This manual provides comprehensive service and repair information for the 1982 Suzuki GSX400FZ motorcycle. Engineered with a 398cc, DOHC, air-cooled inline-four engine, the GSX400FZ represents Suzuki's commitment to performance and reliability in the sportbike segment of its era. Its design philosophy focused on bridging the gap between commuter and track-ready machines, offering a balanced blend of power and handling. This motorcycle is intended for enthusiasts and owners who appreciate classic Japanese engineering and are looking for a capable machine for spirited riding. The scope of this Service and Repair Manual is extensive, covering all facets of the 1982 Suzuki GSX400FZ. It details maintenance procedures, troubleshooting guides, technical specifications, and essential safety guidelines. Within its pages, you will find in-depth coverage of the engine, fuel system, ignition, transmission, brakes, suspension, and electrical systems, including detailed diagrams and step-by-step instructions for disassembly, assembly, and repair. This manual is an indispensable resource for owners, mechanics, and technicians aiming to maintain, diagnose, and restore the GSX400FZ to optimal operating condition. 🏷️ Basic Information Identification Make: Suzuki Model: GSX400FZ Year: 1982 Codes Chassis Code: GSX400FZ 👋 Introduction Market Position Segment: Sportbike/Naked Bike Target Audience: Enthusiasts and owners seeking to perform maintenance, repairs, and tuning on their classic Suzuki sportbike. Competitive Analysis Competitors 1982: Yamaha XJ Series, Kawasaki GPz Series, Honda CB Series of similar displacement. Key Features Engine Layout: DOHC inline-four, air-cooled, providing a balance of performance and reliability for its era. Design Philosophy: Suzuki's focus on performance-oriented, multi-cylinder motorcycles that bridged the gap between commuter and track-focused machines. 📋 Manual Details Coverage Areas General Coverage: Comprehensive service and repair for the 1982 Suzuki GSX400FZ motorcycle. Page Count Estimated Pages: 300-400 (estimated based on typical service manuals for this era) Manual Type Type: Service and Repair Manual Scope: Factory service manual covering all aspects of the motorcycle's mechanical and electrical systems. Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed diagrams, specifications, disassembly, assembly, troubleshooting, and tuning of the 398cc 4-stroke, DOHC, air-cooled engine. Fuel System: Carburetor identification, adjustment, overhaul, and troubleshooting (likely Mikuni VM series or similar). Ignition System: CDI ignition timing, component testing, troubleshooting, and specifications. Transmission: Gearbox disassembly, inspection, repair, clutch operation, and specifications. Drivetrain: Chain and sprocket maintenance, adjustment, and replacement procedures. Brakes: Front and rear brake system maintenance, hydraulic system bleeding, pad/shoe replacement, and caliper/master cylinder service. Suspension: Front fork disassembly, seal replacement, oil specifications, damping adjustment, and rear shock absorber service. Electrical System: Wiring diagrams, component testing (lights, starter, charging system), battery maintenance, and troubleshooting. Cooling System: Air-cooling system efficiency, cleaning, and related components. Frame And Bodywork: Frame inspection, fairing removal/installation, and general chassis components. Procedures Included Maintenance: Regular service intervals, oil changes, filter replacements, lubrication points, chain adjustment, and brake fluid checks. Troubleshooting: Diagnostic flowcharts and common problem-solving guides for engine, electrical, and chassis issues. Repair: Step-by-step instructions for component removal, overhaul, installation, and adjustment. Disassembly Assembly: Complete breakdown and reassembly procedures for all major mechanical and electrical components. Engine Tuning: Includes guidance on spark plug selection, ignition timing verification, and carburetor synchronization and jetting adjustments. Wheel And Tire Service: Information on wheel bearing maintenance, tire removal/installation, and correct tire pressures. Technical Depth Depth: Comprehensive, covering everything from basic user maintenance to advanced engine rebuilds and electrical diagnostics. Wiring Diagrams: Detailed, high-resolution wiring diagrams essential for electrical troubleshooting. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Print Quality Quality: Digital scan, quality may vary but designed for legibility and usability on screen. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: 398cc, 4-stroke, DOHC, air-cooled, inline-four cylinder Bore X Stroke: 53.4 mm x 44.9 mm (typical for this engine configuration) Compression Ratio: 9.7:1 (typical) Performance Horsepower Estimated: Approx. 40-45 HP @ 9,000 RPM (estimated) Torque Estimated: Approx. 30-34 Nm @ 7,000 RPM (estimated) Fuel System Carburetor Type: Twin Mikuni VM24SS or similar dual-throat carburetors (specified in manual) Fuel Tank Capacity: 16 Liters (approx.) Lubrication Oil Type: SAE 10W-40 API SE (specified in manual) Oil Capacity: 3.0 Liters (with filter change, specified in manual) Ignition System Ignition Type: Electronic Ignition (CDI) 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch Type: Wet, multi-plate Final Drive: Chain drive 📐 Dimensions Exterior Length: 2055 mm (approx.) Width: 750 mm (approx.) Height: 1160 mm (approx.) Weights Dry Weight: 170 kg (approx.) Wet Weight: 185 kg (approx.) 🛡️ Safety Features Ratings Crash Test Data: N/A (Motorcycle, pre-dates standardized motorcycle crash testing as known today) Active Features Braking System: Hydraulic disc brakes front and rear (typically single disc front, possibly drum or disc rear depending on exact spec). Lighting: Halogen headlight, taillight, brake light, turn signals. 💡 Technology Features Infotainment Features: N/A (Motorcycle of this era focuses on mechanical and performance aspects, no integrated infotainment systems)....