The Suzuki GSX400, produced for the 1981, 1982, and 1983 model years, represents a significant entry in Suzuki's line of sport-oriented motorcycles. Known for its air-cooled, 4-stroke, DOHC inline-4 cylinder engine, typically displacing around 398cc, this model offered a blend of performance and engineering that was well-regarded during its era. With an estimated 40-45 horsepower and a 6-speed transmission, the GSX400 was designed for riders seeking an engaging and reliable machine, embodying Suzuki's reputation for quality manufacturing in Japan. Its robust construction and characteristic GSX series sporty attributes made it a popular choice for enthusiasts and daily riders alike. This comprehensive Factory Service Repair Manual in English is designed to assist do-it-yourself enthusiasts and professional mechanics in maintaining and repairing the Suzuki GSX400. It covers all essential systems, including detailed procedures for the engine, fuel system, cooling system, clutch, drivetrain, wheels and tires, brakes, suspension, steering, frame, and electrical system. The manual provides step-by-step instructions for routine maintenance, troubleshooting common issues, and complete disassembly and reassembly. With hundreds of photos and illustrations, it offers a complete resource for ensuring the longevity and optimal performance of your motorcycle. 🏷️ Basic Information Identification Make: Suzuki Model: GSX400 Model Years Covered: 1981, 1982, 1983 Codes Chassis Code Variants: Specific chassis codes may vary by market, but common variations include GK72A for early models. 👋 Introduction Market Position Target Audience: Do-it-yourself enthusiasts and experienced mechanics. Competitive Analysis Comparison To Physical Manuals: Offers greater convenience and cost-effectiveness compared to older paper manuals. Key Features Convenience: Digital format allows for easy access, printing of specific pages, and portability. Cost Effectiveness: An inexpensive way to maintain and repair the vehicle, saving on labor costs. Information Completeness: Provides all necessary service information without extra fees or expiry dates. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: PDF Download File Format: PDF Printability: Yes, all pages printable Compatibility: All Windows versions, Mac, Smartphones, Tablets, Web Browser Access Software Requirements: Adobe PDF Reader, Winzip (free) 📖 Manual Coverage Systems Covered Engine Overview: Comprehensive coverage of the engine, including top-end, lubrication, removal, and installation. Fuel System: Detailed information on the fuel delivery system, carburetors, and fuel tank. Cooling System: Coverage of the cooling system, including radiator, coolant, and related components. Clutch System: In-depth details on clutch operation, maintenance, and repair. Drivetrain: Covers crankshaft, transmission, and final drive components. Wheels Tires: Information on wheel and tire maintenance, mounting, and balancing. Brakes: Complete brake system service and repair instructions. Suspension: Detailed guidance on front and rear suspension systems. Steering: Information on the steering system for safe operation and repair. Frame: Coverage of the motorcycle frame, including inspection and minor repairs. Electrical System: Extensive coverage of the electrical system, including wiring diagrams, ignition, and lighting. Appendix Information: Includes supplementary data and often troubleshooting guides. Procedures Included Maintenance: Routine maintenance tasks, fluid changes, filter replacements, and tune-ups. Repair: Step-by-step instructions for diagnosing and repairing all major components and systems. Troubleshooting: Diagnostic procedures and solutions for common and uncommon issues. Disassembly Reassembly: Complete disassembly and reassembly instructions for all major systems. Technical Depth Depth Of Coverage: Complete full factory service repair manual, covering all styles and levels of repair. Illustration Quality: Hundreds of photos and illustrations guiding procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable within the PDF. Print Quality Resolution: Assumed to be high-resolution for clear printing of text and images. Binding Type Binding Format: Digital download, printable for physical binding. Paper Type Paper Recommendation: Standard printer paper recommended for printing. ⚙️ Engine Specifications Primary Engine Engine Type: Air-cooled, 4-stroke, DOHC, Inline-4 Cylinder (typical for this model range) Displacement: Approximately 398cc (1981-1983 models) Bore X Stroke: Specific dimensions would be detailed in the manual, typically around 53.0mm x 40.0mm. Compression Ratio: Generally around 9.2:1 to 9.5:1. Performance Horsepower: Estimated 40-45 HP at 9,000-9,500 RPM (specifications vary by market and specific tuning). Torque: Estimated 30-33 Nm at 7,500-8,000 RPM. Fuel System Fuel Delivery: Carburetor(s) - likely Mikuni VM series or similar twin-carburetor setup. Carburetor Size: Typically 26mm or 28mm. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-plate Features Gear Ratios: Specific gear ratios will be detailed in the manual. 📐 Dimensions Exterior Length: Specifications vary slightly by year and market, typically around 2,155 mm. Width: Typically around 750 mm. Height: Typically around 1,160 mm. Weights Dry Weight: Approximately 170-180 kg. Wet Weight: Approximately 180-190 kg. Fuel Capacity: Approximately 16 liters (including reserve). 🛡️ Safety Features Ratings Safety Standards: Met Japanese and international safety standards of the era. Active Features Braking System: Front: Disc brake; Rear: Drum brake or Disc brake (depending on variant). Passive Features Lighting: Standard headlight, taillight, and turn signals. 💡 Technology Features Infotainment Instrument Cluster: Analog speedometer, tachometer, odometer, and indicator lights. Driver Assistance ABS: Not typically equipped with...