modification has been carried out on and afte the following engine number. (GSX400F ...€/NO, 118089 ~ SxA00FZ an REMOVAL # Using rotor holder (D, remove rotor securing bot 09830.44811 Rotor holder ‘Install rotor emover attachment ad aiing shaft Dinto the boss of rotor and remove rotor ‘with starter clutch assembly while sling the NOTE: Do not hit the rotor with 2 hamoe. (0099030102 | __ Rotor remover shaft, (0985039710 | Attachment INSTALLATION ‘Degrease the tapered portion ofthe rotor and ‘ko the crankshaft. Use nonflarmable leaning solvent to wipe off the oly or greasy matter to rake thee surfaces completly dy # After mounting the rotor, secure the rotor by ‘Sighting the canter bolt tothe specified torque vale, 10K = sxeonFz FOR BELGIUM Eossssaseen fag _osxt00F2 FOR AUSTRIA, Eosscoaten. ssxt00F?_850 Foscattoes FOR THE NETHERLANDS 51 osxtoorz FOR ITALY i 2 5 jomacditoa3> 1_osxaooFa SERVICE DATA VALVE + GUIDE Lit mm TEM T ‘SYANDARO or Valve ar ™ 190) x | W70 ave itt %. 70 = 62 Wave deine eet Sea a oy 08-018 Valve guide to valve stem ceornee| IN. | 0025-0082, 03 x #0.047-0.067 "035 Valve auide 10. IN. 8 ex 5500-5612 - ‘Valve som 0. 1 5460-5475 & 5.465—5.460 Vole stem wunowt 005 ‘| ‘eve ead thickness co ‘ive stom ond tenath 36 ‘Velvet with a Valve head edit unet oo ‘| twa ex) (wea exs OuTER [69-88 4g et length an.6 mm sxan0Fo 92 CAMSHAFT + CYLINDER HEAD seve Ta STanORR mar ‘Cam height nm | '34.620— 34.660 734.320 m 94.170-34210 33870 Cans oars olcewnnee | W-86k.| ¥ 0.052-0088 0180 cansttoonn nocnri0. | WW &ex,| 22072-22088 Cams ora 00 waex | 2880—21.000 = << [wef ano tam en 20h th —— 1288 Conctanpinierwrow "959 fouwemio. | Wee | T2000- 12078 — Foci am st 08 ween 976-1108 = Conder ned deren z — a2 CYLINDER + PISTON + PISTON RING tie men Ta rao i Canorssin ne 1-18 wen [EF e soem Compression presse aifeoce = Za Pision t9 eylinder clesrence __-¥# 0.025-0.035 0.120 Chino sec00-s3018 —~+| satan meen 7 awn rome = a - : |

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