GS400 Complete Manual

FOREWORD
The SUZUKI GSX400 has been developed as a new generation motorcycle to the GS
models. It is packed with highly advanced design concepts including a forged one piece
crankshaft assembly and a new highly efficient combustion system (TSCC). Combined
with precise control and easy handling, the GSX400 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 GSX400 manufactured to standard specifications is the main subject matter of this
manual. However, the GSX400 machines distributed in your country might differ in
minor respects from the standard-specification GSX400 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 in formation at the time of its issue. Latermade modifi
cations 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.
NOTE:
This service manual gives only servicing procedures which differ from those of
the GSX25O and describes the new features of the GSX4OU Before performing
any servicing, please read thoroughly GSX25O service manual
SUZUKI MOTOR CO.,LTD.

Administration Department
Overseas Service Division
Quoting, copying or otherwise using any part of this manual without ex

plicit authorization from Suzuki Motor Co., Ltd. is not permitted as all
rights to the publication are reserved under copyright law.
CONTENTS
VIEW OF SUZUKI GSX400E 1
BREAKING-IN RIMIN 2
SPECIFICATIONS 2
ENG1NE
CYLINDER HEAD COVER 4
VALVE AND CAMSHAFT 5
CYLINDER HEAD 7
CYLINDER, PISTON AND RING 8
CRANKSHAFT AND CONNECTING ROD 9
COUNTER BALANCER 11
CRANKCASE 13
TRANSMISSION.. 15
GEARSHIFT CAM AND FORK 18
CLUTCH AND OIL PUMP 19
STARTER CLUTCH AND GENERA TOR 22
EXHAUST PIPE AND MUFFLER 23
CARBURETOR 24
LUBRICATION SYSTEM 25
SPEEDOMETER AND TACHOMETER 26
STEERING STEM 27
REAR WHEEL 32
WIRING DIAGRAM 33
WIRE ROUTING 37
CABLE ROUTING 39
SPECIAL TOOLS 40
TIGHTENING TORQUE 41
SERVICE DATA 44
1 GSX400E GENERAL INFORMATION GSX400E GENERAL INFORMATION 2
VIEW OF SUZUI(I GSX400E BREAKING-IN R/MIN
1 I Keep to these breaking-in engine speed limits: Initial 800 km Below 4,000 r/min
Up to 1,600 km Below 6,000 r/min
b -
Over 1,600 km Below 9,500 r/min
At
SPECI Fl CATI ONS

DIMENSIONS AND DRY MASS
i Overall length
Overall width
Overall height
Wheelbase
2 075 mm
755
1 075
1 385
mm
mm
mm
Ground clearance 155 mm
Seat height 815 mm
Dry mass 175 kg
ENGINE
Type Four-stroke, air-cooled, DOHC
Number of cylinders 2
Bore 67.0 mm
RIGHT SIDE 56.6 mm
Stroke
Piston displacement 399 cm
3
Compression ratio 10.0 : 1
Carburetor MIKUNI BS34SS, twin
Air cleaner Polyurethane foam element
I Starter system
Lubrication system
Electric
Wet sump
TRANSMI SSI ON
Clutch Wet multi-plate type
Transmission 6-speed constant mesh
Gearshift pattern 1-down, 5-up
Primary reduction 2.714 (76/28)
**Final reudction 2.750 (44/16)
Gear ratios, Low 2.46 1 (32/13)
2nd 1.777 (32/18)
3rd 1.380 (29/21)
4th 1.125 (27/24)
5th 0.961 (25/26)
Top 0.851 (23/27)
Drive chain DAIDO DID5OUB, 104 links
**Modification of Rear sprocket for manufactured on
and after June, 1981 [2.812 (45/16)1
LEFT SIDE
1 GSX400E GENERAL INFORMATION GSX400E GENERAL INFORMATION 2
VIEW OF SUZUI(I GSX400E BREAKING-IN R/MIN
1 I Keep to these breaking-in engine speed limits: Initial 800 km Below 4,000 r/min
Up to 1,600 km Below 6,000 r/min
b -
Over 1,600 km Below 9,500 r/min
At
SPECI Fl CATI ONS

i Overall length
Overall width
Overall height
Wheelbase
2 075 mm
755
1 075
1 385
mm
mm
mm
Ground clearance 155 mm
Seat height 815 mm
Dry mass 175 kg
ENGINE
Bore 67.0 mm
RIGHT SIDE 56.6 mm
Stroke
3
I Starter system
Lubrication system
Electric
Wet sump
TRANSMI SSI ON
Primary reduction 2.714 (76/28)
**Final reudction 2.750 (44/16)
Gear ratios, Low 2.46 1 (32/13)
2nd 1.777 (32/18)
3rd 1.380 (29/21)
4th 1.125 (27/24)
5th 0.961 (25/26)
Top 0.851 (23/27)
Drive chain DAIDO DID5OUB, 104 links
and after June, 1981 [2.812 (45/16)1
LEFT SIDE
3 GSX400E GENERAL INFORMATION ENGINE GSX400E 4
ENGINE
CHASSIS CYLINDER HEAD COVER
Front suspension Telescopic, oil dampened
Rear suspension • Swing arm, oil dampened
spring 5-way adjustable
Steering angle 42° (right & left)
Caster 62° 00’
Trail 105mm
Turning radius .2.4m
Front brake Disc brake
Rear brake Internal expanding
Front tire size. 3.OOS1B 4PR
Rear tire size 3.50S18 4PR
3.75S18 4PR (for W. Germany and Denmark)
Front fork stroke .140mm
Rear wheel travel .100mm
Front tire pressure 175 kPa (1.75 kg/cm
2
(Normal solo riding)
Rear tire pressure 200 kPa (2.00 kg/cm
2
ELECTRI CAL
Ignition type ignition (for General)
Fully transistorized (for the others)
Ignition timing Contact point type
20° B.T.D.C. below at 1 650 r/min and
35° B.T.D.C. above at 3 500 r/min
Fully transistorized type
Spark plug . NGK DBEA/DR8ES-Lor
NIPPON DENSO X24ES-U/X24ESR-U
Battery 12V 43.2 kC (12 Ah)/10 HR
Generator . Three-phase A.C. generator REMOVAL I NSTALLATI ON
Fuse 15A • It is unnecessary to remove four cover cap • Be sure to replace gaskets ® and ® with
bolts ® before removing cylinder head cover new ones.
®. Four bolts ® cannot be remove unless • Fill approx. 50 ml of engine oil in four
CAPACITI ES camshaft end caps ® are not removed. pockets of the cylinder head before mounting
Fuel tank including reserve. 14.5 L (3.2 Imp gal) the head cover on the cylinder head.
Reserve 3.0 L (2.6 Imp qt) • Set two positioning pins at proper
Engine oil 2.6 L (2.3 Imp qt) position and tighten with long bolts (6 x
*
Front fork oil (each leg) ..145 ml (5.11 lmpoz)
These specifications are subject to change without notice.

99000-32040 I
Suzuki Thread lock
cement
] 35mm).
• Apply small amount of SUZUKI thread lock
cement on screw ® which clamps camshaft
TIGHTENING TORQUE end cap ®.
• Install tachometer drive gear after cylinder
9— 10 N.m head cover is fitted to the cylinder head.
Bolt(j,®and®
(0.9—1.0kg-rn)
• Gasket ® should be fit that breather hole
side faces toward front.
3 GSX400E GENERAL INFORMATION ENGINE GSX400E 4
ENGINE
CHASSIS CYLINDER HEAD COVER
Rear suspension • Swing arm, oil dampened
Caster 62° 00’
Trail 105mm
Turning radius .2.4m
Front tire size. 3.OOS1B 4PR
3.75S18 4PR (for W. Germany and Denmark)
Front fork stroke .140mm
Rear wheel travel .100mm
Front tire pressure 175 kPa (1.75 kg/cm
2
2
ELECTRI CAL
Ignition type ignition (for General)
Fully transistorized (for the others)
Ignition timing Contact point type
Fully transistorized type
Spark plug . NGK DBEA/DR8ES-Lor
NIPPON DENSO X24ES-U/X24ESR-U
Battery 12V 43.2 kC (12 Ah)/10 HR
Generator . Three-phase A.C. generator REMOVAL I NSTALLATI ON
Fuse 15A • It is unnecessary to remove four cover cap • Be sure to replace gaskets ® and ® with
bolts ® before removing cylinder head cover new ones.
®. Four bolts ® cannot be remove unless • Fill approx. 50 ml of engine oil in four
CAPACITI ES camshaft end caps ® are not removed. pockets of the cylinder head before mounting
Fuel tank including reserve. 14.5 L (3.2 Imp gal) the head cover on the cylinder head.
Reserve 3.0 L (2.6 Imp qt) • Set two positioning pins at proper
Engine oil 2.6 L (2.3 Imp qt) position and tighten with long bolts (6 x
*
Front fork oil (each leg) ..145 ml (5.11 lmpoz)

99000-32040 I
Suzuki Thread lock
cement
] 35mm).
• Apply small amount of SUZUKI thread lock
cement on screw ® which clamps camshaft
TIGHTENING TORQUE end cap ®.
• Install tachometer drive gear after cylinder
9— 10 N.m head cover is fitted to the cylinder head.
Bolt(j,®and®
(0.9—1.0kg-rn)
• Gasket ® should be fit that breather hole
side faces toward front.
5 GSX400E ENGINE ENGINE GSX400E 6
VALVE AND CAMSHAFT

VALVE TIMING
IN.open Ex. close
Moly paste
I NOTE:
The timing chain is now riding on all three sprockets. Be careful not to disturb the crankshaft until
four holders are secured.
I N.close
20th pin 1St
V
£
IN. open Ex. close
Moly paste
REASSEMBLY
• Apply SUZUKI MOLY PASTE lightly with
out break on camshaft journal and valve stem.
• Apply Suzuki thread lock super “13038” to
the cam sprocket bolts(.
TIGHTENING TORQUE
( 15—20 N.m (1.5— 2.0kg-rn)
® 8—10 N.m (0.8— 1.0 kg-rn)
® 9—11 N.m (0.9—1.1 kg-m)
VALVE AND CAMSHAFT

VALVE TIMING
IN.open Ex. close
Moly paste
I NOTE:
The timing chain is now riding on all three sprockets. Be careful not to disturb the crankshaft until
four holders are secured.
I N.close
20th pin 1St
V
£
IN. open Ex. close
Moly paste
REASSEMBLY
• Apply SUZUKI MOLY PASTE lightly with
out break on camshaft journal and valve stem.
• Apply Suzuki thread lock super “13038” to
the cam sprocket bolts(.
TIGHTENING TORQUE
( 15—20 N.m (1.5— 2.0kg-rn)
® 8—10 N.m (0.8— 1.0 kg-rn)
® 9—11 N.m (0.9—1.1 kg-m)
CYLINDER HEAD CYLINDER, PISTON AND RING
ID
VALVE GUIDE TIGHTENING TORQUE • Use special tools when mounting piston on
OVERSIZE OIL RING
Part No. Part Name N.m kg-rn cylinder.
SIZE
1 1 1 15-49290 Valve guide ) 35—40 3.5—4.0
09289-05003 rD
Oil seal ® 8—12 0.8—1.2 Part Name
Part No.
REASSEMBLY ( 7—11 0.7—1.1 09916-74520 Piston ring holder
• Be sure to replace cylinder head gasket 75 mrn)
099 16-74540 Band (bore 63 —
® with new one. REASSEMBLY

• There are two different washers ) and ) for gasket () and circlips • Confirm that 0-ring ID is properly installed
• Mount new 0-ring ID,
cylinder head nuts, so identify each to use to groove of the lower cylinder, and then
in the specified place.
D.
• Be sure to apply oil on cylinder surface, install piston into the cylinder.
• Camshaft cap bolt ® has “9” mark on crown piston sliding part, piston rings () and piston
part, so do not use other bolt. pin ®.
CYLINDER HEAD CYLINDER, PISTON AND RING
ID
VALVE GUIDE TIGHTENING TORQUE • Use special tools when mounting piston on
OVERSIZE OIL RING
Part No. Part Name N.m kg-rn cylinder.
SIZE
1 1 1 15-49290 Valve guide ) 35—40 3.5—4.0
09289-05003 rD
Oil seal ® 8—12 0.8—1.2 Part Name
Part No.
REASSEMBLY ( 7—11 0.7—1.1 09916-74520 Piston ring holder
• Be sure to replace cylinder head gasket 75 mrn)
099 16-74540 Band (bore 63 —
® with new one. REASSEMBLY

• There are two different washers ) and ) for gasket () and circlips • Confirm that 0-ring ID is properly installed
• Mount new 0-ring ID,
cylinder head nuts, so identify each to use to groove of the lower cylinder, and then
in the specified place.
D.
• Be sure to apply oil on cylinder surface, install piston into the cylinder.
• Camshaft cap bolt ® has “9” mark on crown piston sliding part, piston rings () and piston
part, so do not use other bolt. pin ®.
CRANKSHAFT AND CONNECTING ROD
I CRANKSHAFT AND COUNTER

BALANCER BEARINGS
• Both bearings have their l.D. color code
painted on the side of bearing. According to
the specifications for crankcase and crank
shaft, select proper bearing. (Refer to the
I
GSX25O Service Manual page 3-43.)
STANDARD SIZE BEARING

SPECI FICATIONS
J7___MoIv_paste
COLOR
(Part Number)
REASSEMBLY
Green • Be sure to apply SUZUKI MOLY PASTE
(12229-44100-010)
(99000-25140) on connecting rod bearings,
Black counter balancer bearings and crankshaft
(12229-44100-020) bearings at the time of reassembly.
Brown • The washer ® between primary drive gear
(12229-44100-030) and nut is in dish form when free state.
Yellow Be sure to face its concave side to the gear
Moly pa (12229-44100-040) as shown below when fitting.
UNDER-SIZE BEARING Tightening 90—110 N.m

SPECI FICATIONS torque (9.0 11 .0 kg-rn)
—
THICKNESS (mm)
(Part
TIGHTENING TORQUE
COLOR
THICKNESS (mm)
I 0.25 Under size 1.625
(Part Number) 1 (12229-44100-025)
Green 0.50 Undersize 1.750
(12164-44100-010) 1.484 1.488 (12229-44100-050)
—
I
Black
CONNECTING ROD BIG END BEARING (12164-44100-020) 1.488 — 1.492 THRUST BEARING THICKNESS
• Connecting rod bearing side part has each Brown • Check the crankshaft thrust bearing ®
color code, so identify l.D. code of crankshaft (12164-44100-030) 1.492 — 1.496 thickness for wear. If wearing portion
and connecting rod to mount proper color exceeds the following limit, replace with
Yellow
one. (Refer to GSX25O Service Manual (12164-44100-040) 1.496 — 1.500 new ones as a set.
page 3-39.)
Service Limit 2.85 mm
NOTE:
CAUTION:
Two kinds of under-size bearings are
Bearings should be replaced as a set.
available as an optional parts.
SIZE
(Part Number) THICKNESS (mm)
0.25 Under-size
(12164-44100-025) 1.625
0.50 Under-size
(12164-44100-050) 1.750
CRANKSHAFT AND CONNECTING ROD
I CRANKSHAFT AND COUNTER

BALANCER BEARINGS
• Both bearings have their l.D. color code
painted on the side of bearing. According to
the specifications for crankcase and crank
shaft, select proper bearing. (Refer to the
I
GSX25O Service Manual page 3-43.)
STANDARD SIZE BEARING

SPECI FICATIONS
J7___MoIv_paste
COLOR
(Part Number)
REASSEMBLY
Green • Be sure to apply SUZUKI MOLY PASTE
(12229-44100-010)
(99000-25140) on connecting rod bearings,
Black counter balancer bearings and crankshaft
(12229-44100-020) bearings at the time of reassembly.
Brown • The washer ® between primary drive gear
(12229-44100-030) and nut is in dish form when free state.
Yellow Be sure to face its concave side to the gear
Moly pa (12229-44100-040) as shown below when fitting.
UNDER-SIZE BEARING Tightening 90—110 N.m

SPECI FICATIONS torque (9.0 11 .0 kg-rn)
—
THICKNESS (mm)
(Part
TIGHTENING TORQUE
COLOR
THICKNESS (mm)
I 0.25 Under size 1.625
(Part Number) 1 (12229-44100-025)
Green 0.50 Undersize 1.750
(12164-44100-010) 1.484 1.488 (12229-44100-050)
—
I
Black
CONNECTING ROD BIG END BEARING (12164-44100-020) 1.488 — 1.492 THRUST BEARING THICKNESS
• Connecting rod bearing side part has each Brown • Check the crankshaft thrust bearing ®
color code, so identify l.D. code of crankshaft (12164-44100-030) 1.492 — 1.496 thickness for wear. If wearing portion
and connecting rod to mount proper color exceeds the following limit, replace with
Yellow
one. (Refer to GSX25O Service Manual (12164-44100-040) 1.496 — 1.500 new ones as a set.
page 3-39.)
Service Limit 2.85 mm
NOTE:
CAUTION:
Two kinds of under-size bearings are
Bearings should be replaced as a set.
available as an optional parts.
SIZE
(Part Number) THICKNESS (mm)
0.25 Under-size
(12164-44100-025) 1.625
0.50 Under-size
(12164-44100-050) 1.750
fl GSX400E ENGINE ENGINE GSX400E12
• Thrust bearing for the crankshaft go into • Pull out the counter balancer inner race with
place with their oil groove side (ID facing the special tool.
crank webs.
13-61110 Bearing puller
COUNTER BALANCER
• When mounting the balancer drive gear, be
sure to locate the dent mark ® right on the
radial line through punch mark ® provided
on the race.
REASSEMBLY
• Locate washer ID on the balancer shaft and
fix the key in the groove, then tap the
counter balancer inner race by using special
tool ID during the punched mark side facing
out side.
09913-80112 Bearing installer
• Check the springs for strength by measuring

their free length and if one of them is shorter
than limit, replace all of them with new
ones.
Moty paste 14.2 mm I

‘I’ Service Limit
(0.56 in)
I
DISASSEMBLY
• Remove the counter balancer setting bolt. —
• Pull out the counter balancer drive gear.
TIGHTENING TORQUE
I I 35—45N•m
(3.5—4.5kg-rn)
I
I
fl GSX400E ENGINE ENGINE GSX400E12
• Thrust bearing for the crankshaft go into • Pull out the counter balancer inner race with
place with their oil groove side (ID facing the special tool.
crank webs.
13-61110 Bearing puller
COUNTER BALANCER
• When mounting the balancer drive gear, be
sure to locate the dent mark ® right on the
radial line through punch mark ® provided
on the race.
REASSEMBLY
• Locate washer ID on the balancer shaft and
fix the key in the groove, then tap the
counter balancer inner race by using special
tool ID during the punched mark side facing
out side.
09913-80112 Bearing installer
• Check the springs for strength by measuring

their free length and if one of them is shorter
than limit, replace all of them with new
ones.
Moty paste 14.2 mm I

‘I’ Service Limit
(0.56 in)
I
DISASSEMBLY
• Remove the counter balancer setting bolt. —
• Pull out the counter balancer drive gear.
TIGHTENING TORQUE
I I 35—45N•m
(3.5—4.5kg-rn)
I
I
• Fix the washer (j, spacer ® and washer

®, TIGHTENING TORQUE • Apply Suzuki Bond No. 4 to the mating
tighten the counter balancer setting bolt with surface of the upper crankcase.
40 N.m (4.0 kg-rn)
specified torque.
• Mate the lower crankcase with the upper
• Check oil orifice ® for clogging by foreign crankcase and tighten the crankcase securing
Tightening 35 45 N.m materials. bolts with specified torque value in the
torque (3.5 — 4.5 kg-m)
r following order.
Ft
1]
L
• Fix two oil separater plate ® with 4 screws

applying thread lock cement.
CRANKCASE
r 9900-32040 Thread lock cementj
H
CAUTION:
bearing
allow to applY
surface .
B00.4t0 t
• Seat washer and tighten oil pressure regulator

© with specified torque.
Tightening 17 —20 N.m
torque (1.7 —2.0 kg-rn)
\‘
• Fix the washer (j, spacer ® and washer

®, TIGHTENING TORQUE • Apply Suzuki Bond No. 4 to the mating
tighten the counter balancer setting bolt with surface of the upper crankcase.
40 N.m (4.0 kg-rn)
specified torque.
• Mate the lower crankcase with the upper
• Check oil orifice ® for clogging by foreign crankcase and tighten the crankcase securing
Tightening 35 45 N.m materials. bolts with specified torque value in the
torque (3.5 — 4.5 kg-m)
r following order.
Ft
1]
L
• Fix two oil separater plate ® with 4 screws

applying thread lock cement.
CRANKCASE
r 9900-32040 Thread lock cementj
H
CAUTION:
bearing
allow to applY
surface .
B00.4t0 t
• Seat washer and tighten oil pressure regulator

© with specified torque.
Tightening 17 —20 N.m
torque (1.7 —2.0 kg-rn)
\‘
TRANSMI SSI ON
Moly paste
Tightening
torque
90—110Nm Countershaft length (low to 2nd)
® (9.0— 11.0 kg-rn) MOUNTING 2ND DRIVE GEAR
Force-fit 2nd drive gear to a position where the
Low driven gear (32T) distance between this drive gear and the 1st STD Length 114.7mm
5th driven gear (25T) drive gear assumes the value indicated: (4.52 in)
® 4th driven gear (27T)
3rd driven gear (29T) 99000-32020 Thread lock super “1303B”
® Top driven gear (23T)
® 2nd driven gear (32T) —114.7— 114.8 mm-—--
1
) Driveshaft
Engine sprocket (15T) NOTE
*
Engine sprocket nut Before mounting 2nd drive gear, apply
Bearing retainer THREAD LOCK SUPER “1303B” to
© Countershaft (13T) its bore, taking care not to smear top
© 5th drive gear (26T)
Conft drive gear with “SUPER 1303B”.
© 3rd/4th drive gear (21/24T)
Thread lock “1303B” *
© Top drive gear (27T) After mounting the 2nd drive gear,
1) 2nd drive gear (18T) 2nd 6th 3rd 4th 5th 1st check that top drive gear spins
smoothly by moving it with your
fingers.
TRANSMI SSI ON
Moly paste
Tightening
torque
90—110Nm Countershaft length (low to 2nd)
® (9.0— 11.0 kg-rn) MOUNTING 2ND DRIVE GEAR
Force-fit 2nd drive gear to a position where the
Low driven gear (32T) distance between this drive gear and the 1st STD Length 114.7mm
5th driven gear (25T) drive gear assumes the value indicated: (4.52 in)
® 4th driven gear (27T)
3rd driven gear (29T) 99000-32020 Thread lock super “1303B”
® Top driven gear (23T)
® 2nd driven gear (32T) —114.7— 114.8 mm-—--
1
) Driveshaft
Engine sprocket (15T) NOTE
*
Engine sprocket nut Before mounting 2nd drive gear, apply
Bearing retainer THREAD LOCK SUPER “1303B” to
© Countershaft (13T) its bore, taking care not to smear top
© 5th drive gear (26T)
Conft drive gear with “SUPER 1303B”.
© 3rd/4th drive gear (21/24T)
Thread lock “1303B” *
© Top drive gear (27T) After mounting the 2nd drive gear,
1) 2nd drive gear (18T) 2nd 6th 3rd 4th 5th 1st check that top drive gear spins
smoothly by moving it with your
fingers.
GEARSHIFT CAM AND FORK

• When mounting circlip, pay attention to • Install the two drive shaft oil seals,
the direction of the circlip. Fit it to the positioning each as shown.
side where the thrust is as shown in the
figure.
• Place two “C” rings (fj and knock pin @J

and install drive and counter shafts.
3RD DRIVEN GEAR ASSEMBLY
When mounting the 3rd driven gear on the Thread lock
drive shaft, insert lock washer No. 2 into the “1 333B
drive shaft, and turn it to fit it into the groove.
Then, fit the lock washer No. 1 c in the
lock washer No. 2.
• Be sure to install the bearing dowel pins

T
®
in the locations indicated.
Thread lock
“1342”
TIGHTENING TORQUE
L 18—28N.m(1.8—2.Skg-m)
I
GEARSHIFT CAM AND FORK

• When mounting circlip, pay attention to • Install the two drive shaft oil seals,
the direction of the circlip. Fit it to the positioning each as shown.
side where the thrust is as shown in the
figure.
• Place two “C” rings (fj and knock pin @J

and install drive and counter shafts.
3RD DRIVEN GEAR ASSEMBLY
When mounting the 3rd driven gear on the Thread lock
drive shaft, insert lock washer No. 2 into the “1 333B
drive shaft, and turn it to fit it into the groove.
Then, fit the lock washer No. 1 c in the
lock washer No. 2.
• Be sure to install the bearing dowel pins

T
®
in the locations indicated.
Thread lock
“1342”
TIGHTENING TORQUE
L 18—28N.m(1.8—2.Skg-m)
I
CLUTCH AND OIL PUMP

• Oil pump drive gear has a boss on each • After tightening the clutch sleeve hub nut ,
side. Be sure to position it so that the tall be sure to lock the nut by positively bending
boss cj faces on the clutch side and its the tongue of the washer. Tightening torque
groove ® admit locating pin ®. for the nut is specified.
• Fix it with circlip ®.
09920-50410 Clutch sleeve hub holder
Tightening 40 — 60 N.m
torque (4.0 — 6.0 kg-rn)
• Driven plate is the first to go into the sleeve

hub.
• Install push piece thrust bearing ( and
thrust washer ® properly.
• Install primary driven gear and thrust washer
• --
a.-
CLUTCH AND OIL PUMP

• Oil pump drive gear has a boss on each • After tightening the clutch sleeve hub nut ,
side. Be sure to position it so that the tall be sure to lock the nut by positively bending
boss cj faces on the clutch side and its the tongue of the washer. Tightening torque
groove ® admit locating pin ®. for the nut is specified.
• Fix it with circlip ®.
09920-50410 Clutch sleeve hub holder
Tightening 40 — 60 N.m
torque (4.0 — 6.0 kg-rn)
• Driven plate is the first to go into the sleeve

hub.
• Install push piece thrust bearing ( and
thrust washer ® properly.
• Install primary driven gear and thrust washer
• --
a.-
t
STARTER CLUTCH AND GENERATOR
NOTE • Position new gasket to align two holes ©

Using conrod stopper, tighten the clutch with oil passage of crankcase.
spring set bolts in the indicated manner,
making sure that they are tightened just a
little at a time to the same final tighteness.
09910-20115 Con rod stopper
Tightening 4 6 N.m
—
torque (0.4 0.6 kg-rn)

—
• Apply grease to oil seal lip of the crankshaft.
• Check gearshifting shaft stopper screw on

clutch cover for loose.
• Apply suzuki bond No. 4 to oil pressure Thread lock

switch thread. “1 332B”J
Thread lock “1342”
99000-31030 Suzuki Bond No. 4
t
STARTER CLUTCH AND GENERATOR
NOTE • Position new gasket to align two holes ©

Using conrod stopper, tighten the clutch with oil passage of crankcase.
spring set bolts in the indicated manner,
making sure that they are tightened just a
little at a time to the same final tighteness.
09910-20115 Con rod stopper
Tightening 4 6 N.m
—
torque (0.4 0.6 kg-rn)

—
• Apply grease to oil seal lip of the crankshaft.
• Check gearshifting shaft stopper screw on

clutch cover for loose.
• Apply suzuki bond No. 4 to oil pressure Thread lock

switch thread. “1 332B”J
Thread lock “1342”
99000-31030 Suzuki Bond No. 4
FUEL AND LUBRICATION SYSTEM GSX400E 24
23 GSX400E ENGINE
EXHAUST PIPE AND MUFFLER CARBURETOR
T-model
Thread lock “1333B”
4
X-model
Ljad_lock “1333B”
D Carburetor top cap , Throttle valve shaft

Spring 1 Throttle valve shaft
® Stopper plate
® Spacer
E-ring
® Washer
(I Throttle valve
Idle adjuster
Pilot jet
( Plug
(; Needle jet
K
Spring
Jet needle , Washer
Diaphragm and piston ( Main jet
Throttle cable bracket ® Filter
Ei) Fuel pipe joint I) 0-ring
J2 Choke shaft ‘:
Needle valve
TIGHTENING TORQUE Breather hose Float
3 Vaccum hose Gasket
(fJ Spring (J) Drain plug
f Steel ball
FUEL AND LUBRICATION SYSTEM GSX400E 24
23 GSX400E ENGINE
EXHAUST PIPE AND MUFFLER CARBURETOR
T-model
Thread lock “1333B”
4
X-model
Ljad_lock “1333B”
D Carburetor top cap , Throttle valve shaft

Spring 1 Throttle valve shaft
® Stopper plate
® Spacer
E-ring
® Washer
(I Throttle valve
Idle adjuster
Pilot jet
( Plug
(; Needle jet
K
Spring
Jet needle , Washer
Diaphragm and piston ( Main jet
Throttle cable bracket ® Filter
Ei) Fuel pipe joint I) 0-ring
J2 Choke shaft ‘:
Needle valve
TIGHTENING TORQUE Breather hose Float
3 Vaccum hose Gasket
(fJ Spring (J) Drain plug
f Steel ball
25 GSX400E FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM GSX400E 26
LUBRICATION SYSTEM SPEEDOMETER AND TACHOMETER
ROCKER ARM
CYLINDER
WALL
CAM FACE
CON ROD
SMALL END,
CAM CHAINJ
MAIN GALLERY
f) Meter hood
@ Bulb (12V, 1.1W)
® Gear position indicator
‘I ® Trip meter knob
b4 ® Speedometer
® Tachometer
Meter case
‘oh
I h ® Meter bracket
® Cushion
Cushion
‘I
@ Socket
Bulb (12V,3.4W)
Speedometer cable
cf Tachometer cable
01 L PA N
25 GSX400E FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM GSX400E 26
LUBRICATION SYSTEM SPEEDOMETER AND TACHOMETER
ROCKER ARM
CYLINDER
WALL
CAM FACE
CON ROD
SMALL END,
CAM CHAINJ
MAIN GALLERY
f) Meter hood
@ Bulb (12V, 1.1W)
® Gear position indicator
‘I ® Trip meter knob
b4 ® Speedometer
® Tachometer
Meter case
‘oh
I h ® Meter bracket
® Cushion
Cushion
‘I
@ Socket
Bulb (12V,3.4W)
Speedometer cable
cf Tachometer cable
01 L PA N
27 GSX400E CHASSIS CHASSIS GSX400E 28
STEERING STEM
•1 REMOVAL • Disconnect the right handlebar switch lead
. Remove the following items. wires.
Seat
*
Fuel tank
*
Front wheel
*
Front fork
*
Speedometer and tachometer
*
Headlight
• Take off turn signal light with headlight

bracket and front fork cover.
• Take off right handlebar switch.
. Remove ignition switch by using special

tool.
0991 1-73730 T type hexagon wrench
• Disconnect clutch cable.

(ID Handlebar pad
( Handlebar clamp bracket
® Steering stem upper bracket
® Headlight bracket (R)
® Headlight bracket (L)
® Steering stem bearing (Upper)
Steering stem bearing (Lower)
() Steering stem lower bracket
Front fork cover
I
Tightening torque
Nm kg-rn
® 12—20 1.2—2.0
( 36—52 3.6—5.2
© 15—25 1.5—2.5
© 20—30 2.0—3.0
© 40—50 4.0—5.0
() 25—40 2.5—4.0
STEERING STEM
•1 REMOVAL • Disconnect the right handlebar switch lead
. Remove the following items. wires.
Seat
*
Fuel tank
*
Front wheel
*
Front fork
*
Speedometer and tachometer
*
Headlight
• Take off turn signal light with headlight

bracket and front fork cover.
• Take off right handlebar switch.
. Remove ignition switch by using special

tool.
0991 1-73730 T type hexagon wrench
• Disconnect clutch cable.

(ID Handlebar pad
( Handlebar clamp bracket
Steering stem bearing (Lower)
() Steering stem lower bracket
Front fork cover
I
Tightening torque
Nm kg-rn
® 12—20 1.2—2.0
( 36—52 3.6—5.2
© 15—25 1.5—2.5
© 20—30 2.0—3.0
© 40—50 4.0—5.0
() 25—40 2.5—4.0
• Remove handlebar pad caps. • Remove steering stem nut by using special REASSEMBLY
tool. Reassemble and remount the steering stem in
• Remove handlebar clamp bolts and take off the reverse order of disassembly and removal
handlebars. NOTE: and also carry the following steps.
Hold the steering stem lower bracket by
09914-2581 1 “T” type hexagon wrench hand to prevent dropping. OUTER RACES
Press in the upper and lower outer races using
Steering nut special tool.
09940-14910
socket wrench
09941-34511 Steering outer
race installer
• Draw out bearing outer races upper and

lower by using special tool.
I 09941-54910 - Steering race remover

1
I 09941-74910 Steering bearing installer
• Remove steering stem head bolt and loosen

clamp bolt.
• Draw out bearing and steering stem lower

bracket.
F’
• Take off steering stem upper bracket.
• Draw out bearing by using special tool.

Head pipe
09941-84510
Bearing inner II bearing—
race remover
I
1 i: Bearing outer
race remover
• Remove handlebar pad caps. • Remove steering stem nut by using special REASSEMBLY
tool. Reassemble and remount the steering stem in
• Remove handlebar clamp bolts and take off the reverse order of disassembly and removal
handlebars. NOTE: and also carry the following steps.
Hold the steering stem lower bracket by
09914-2581 1 “T” type hexagon wrench hand to prevent dropping. OUTER RACES
Press in the upper and lower outer races using
Steering nut special tool.
09940-14910
socket wrench
09941-34511 Steering outer
race installer
• Draw out bearing outer races upper and

lower by using special tool.
I 09941-54910 - Steering race remover

1
I 09941-74910 Steering bearing installer
• Remove steering stem head bolt and loosen

clamp bolt.
• Draw out bearing and steering stem lower

bracket.
F’
• Take off steering stem upper bracket.
• Draw out bearing by using special tool.

Head pipe
09941-84510
Bearing inner II bearing—
race remover
I
1 i: Bearing outer
race remover
REAR WHEEL
BEAR I NGS STEM NUT
Press in the lower bearing by using special Tighten the steering stem nut by using special
/
tool. tool with specified torque.
Turn the front forks right and left 5 or 6 times
I 09941-74910 Steering bearing installer to seat the bearings.

Turn out the steering stem out 1/2 turn.
09940-149 10 Steering nut

socket wrench
REA
Tightening torque I 40—50N.m

(4.0 5.0 kg-rn)
—
Apply grease upper and lower bearings betore

remount the steering stem.
99000-25010 Suzuki super grease “A”
HANDLEBARS
Set the handlebars to match its punched mark
to the protrusion of the handlebar pad.
TIGHTENING TORQUE
Item N•m kg-rn
L 5— 8 0.5—0.8
: 50—80 5.0—8.0
® 25—40 2.5—4.0
REAR WHEEL
BEAR I NGS STEM NUT
Press in the lower bearing by using special Tighten the steering stem nut by using special
/
tool. tool with specified torque.
Turn the front forks right and left 5 or 6 times
I 09941-74910 Steering bearing installer to seat the bearings.

Turn out the steering stem out 1/2 turn.
09940-149 10 Steering nut

socket wrench
REA
Tightening torque I 40—50N.m

(4.0 5.0 kg-rn)
—
Apply grease upper and lower bearings betore

remount the steering stem.
99000-25010 Suzuki super grease “A”
HANDLEBARS
TIGHTENING TORQUE
Item N•m kg-rn
L 5— 8 0.5—0.8
: 50—80 5.0—8.0
® 25—40 2.5—4.0
CFD
Ui
WIRE COLOR
B Black Br/R • . Brown with Red tracer
SI Blue GIRl • • Green with Blue tracer
Co Br Brown GIW • Green with White tracer
G.... Green GIY • . Green with Yellow tracer
0 Gr Gray O/W • Orange with White tracer
F— Lbl Light blue Red with Black tracer
R/B • .
Lg Light green W/Bl • White with Blue tracer
0.... Orange W/G • White with Green tracer
R.... Red W/R • White with Red tracer
0
U 7 TURN SIGNAL INDICATOR LIGHT W. White WIY • White with Yellow tracer
HIGH BEAM INDICATOR LIGHT
P NEUTRAL INDICATOR LIGHT Y.... Yellow Yellow with Blue tracer
Y/Bl • •
N NEUTRAL INDICATOR LIGHT SWITCH B/W Black with White tracer Y/G • . Yellow with Green tracer
Co BIY Black with Yellow tracer
C-)
>
Ui
Cl)
TAILIBRAKE LIGHT
PARKING OR CITY LIGHT I
C
C
LU
S. LEFT HANDLEBAR SWITCH
0
1.L.
WIRE COLOR
B Black Br/R Brown with Red tracer
BI Blue G/BI .. Green with Blue tracer
Br Brown G/W Green with White tracer
G • Green G/Y Green with Yellow tracer
A ENGINE KILL SWITCH Gr Gray 0/W Orange with White tracer
A B STARTER BUTTON
LbI Light blue R/B Red with Black tracer
C FRONT BRAKE LIGHT SWITCH
Lg Light green W/Bl White with Blue tracer
V
T TURN SIGNAL INDICATOR LIGHT
TACHOMETER 0 Orange
.
W/G White with Green tracer
B HIGH BEAM INDICATOR LIGHT R.... Red WIR White with Red tracer
P OIL PRESSURE INDICATOR LIGHT
N NEUTRAL INDICATOR LIGHT
W White .
W/Y White with Yellow tracer
Y Yellow
....
Y/Bl Yellow with Blue tracer
SPEEDOMETER BIW Black with White tracer
. .
Y/G Yellow with Green tracer
BIY Black with Yellow tracer
FRONT TURN SIGNAL LIGHT RI
REAR TURN SIGNAL LIGHT RI
TAILIBRAKE LIGHT
HEADLIGHT
FRONT TURN SIGNAL LIGHT CL)
REAR TURN SIGNAL LIGHT CL)
0
F STAHTER DISCONNECT SWITCH
0
I CONTACT BREAKER
2 OIL PRESSURE SWITCH
Co 3 STARTER MOTOR
4 STARTER RELAY
6 REGULATOR/RECTIPIER
7 AC. GENERATOR
6
-
- R TURN SIGNAL RELAY
CO HORN SWITCH
LEFT HANDLEBAR SWITCH
zz:
I.
-
____VV____V___—__V•-:
-
—-=-r-—----- -
CFD
Ui
WIRE COLOR
B Black Br/R • . Brown with Red tracer
SI Blue GIRl • • Green with Blue tracer
Co Br Brown GIW • Green with White tracer
G.... Green GIY • . Green with Yellow tracer
0 Gr Gray O/W • Orange with White tracer
F— Lbl Light blue Red with Black tracer
R/B • .
0.... Orange W/G • White with Green tracer
R.... Red W/R • White with Red tracer
0
U 7 TURN SIGNAL INDICATOR LIGHT W. White WIY • White with Yellow tracer
P NEUTRAL INDICATOR LIGHT Y.... Yellow Yellow with Blue tracer
Y/Bl • •
N NEUTRAL INDICATOR LIGHT SWITCH B/W Black with White tracer Y/G • . Yellow with Green tracer
Co BIY Black with Yellow tracer
C-)
>
Ui
Cl)
TAILIBRAKE LIGHT
PARKING OR CITY LIGHT I
C
C
LU
S. LEFT HANDLEBAR SWITCH
0
1.L.
WIRE COLOR
BI Blue G/BI .. Green with Blue tracer
G • Green G/Y Green with Yellow tracer
A ENGINE KILL SWITCH Gr Gray 0/W Orange with White tracer
A B STARTER BUTTON
C FRONT BRAKE LIGHT SWITCH
V
T TURN SIGNAL INDICATOR LIGHT
TACHOMETER 0 Orange
.
W/G White with Green tracer
B HIGH BEAM INDICATOR LIGHT R.... Red WIR White with Red tracer
P OIL PRESSURE INDICATOR LIGHT
W White .
W/Y White with Yellow tracer
Y Yellow
....
Y/Bl Yellow with Blue tracer
SPEEDOMETER BIW Black with White tracer
. .
Y/G Yellow with Green tracer
REAR TURN SIGNAL LIGHT RI
TAILIBRAKE LIGHT
HEADLIGHT
FRONT TURN SIGNAL LIGHT CL)
REAR TURN SIGNAL LIGHT CL)
0
F STAHTER DISCONNECT SWITCH
0
I CONTACT BREAKER
2 OIL PRESSURE SWITCH
Co 3 STARTER MOTOR
4 STARTER RELAY
6 REGULATOR/RECTIPIER
7 AC. GENERATOR
6
-
- R TURN SIGNAL RELAY
CO HORN SWITCH
zz:
I.
-
____VV____V___—__V•-:
-
—-=-r-—----- -
___
____
to
UI
CD WIRE COLOR
CD
B.... Black BrIR • . Brown with Red tracer
><
U) BI. Blue GIBI Green with Blue tracer
CD Br Brown G/W • . Green with White tracer
G.... Green G IY Green with Yellow tracer
0 Gr Gray 0/W Orange with White tracer
Lbl . Light blue. .
R/B Red with Black tracer
F
A ENGINE KILL SWITCH Light green W/Bl White with Blue tracer
B STARTER SUTTON
Orange W/G White with Green tracer
RIGHT HANDLEBAR SWITCH
TURN SIGNAL INDICATOR LIGHT Red W/R White with Red tracer
CD HIGH BEAM INOICATGR LIGHT
White White with Yellow tracer
U P NEUTRAL INDICATOR LIGHT W/Y
N - NEUTRAL INDICATOR LIGHT SWITCH Yellow Y fBI Yellow with Blue tracer
Black with White tracer Y /G Yellow with Green tracer
CD Black with Yellos tracer
C-)
>
UI
C/)
TAILIRRAKE LIGHT
PARKING OR CITY LIGHT
>-
z
UI
I
C,,
UI
0
U-
WIRE COLOR
B . . . Black BrIR Brown with Red tracer
BI . . . . Blue GIBI Green with Blue tracer
Br . . . Brown G/W Green with White tracer
G . . . Green G/Y Green with Yellow tracer
Gr . . . Gray 01W Orange with White tracer
Lbl . . Light blue R/B Red with Black tracer
A ENGINE KILL SWITCH
B STARTER HUTTON Lg . . Light green WIBI White with Blue tracer
TACHOMETER RIGHT HANDLEBAR SWITCH 0 . . Orange WIG White with Green tracer
T TURN SIGNAL INDICATOR LIGHT IGNITION COIL R.... Red WIR White with Red tracer
H HIGH BEAM INDICATDR LIGHT
P NEUTRAL INDICATOR LIGHT W . . White W/Y White with Yellow tracer
N NEUTRAL INDICATOR LIGHT SWITCH Yellow with Blue tracer
Y. ... Yellow YIBI
BIW . Black with White tracer Y/G Yellow with Green tracer
B/Y . Black with Yellow tracer
FRONT TURN SIGNAL LIGHT IR)
REAR BRAKE LIGHT SWITCH REAR CR)
HEADLIGHT
0
F FRONT TURN SIGNAL LIGHT CL) REAR TURN SIGNAL LIGHT CL)
0
U
I SIGNAL DENERATOR
CD OIL PRESSIJRE SWITCH
2
3 STARTER MOTOR
C-) 4 STARTER RELAY
5 FUSE
> 6 REGULATOR/RECTIFIER
DEAR POSITION LIGHT SWITCH
7 AC. DENKRATOR
UI B IGNITOR
C,)
LII TURN SIGNAL RELAY
UI
CD
ci
CD
C,)
CD U-
LtD
C) LL.
___
____
to
UI
CD WIRE COLOR
CD
B.... Black BrIR • . Brown with Red tracer
><
U) BI. Blue GIBI Green with Blue tracer
CD Br Brown G/W • . Green with White tracer
G.... Green G IY Green with Yellow tracer
0 Gr Gray 0/W Orange with White tracer
Lbl . Light blue. .
R/B Red with Black tracer
F
A ENGINE KILL SWITCH Light green W/Bl White with Blue tracer
B STARTER SUTTON
Orange W/G White with Green tracer
TURN SIGNAL INDICATOR LIGHT Red W/R White with Red tracer
CD HIGH BEAM INOICATGR LIGHT
White White with Yellow tracer
U P NEUTRAL INDICATOR LIGHT W/Y
N - NEUTRAL INDICATOR LIGHT SWITCH Yellow Y fBI Yellow with Blue tracer
Black with White tracer Y /G Yellow with Green tracer
CD Black with Yellos tracer
C-)
>
UI
C/)
TAILIRRAKE LIGHT
>-
z
UI
I
C,,
UI
0
U-
WIRE COLOR
B . . . Black BrIR Brown with Red tracer
BI . . . . Blue GIBI Green with Blue tracer
Br . . . Brown G/W Green with White tracer
G . . . Green G/Y Green with Yellow tracer
Gr . . . Gray 01W Orange with White tracer
Lbl . . Light blue R/B Red with Black tracer
B STARTER HUTTON Lg . . Light green WIBI White with Blue tracer
TACHOMETER RIGHT HANDLEBAR SWITCH 0 . . Orange WIG White with Green tracer
T TURN SIGNAL INDICATOR LIGHT IGNITION COIL R.... Red WIR White with Red tracer
H HIGH BEAM INDICATDR LIGHT
P NEUTRAL INDICATOR LIGHT W . . White W/Y White with Yellow tracer
N NEUTRAL INDICATOR LIGHT SWITCH Yellow with Blue tracer
Y. ... Yellow YIBI
BIW . Black with White tracer Y/G Yellow with Green tracer
B/Y . Black with Yellow tracer
FRONT TURN SIGNAL LIGHT IR)
REAR BRAKE LIGHT SWITCH REAR CR)
HEADLIGHT
0
F FRONT TURN SIGNAL LIGHT CL) REAR TURN SIGNAL LIGHT CL)
0
U
I SIGNAL DENERATOR
CD OIL PRESSIJRE SWITCH
2
3 STARTER MOTOR
C-) 4 STARTER RELAY
5 FUSE
> 6 REGULATOR/RECTIFIER
DEAR POSITION LIGHT SWITCH
7 AC. DENKRATOR
UI B IGNITOR
C,)
LII TURN SIGNAL RELAY
UI
CD
ci
CD
C,)
CD U-
LtD
C) LL.
c)
Clamp
tch lead) C’)
Brake hose
m >(
Neutral indicato m
0
ing harness to C C/)
m
headlight housing -I
<
z C)
Clamp Clutch cable Make sure that the boot Clamp
Clamp should not block air cleaner
Tachometer cable To meter
inlet.
To right handlebar switch 11
0
Wiring harness To left handlebar switch
Wiring harness
Clamp (Neutral indicator
lead >
-
( j_B rake hose
clamp 0
Regulator/Rectifier
Clamping direction Transistor unit
Ground
Clamp Brake light switch lead
Neutral
Clamp indicator lead Ground
Brake hose Fuse
Turn signal relay
Wiring harness Starter relay
cable Clamp
Clamp (generator lead) (Signal generator lead)
cTachometer
Clamp
iStarter motor lead
(Generator lead T o starter relay o battery holder bolt
Neutral indicator lead To fuse
To crankcase bolt
Wiring harness
Battery
Clamp G
Secure with battery holder bolt

Secure with crankcase bolt
I —
-
— — —
\ V
h-i ç3oJ
(0
0
D
I
U)
m
o\./
4 C)
C-)
m
0
CDCD -
CD 0
0 C-)
U)
><
0
0 0
m
CD
U,
U, c)
-,
CD
c)
Clamp
tch lead) C’)
Brake hose
m >(
Neutral indicato m
0
ing harness to C C/)
m
<
z C)
Clamp Clutch cable Make sure that the boot Clamp
Clamp should not block air cleaner
Tachometer cable To meter
inlet.
To right handlebar switch 11
0
Wiring harness To left handlebar switch
Wiring harness
Clamp (Neutral indicator
lead >
-
( j_B rake hose
clamp 0
Regulator/Rectifier
Clamping direction Transistor unit
Ground
Neutral
Clamp indicator lead Ground
Brake hose Fuse
Turn signal relay
cable Clamp
Clamp (generator lead) (Signal generator lead)
cTachometer
Clamp
iStarter motor lead
(Generator lead T o starter relay o battery holder bolt
To crankcase bolt
Wiring harness
Battery
Clamp G
Secure with battery holder bolt

I —
-
— — —
\ V
h-i ç3oJ
(0
0
D
I
U)
m
o\./
4 C)
C-)
m
0
CDCD -
CD 0
0 C-)
U)
><
0
0 0
m
CD
U,
U, c)
-,
CD
39 GSX400E SERVICING INFORMATION SERVICING INFORMATION GSX400E 40
CABLE ROUTING SPECIAL TOOLS

Following special tools are required for servicing the steering head items of the GSX400.
Item Part No. Part Name

c 09941-54911 Steering race remover
09941-74910 Steering bearing installer
® 09941-84510 Bearing inner race remover
cable
Throttle cable
Clutch cable
CABLE ROUTING SPECIAL TOOLS

Following special tools are required for servicing the steering head items of the GSX400.
Item Part No. Part Name

c 09941-54911 Steering race remover
09941-74910 Steering bearing installer
® 09941-84510 Bearing inner race remover
cable
Throttle cable
Clutch cable
p
TIGHTENING TORQUE
ENGINE CHASSIS
ITEM 1 N.m kg-rn
ITEM
Cylinder head cover bolt 9 — 10 0.9 1.0
Front axle nut
—
Cam shaft journal holder bolt 8 — 12 0.8 1.2

Front axle holder nut
—
Cam shaft sprocket bolt 9 — 12 0.9 1 .2

Front fork damper rod bolt
—
Rocker arm shaft stopper bolt 8 — 10 0.8 — 1.0

Valve clearance adjuster lock nut Disc plate bolt
9 — 11 0.9— 1.1
Cylinder head bolt Caliper bolt
7 — 11 0.7 1.1
—
Cylinder head nut Caliper axle bolt

35 — 40 3.5 4.0
—
Cam chain tensioner adjuster fitting bolt Caliper bleeder

6 — 8 0.6 0.8
Front fork lower clamp bolt
—
Cam chain tensioner shaft assy

Cam chain tensioner adjuster lock nut
31 — 35 3.1 3.5
—
i Front fork upper clamp bolt
9 — 14 0.9 1.4
—
Cam chain tensioner shaft lock nut Front fork cap bolt
8 — 10 0.8 1.0
—
Starter motor bolt Steering stem nut

4 — 7 0.4 0.7
—
Generator rotor bolt Steering stem clamp bolt

90 —100 9.0 10.0
—
Starterclutch allen bolt Steering stem head bolt

15— 20 1.5— 2.0
Primary drive gear nut Handlebars clamp bolt
90— 110 9.0— 11.0
Counter balancer center bolt Brake hose union bolt
35 — 45 3.5 4.5
—
Con rod nut Master cylinder clamp bolt

30 — 34 3.0 3.4
—
Oil pressure regulator Brake pedal arm bolt

17— 20 1.7— 2.0
Governor bolt Swinging arm pivot nut
13 — 23 1.3 2.3
Front footrest bolt 10mm
—
Pressureswitch 13— 17 1.3— 1.7

8mm
Neutral stopper housing 18— 28 1.8— 2.8
Clutch spring bolt Muffler bracket mounting bolt
4 — 6 0.4 0.6
—
Clutch sleeve hub nut Rear footrest bolt

40 — 60 4.0 — 6.0
Gearshifting arm stopper Muffler bracket bolt
15 — 23 — 1.5 — 2.3
Oil pan bolt Rear torque link nut
10 1.0
Crankcase bolt ‘f Rear shock absorber fitting nut
— 20 — 24 2.0 —2.4
Rear axle nut
®f 9— 13 0.9— 1.3
6mmbolt Rear sprocket nut
10 1.0
8 mm bolt Rear brake cam lever bolt
20 2.0
Engine sprocket nut Spoke nipple
90— 110 9.0— 11.0
Engine mountingbolt 8 mm 20 30
—
2.0 — 3.0
10 mm 30 37
—
3.0 — 3.7
Coupler tube bolt 9— 14 0.9— 1.4
Exhaust pipe clamp bolt 9— 14 0.9— 1.4
p
TIGHTENING TORQUE
ENGINE CHASSIS
ITEM 1 N.m kg-rn
ITEM
Cylinder head cover bolt 9 — 10 0.9 1.0
Front axle nut
—
Cam shaft journal holder bolt 8 — 12 0.8 1.2

Front axle holder nut
—
Cam shaft sprocket bolt 9 — 12 0.9 1 .2

Front fork damper rod bolt
—
Rocker arm shaft stopper bolt 8 — 10 0.8 — 1.0

Valve clearance adjuster lock nut Disc plate bolt
9 — 11 0.9— 1.1
Cylinder head bolt Caliper bolt
7 — 11 0.7 1.1
—
Cylinder head nut Caliper axle bolt

35 — 40 3.5 4.0
—
Cam chain tensioner adjuster fitting bolt Caliper bleeder

6 — 8 0.6 0.8
Front fork lower clamp bolt
—
Cam chain tensioner shaft assy

Cam chain tensioner adjuster lock nut
31 — 35 3.1 3.5
—
i Front fork upper clamp bolt
9 — 14 0.9 1.4
—
Cam chain tensioner shaft lock nut Front fork cap bolt
8 — 10 0.8 1.0
—
Starter motor bolt Steering stem nut

4 — 7 0.4 0.7
—
Generator rotor bolt Steering stem clamp bolt

90 —100 9.0 10.0
—
Starterclutch allen bolt Steering stem head bolt

15— 20 1.5— 2.0
Primary drive gear nut Handlebars clamp bolt
90— 110 9.0— 11.0
Counter balancer center bolt Brake hose union bolt
35 — 45 3.5 4.5
—
Con rod nut Master cylinder clamp bolt

30 — 34 3.0 3.4
—
Oil pressure regulator Brake pedal arm bolt

17— 20 1.7— 2.0
Governor bolt Swinging arm pivot nut
13 — 23 1.3 2.3
Front footrest bolt 10mm
—
Pressureswitch 13— 17 1.3— 1.7

8mm
Neutral stopper housing 18— 28 1.8— 2.8
Clutch spring bolt Muffler bracket mounting bolt
4 — 6 0.4 0.6
—
Clutch sleeve hub nut Rear footrest bolt

40 — 60 4.0 — 6.0
Gearshifting arm stopper Muffler bracket bolt
15 — 23 — 1.5 — 2.3
Oil pan bolt Rear torque link nut
10 1.0
Crankcase bolt ‘f Rear shock absorber fitting nut
— 20 — 24 2.0 —2.4
Rear axle nut
®f 9— 13 0.9— 1.3
6mmbolt Rear sprocket nut
10 1.0
8 mm bolt Rear brake cam lever bolt
20 2.0
Engine sprocket nut Spoke nipple
90— 110 9.0— 11.0
Engine mountingbolt 8 mm 20 30
—
2.0 — 3.0
10 mm 30 37
—
3.0 — 3.7
Coupler tube bolt 9— 14 0.9— 1.4
Exhaust pipe clamp bolt 9— 14 0.9— 1.4
43 GSX400E SERVICING INFORMATION
SERVICING INFORMATION GSX400E 44
TIGHTENING TORQUE CHART
SERVICE DATA
For other bolts and nuts not listed, refer to this chart:
VALVE + GUIDE Unit: mm (in)
Tightening torque ITEM STANDARD LIMIT
Conventional or “4” marked bolt “7” marked bolt Valve diam. 23
Bolt Diameter IN.
(mm) ( 0.90
kg-rn lb-ft Nm kg-rn lb-ft N.m
EX 20
4
(0.78)
0.1 0.2 0.7— 1.5 1 2 0.15— 0.3 1.0— 2.0
—
—
1.5— 3 Valve lift
I *
IN. 7.0
5 0.2 0.4 1.5 3.0 2 4 0.3 0.6 0.28
—
— —
— 2.0 — 4.5 3 — 6 (
6 0.4 0.7 3.0 5.0 4 7 0.8 1.2 6.0 7.0
—
— —
— — 8.5 8 — 12 EX
8 1.0— 1.6 ( 0.28
7.0— 11.5 10— 16 1.8 — 2.8 13.0— 20.0 18 28
—
Valve clearance 0.08 0.13

10 2.2 3.5 16.0 25.5 22 35 4.0 (when cold) IN.&EX. —
—
—
—
— 6.0 29.0 — 43.5 40 — 60 ( 0.003 — 0.005
12 3.5— 5.5 25.5— 40.0 35— 55 7.0 10.0 50.5— 72.5 Valve guide to Valve stem 0.025 0.052 0.090
—
70 — 100 IN
—
14 5.0 8.0
clearance ( 0.0010— 0.0020) (0.0035)
— 36.0 — 58.0 50 — 80 1 1.0 — 16.0 79.5 — 11 5.5 1 10 — 160
16 0.040 0.067 0.100
EX
—
8.0— 13.0 58.0 94.0 80 130 17.0 25.0 123.0— 181.0

—
—
—
170 — 250 . (0.0016—0.0026) (0.0039)
18 13.0— 19.0 94.0— 137.5 130— 190 20.0 — 28.0 144.5 202.5 200 280 Valve guide I.D. 5.500 5.512
IN. & EX.
— —
—
(_0.2165—_0.2170)
Valve stem O.D. 5.460 5.475
—
IN.
(0.2150—0.2156)
5.445 5.460
EX
—
(0.2144—0.2150)
—,
Valve stem runout 0.05

IN. & EX.
_____
___
(0.002)
Valvheadthickness 0.5
lN.&EX.
Conventional Bolt “4” Marked Bolt “7” Marked Bolt ( 0.02
Valve stem end length 3.6
IN. & EX.
(__0.14
I I Valve seat width 0.9 1.1
IN. & EX.
—
( 0.035 — 0.043
Valve head radial runout 0.03
IN. & EX.
( 0.001
Valve spring free length 31.9
INNER
(IN. & EX.) ( 1.26
OUTER 35.5
C 1.40
Valve spring tension 4.4 — 6.4 kg
(IN. & EX.) INNER ( 9.7— 14.1 Ibs)
at length 28.5mm (1.12 in)
6.5— 8.9 kg
OUTER ( 14.3 — 19.6 Ibs)
at length 32.0 mm (1.26 in)
TIGHTENING TORQUE CHART
SERVICE DATA
For other bolts and nuts not listed, refer to this chart:
VALVE + GUIDE Unit: mm (in)
Tightening torque ITEM STANDARD LIMIT
Conventional or “4” marked bolt “7” marked bolt Valve diam. 23
Bolt Diameter IN.
(mm) ( 0.90
kg-rn lb-ft Nm kg-rn lb-ft N.m
EX 20
4
(0.78)
0.1 0.2 0.7— 1.5 1 2 0.15— 0.3 1.0— 2.0
—
—
1.5— 3 Valve lift
I *
IN. 7.0
5 0.2 0.4 1.5 3.0 2 4 0.3 0.6 0.28
—
— —
— 2.0 — 4.5 3 — 6 (
6 0.4 0.7 3.0 5.0 4 7 0.8 1.2 6.0 7.0
—
— —
— — 8.5 8 — 12 EX
8 1.0— 1.6 ( 0.28
7.0— 11.5 10— 16 1.8 — 2.8 13.0— 20.0 18 28
—
Valve clearance 0.08 0.13

10 2.2 3.5 16.0 25.5 22 35 4.0 (when cold) IN.&EX. —
—
—
—
— 6.0 29.0 — 43.5 40 — 60 ( 0.003 — 0.005
12 3.5— 5.5 25.5— 40.0 35— 55 7.0 10.0 50.5— 72.5 Valve guide to Valve stem 0.025 0.052 0.090
—
70 — 100 IN
—
14 5.0 8.0
clearance ( 0.0010— 0.0020) (0.0035)
— 36.0 — 58.0 50 — 80 1 1.0 — 16.0 79.5 — 11 5.5 1 10 — 160
16 0.040 0.067 0.100
EX
—
8.0— 13.0 58.0 94.0 80 130 17.0 25.0 123.0— 181.0

—
—
—
170 — 250 . (0.0016—0.0026) (0.0039)
18 13.0— 19.0 94.0— 137.5 130— 190 20.0 — 28.0 144.5 202.5 200 280 Valve guide I.D. 5.500 5.512
IN. & EX.
— —
—
(_0.2165—_0.2170)
Valve stem O.D. 5.460 5.475
—
IN.
(0.2150—0.2156)
5.445 5.460
EX
—
(0.2144—0.2150)
—,
Valve stem runout 0.05

IN. & EX.
_____
___
(0.002)
Valvheadthickness 0.5
lN.&EX.
Conventional Bolt “4” Marked Bolt “7” Marked Bolt ( 0.02
IN. & EX.
(__0.14
I I Valve seat width 0.9 1.1
IN. & EX.
—
( 0.035 — 0.043
Valve head radial runout 0.03
IN. & EX.
( 0.001
Valve spring free length 31.9
INNER
(IN. & EX.) ( 1.26
OUTER 35.5
C 1.40
Valve spring tension 4.4 — 6.4 kg
(IN. & EX.) INNER ( 9.7— 14.1 Ibs)
6.5— 8.9 kg
OUTER ( 14.3 — 19.6 Ibs)
CAMSHAFT + CYLINDER HEAD RING CYLINDER Unit: mm (in)

Unit: mm (in) PISTON + +
ITEM STANDARD LIMIT ITEM STANDARD LIMIT
* Cam height 34.650 34.690 10 14 2
kg/cm 8 kg/cm
2
IN. —
34.350 Compression pressure —
1.3657) ( 1.3524) ( 142— 199 psi) ( 114 psi)

EX. 5ã9t5 Compression pressure difference 2 kg/cm
2
( 1.3642— 1.3657) ( ( 28.4__psi)
Camshaft journal oil clearance 0.032 0.066 0.050 0.060 0.120
IN. & EX. — Piston to Cylinder clearance —
( 0.0013 0.0026)
— (0.0059) ( 0.00200.0024)
— ( 0.0047)
Camshaft journal holder I.D. 67.000—67.015 67.080
IN. & EX. 22.012—22.025 Cylinderbore
( 0.8666 0.8671
— ( 2.6378— 2.6384) ( 2.6410)
Camshaft journal O.D. 21.959—21.980 66.945 66.960
IN. & EX. Piston diam. —
(0.8645—0.8654) ( 2.6356 — 2.6362) 66.880

Camshaft runout Measure the 15.0 (0.59) ( 2.6331
IN. & EX. 0.10
from piston skirt end.
( 0.004
Cam chain 20 pitch length Cylinder distortion 0.10
157 .80
( 6.2 13
( 0.004
Piston ring free end gap 9.5 7.6
20th pin N Approx.
—
( 0.37 ) ( 0.30
1 St
Rocker arm l.D. 12.000— 12.018 9.5 7.6
IN. & EX. R Approx.
(0.4724—0.4731) ( 0.37 ) ( 0.30
RockerarmshaftQ.D. 11.973— 11.984 10.0 8.0
lN.& EX. N Approx.
(0.4714— 0.4718) ( 0.39 ) ( 0.31
2nd
Cylinder head distortion 10.0 8.0
0.10 R Approx.
0.004 ( 0.39 ) ( 0.31
Piston ring end gap 0.10 0.30
— 0.7
1st
( 0.004 0.012 )
— ( 0.03
0.10—0.30 0.7
2nd
Only for E-22 ( 0.004—0.012 ) ( 0.03
Unit: mm (in)
ITEM Piston ring groove clearance 0.180
STANDARD LIMIT 1st (0.0071)
Cam height 33.350 33.390
IN. —
33.050 0.150
( 1.3130— 1.3146) ( 1.3012) 2nd (0.0059)
EX. 33.050 Piston ring groove width 1.21 1.23
—
( 1.3130— 1.3146) (1.3012) 1st

Valve lift ( 0.047 0.048
—
IN. 4.8 1.21 1.23

—
( 0.19 2nd
( 0.047 0.048
—
EX. 4.8 . 2.51 2.53

—
( 0.19 Oil
( 0.099—0.100
Piston ring thickness 1.175 1.190
—
1st
(0.0463—0.0469)
1.170— 1.190
2nd
( 0.0461 0.0469)
—
Piston pin bore 18.002 18.008

—
18.030
(0.7087— 0.7090) (0.7098)
Piston pin O.D. 17.996 18.000
— 17.980
( 0.7085 0.7087)
— ( 0.7079)
CAMSHAFT + CYLINDER HEAD RING CYLINDER Unit: mm (in)

Unit: mm (in) PISTON + +
* Cam height 34.650 34.690 10 14 2
kg/cm 8 kg/cm
2
IN. —
34.350 Compression pressure —
1.3657) ( 1.3524) ( 142— 199 psi) ( 114 psi)

EX. 5ã9t5 Compression pressure difference 2 kg/cm
2
( 1.3642— 1.3657) ( ( 28.4__psi)
Camshaft journal oil clearance 0.032 0.066 0.050 0.060 0.120
IN. & EX. — Piston to Cylinder clearance —
( 0.0013 0.0026)
— (0.0059) ( 0.00200.0024)
— ( 0.0047)
Camshaft journal holder I.D. 67.000—67.015 67.080
IN. & EX. 22.012—22.025 Cylinderbore
( 0.8666 0.8671
— ( 2.6378— 2.6384) ( 2.6410)
Camshaft journal O.D. 21.959—21.980 66.945 66.960
IN. & EX. Piston diam. —
(0.8645—0.8654) ( 2.6356 — 2.6362) 66.880

Camshaft runout Measure the 15.0 (0.59) ( 2.6331
IN. & EX. 0.10
from piston skirt end.
( 0.004
Cam chain 20 pitch length Cylinder distortion 0.10
157 .80
( 6.2 13
( 0.004
Piston ring free end gap 9.5 7.6
20th pin N Approx.
—
( 0.37 ) ( 0.30
1 St
Rocker arm l.D. 12.000— 12.018 9.5 7.6
IN. & EX. R Approx.
(0.4724—0.4731) ( 0.37 ) ( 0.30
RockerarmshaftQ.D. 11.973— 11.984 10.0 8.0
lN.& EX. N Approx.
(0.4714— 0.4718) ( 0.39 ) ( 0.31
2nd
0.10 R Approx.
0.004 ( 0.39 ) ( 0.31
Piston ring end gap 0.10 0.30
— 0.7
1st
( 0.004 0.012 )
— ( 0.03
0.10—0.30 0.7
2nd
Only for E-22 ( 0.004—0.012 ) ( 0.03
Unit: mm (in)
ITEM Piston ring groove clearance 0.180
STANDARD LIMIT 1st (0.0071)
Cam height 33.350 33.390
IN. —
33.050 0.150
( 1.3130— 1.3146) ( 1.3012) 2nd (0.0059)
EX. 33.050 Piston ring groove width 1.21 1.23
—
( 1.3130— 1.3146) (1.3012) 1st

Valve lift ( 0.047 0.048
—
IN. 4.8 1.21 1.23

—
( 0.19 2nd
( 0.047 0.048
—
EX. 4.8 . 2.51 2.53

—
( 0.19 Oil
( 0.099—0.100
Piston ring thickness 1.175 1.190
—
1st
(0.0463—0.0469)
1.170— 1.190
2nd
( 0.0461 0.0469)
—
Piston pin bore 18.002 18.008

—
18.030
(0.7087— 0.7090) (0.7098)
Piston pin O.D. 17.996 18.000
— 17.980
( 0.7085 0.7087)
— ( 0.7079)
CONROD + CRANKSHAFT + BALANCER Unit: mm (in) CLUTCH Unit: mm (in)

Conrod small end l.D. 18.006 18.014
— 18.040 Clutch cable play 4.0
(0.7089—0.7092) (0.7102) ( 0.16
Conrod big end thrust clearance 0.10 0.20
— 0.30 Clutch release screw ¼ 1/2
—
( 0.004 0.008 )
—
( 0.012 turn back
Conrod big end width 22.95 23.00
Drive plate thickness 2.9
—
0.904 3.1 2.6

( 0.906
—
0.11—0.12
—
( ) ( 0.10
Crank pin width 23.10 — 23.15
Drive plate claw width 1 5.8 16.0 15.0
( 0.909—0.911 —
( 0.62 — 0.63 ) ( 0.59

Conrod big end oil clearance 0.024 0.048
— 0.080
(0.0009—0.0019) (0.0031) Driven plate thickness 1 .60 ± 0.06
Crank pin O.D. 33.976 34.000
—
( 0.063± 0.002
( 1.3376— 1.3386) Driven plate distortion 0.1
Crankshaft journal oil clearance 0.020 0.044
— 0.080 ( 0.004
( 0.0008— 0.0017) ( 0.0031 Clutch spring free length 38.4
Crankshaft journal O.D. 31.976 32.000
— ( 1.51
( 1.2589— 1.2598)
Crankshaft thrust bearing thickness 2.95 2.98
— 2.85
( 0.116—0.117 ) ( 0.112
Crankshaft runout 0.05
( 0.002
Balancer journal oil clearance 0.020 0.044
— 0.080
(0.0008—0.0017) (0.0031)
Balancer journal O.D. 31.984 32.000
—
( 1.2592— 1.2598)
OIL PUMP Unit: mm (in)

ITEM STANDARD LIMIT
Oil pump reduction ratio 2.07 1 ( 76 / 28 x 29 / 38
Oil pressure (at 60° C, 140° F) 3.0 2
kg/cm
Above
( 43 psi)
5.5 2
kg/cm
Below
( 78 psi)
at 3000 r/min.
Tip clearance 0.20
( 0.008
Outer rotor clearance 0.25
( 0.010
Side clearance 0.15
(0.006)
CONROD + CRANKSHAFT + BALANCER Unit: mm (in) CLUTCH Unit: mm (in)

— 18.040 Clutch cable play 4.0
(0.7089—0.7092) (0.7102) ( 0.16
— 0.30 Clutch release screw ¼ 1/2
—
( 0.004 0.008 )
—
( 0.012 turn back
Drive plate thickness 2.9
—
0.904 3.1 2.6

( 0.906
—
0.11—0.12
—
( ) ( 0.10
Drive plate claw width 1 5.8 16.0 15.0
( 0.909—0.911 —
( 0.62 — 0.63 ) ( 0.59

Conrod big end oil clearance 0.024 0.048
— 0.080
(0.0009—0.0019) (0.0031) Driven plate thickness 1 .60 ± 0.06
Crank pin O.D. 33.976 34.000
—
( 0.063± 0.002
( 1.3376— 1.3386) Driven plate distortion 0.1
Crankshaft journal oil clearance 0.020 0.044
— 0.080 ( 0.004
( 0.0008— 0.0017) ( 0.0031 Clutch spring free length 38.4
Crankshaft journal O.D. 31.976 32.000
— ( 1.51
( 1.2589— 1.2598)
Crankshaft thrust bearing thickness 2.95 2.98
— 2.85
( 0.116—0.117 ) ( 0.112
( 0.002
Balancer journal oil clearance 0.020 0.044
— 0.080
(0.0008—0.0017) (0.0031)
—
( 1.2592— 1.2598)
OIL PUMP Unit: mm (in)

ITEM STANDARD LIMIT
Oil pump reduction ratio 2.07 1 ( 76 / 28 x 29 / 38
Oil pressure (at 60° C, 140° F) 3.0 2
kg/cm
Above
( 43 psi)
5.5 2
kg/cm
Below
( 78 psi)
at 3000 r/min.
Tip clearance 0.20
( 0.008
Outer rotor clearance 0.25
( 0.010
Side clearance 0.15
(0.006)
TRANSMISSION + DRIVE CHAIN Unit: mm (in) CARBURETOR Unit: mm (in)

ITEM STANDARD LIMIT SPECIFICATION
ITEM
Primary reduction ratio 2.714 ( 76 I 28 E—02, and the others Only4or E-22
Final reduction ratio 2.750 ( 44 / 16 Carburetor type MIKUNI BS34SS
Gear ratios Low 2.461 ( 32 / 13 Bore size 34 (1.34)
V
2nd 1.777 ( 32 / 18 l.D. No. 44201 44202 44220

3rd 1.380 ( 29 / 21 Idle r/min. 1100 ± 50r/min.
4th 1.125 ( 27 / 24 Fuel level 5.0 ± 0.5
5th 0.961 ( 25 / 26 (0.20 ± 0.02)
Top 0.851 23 27 Float height 22.4 ± 1.0

( /
(0.88 ± 0.04)
Shift fork to Groove 0.10 — 0.30 0.50
0.012 ( 0.020
Main jet (M.J.) #117.5
clearance ( 0.004 —
) —
5.5 5.6 Main air jet (M.A.J.) 0.6

Shift fork groove width —
( 0.217 — 0.220 Jet needle (J.N.) 5D69-4

Shift fork thickness 5.3 5.4 —
Needle jet (N.J.) 0-9 P-i P-2
( 0.209—0.213
Pilot jet (P.J.) #42.5
Countershaft length i 14.7 ± 1
g. By pass (B.P.) 0.9, 0.8, 0.8
(Low to 2nd) ( 4.52 ± g.oo4 ) V
Pilot outlet (P.O.) 0.8

Drive chain D.l.D.: 50 UB
Type Valve seat (V.S.) 2.0
V
Starter jet (G.S.) — #32.5

Links 104
Pilot screw (P.S.) 1%
313 Pilot air jet (P.A.J.) #125
IL 20 pitch length
Throttle calbe play 0.5 — 1.0
Drive chain slack 20 30
—
(0.02 — 0.04)
( 0.8—1.2
TRANSMISSION + DRIVE CHAIN Unit: mm (in) CARBURETOR Unit: mm (in)

ITEM STANDARD LIMIT SPECIFICATION
ITEM
Primary reduction ratio 2.714 ( 76 I 28 E—02, and the others Only4or E-22
Final reduction ratio 2.750 ( 44 / 16 Carburetor type MIKUNI BS34SS
Gear ratios Low 2.461 ( 32 / 13 Bore size 34 (1.34)
V
2nd 1.777 ( 32 / 18 l.D. No. 44201 44202 44220

3rd 1.380 ( 29 / 21 Idle r/min. 1100 ± 50r/min.
4th 1.125 ( 27 / 24 Fuel level 5.0 ± 0.5
5th 0.961 ( 25 / 26 (0.20 ± 0.02)
Top 0.851 23 27 Float height 22.4 ± 1.0

( /
(0.88 ± 0.04)
0.012 ( 0.020
Main jet (M.J.) #117.5
clearance ( 0.004 —
) —
5.5 5.6 Main air jet (M.A.J.) 0.6

Shift fork groove width —
( 0.217 — 0.220 Jet needle (J.N.) 5D69-4

Shift fork thickness 5.3 5.4 —
Needle jet (N.J.) 0-9 P-i P-2
( 0.209—0.213
Pilot jet (P.J.) #42.5
Countershaft length i 14.7 ± 1
g. By pass (B.P.) 0.9, 0.8, 0.8
(Low to 2nd) ( 4.52 ± g.oo4 ) V
Pilot outlet (P.O.) 0.8

Drive chain D.l.D.: 50 UB
Type Valve seat (V.S.) 2.0
V
Starter jet (G.S.) — #32.5

Links 104
Pilot screw (P.S.) 1%
313 Pilot air jet (P.A.J.) #125
IL 20 pitch length
Throttle calbe play 0.5 — 1.0
Drive chain slack 20 30
—
(0.02 — 0.04)
( 0.8—1.2
ELECTRICAL Unit: mm (in) BRAKE + WHEEL Unit: mm (in)

ITEM SPECIFICATION ITEM STANDARD LIMIT
Ignition timing 200 B.T.D.C. Below 1650 ± 100 r/min and Only for E-28 Rear brake pedal free travel 20 30—
.35° B.T.D.C. Above 3500 ± 100 r/m in. ( 0.8—1.2

20° B.T.D.C. Below 1650 ± 100 r/min and Transistorized Rear brake pedal height 20
40° B.T.D.C. Above 3500 ± 100 r/min. ignition type 0.8
(
Firingorder 1,2
Brake drum I.D. 160.7
NGK: D8EA Rear
Spark plug Type ( 6.33
N. D.: X24ES-U
Brake lining thickness 1.5
0.6—0.7 ( 0.06
Gap
( 0.024 0.028
—
Brake disc thickness 5.0 ± 0.1 4.5

NGK: DR8ES-L Front
Type ( 0.20 ± 0.004) ( 0.18
N. D.: X24ESR-U [
0.6 0.7 Brake disc runout 0.30

Gap
—
(__0.024 0.028
—
( 0.012
Spark performance Over 8 (0.3) at 1 atm Master cylinder bore 14.000 14.043
Front
—
( 0.5512— 0.5529)
Contact point gap 0.30 0.40
—
E-28
(__0.012 0.016 Master cylinder piston diam. 13.957 13.984
—
Front
—
Dwell angle KOKUSAN 190° E-28 ( 0.5495— 0.5506)

Condensercapacity KOKUSAN 0.25± 0.03 MF E-28 Brake caliper cylinder bore 42.850 42.926
Front
—
Except for
( 1.6870— 1.6900)
Signal coil resistance Approx. 60 80
Br — B/W
E-28
—
G/W B/W
—
42.770 42.820
R ear
—
Ignition coil resistance 01W — W or BIY Except for ( 1.6839— 1.6858)

Primary E-28
Approx. 3.5 4.5 2
Wheel rim runout 2.0
—
Axial
.
Plug cap — W or B/Y Except for ( 0.08

Secondary E-28
Approx. 23 — 25 k2
2.0
01W W or B Radial
Primary
—
E-28 ( 0.08
Approx. 3 — 5
Wheel axle runout 0.25
Plug cap W or B Front
E-28 ( 0.010
—
Secondary
Approx. 21 — 25 k2
0.25
Generator No-Load voltage More than 75V (AC) at 5000 r/min. Rear
( o.oo
Regulated voltage 14— 15V at 5000 r/min.
I I Tire size
Starter motor 9 Front 3.00S18 4PR
Brush length N.D. Limit:
( 0.4
0.2 3.50S18 4PR
Commutator under cut Limit:
0.008) Rear
Starter relay resistance Approx. 3 — 4 &2 3.75S18 4PR [Only for E-22 and E-26]
Battery Type
YB1OL-A2 1.6
designation Tire tread depth
Front
( 0.06
Capacity 12V 43.2 kC (12 Ah)/10 HR
Standard elec 2.0
1.28 at 20°C (68°F) Rear
trolyte S.G. ( 0.08
J___________________________________
Fuse size Main iSA

ITEM SPECIFICATION ITEM STANDARD LIMIT
Ignition timing 200 B.T.D.C. Below 1650 ± 100 r/min and Only for E-28 Rear brake pedal free travel 20 30—
.35° B.T.D.C. Above 3500 ± 100 r/m in. ( 0.8—1.2

20° B.T.D.C. Below 1650 ± 100 r/min and Transistorized Rear brake pedal height 20
40° B.T.D.C. Above 3500 ± 100 r/min. ignition type 0.8
(
Firingorder 1,2
Brake drum I.D. 160.7
NGK: D8EA Rear
Spark plug Type ( 6.33
N. D.: X24ES-U
Brake lining thickness 1.5
0.6—0.7 ( 0.06
Gap
( 0.024 0.028
—

NGK: DR8ES-L Front
Type ( 0.20 ± 0.004) ( 0.18
N. D.: X24ESR-U [
0.6 0.7 Brake disc runout 0.30

Gap
—
(__0.024 0.028
—
( 0.012
Spark performance Over 8 (0.3) at 1 atm Master cylinder bore 14.000 14.043
Front
—
( 0.5512— 0.5529)
Contact point gap 0.30 0.40
—
E-28
(__0.012 0.016 Master cylinder piston diam. 13.957 13.984
—
Front
—
Dwell angle KOKUSAN 190° E-28 ( 0.5495— 0.5506)

Condensercapacity KOKUSAN 0.25± 0.03 MF E-28 Brake caliper cylinder bore 42.850 42.926
Front
—
Except for
( 1.6870— 1.6900)
Br — B/W
E-28
—
G/W B/W
—
42.770 42.820
R ear
—
Ignition coil resistance 01W — W or BIY Except for ( 1.6839— 1.6858)

Primary E-28
Approx. 3.5 4.5 2
Wheel rim runout 2.0
—
Axial
.
Plug cap — W or B/Y Except for ( 0.08

Secondary E-28
Approx. 23 — 25 k2
2.0
01W W or B Radial
Primary
—
E-28 ( 0.08
Approx. 3 — 5
Plug cap W or B Front
E-28 ( 0.010
—
Secondary
Approx. 21 — 25 k2
0.25
Generator No-Load voltage More than 75V (AC) at 5000 r/min. Rear
( o.oo
Regulated voltage 14— 15V at 5000 r/min.
I I Tire size
Starter motor 9 Front 3.00S18 4PR
Brush length N.D. Limit:
( 0.4
0.2 3.50S18 4PR
Commutator under cut Limit:
0.008) Rear
Starter relay resistance Approx. 3 — 4 &2 3.75S18 4PR [Only for E-22 and E-26]
Battery Type
YB1OL-A2 1.6
designation Tire tread depth
Front
( 0.06
Standard elec 2.0
1.28 at 20°C (68°F) Rear
trolyte S.G. ( 0.08
J___________________________________
Fuse size Main iSA
SUSPENSION Unit: mm (in) TIRE PRESSURE

ITEM STANDARD LIMIT SPEC.
NORMAL RIDING CONTINUOUS HIGH SPEED RIDING
Front fork stroke 140
( 5.5 COLD INFLATION
SOLORIDING DUALRIDING SOLORIDING DUALRIDING
TIRE PRESSURE
Front fork spring free length 496 —————————————————
I I
( 19.5 kPa 2
kg/cm psi kPa 2
kg/cm psi kPa 2
kg/cm psi kPa 2
kg/cm psi
Front fork oil level 197 E 22 28 FRONT 175 1.75 25 175 1.75 25 200 2.00 28 200 2.00 28
( 7.8 ) -‘
186 REAR 200 2.00 j28 225 2.25 32[ 225 2.25 32 250 2.50 36
E-02,04
Rear wheel travel 100

( 3.9
Swinging arm pivot shaft runout 0.3
( 0.012) WATTAGE (W)
SPECIFICATION
ITEM
E-02 E-O4 E-22 E-28 E-24 E-16 E-26
Headlight HI 35 36 45 50 45
FUEL + OIL LO 35 36 40 35 45 40
ITEM SPECIFICATION SPEC. Parking or city light 3.4 4 ÷- —
_— 4
Fuel type Use gasoline with an octane number of Tail/Brake light 5/21 - - 8/23 5/21
90 or higher (Research Method), pre
ferably unleaded or low-lead. Turn signal light 21 23 - 21
Fuel tank including reserve 14.5 L Speedometer light 3.4 ÷-
( 3.8 / 3.2 US/Imp gal) Tachometer light 3.4 ÷- ÷-
reserve 3.0 L Turn signal indicator light 3.4 ÷- ÷-
( 3.2 / 2.6 US/Imp qt)

High beam indicator light 3.4 ÷-
Engine oil type SAE 1OW/40

Neutral indicator light 3.4 —
Engine oil capacity 2600 ml

Ch ange Oil pressure indicator light 3.4
( 2.7 / 2.3 US/Imp qt) -
Filter 2900 ml Gear position indicator light 1.1 —
change ( 3.1 / 2.6 US/Imp qt)

3000 ml
Overhaul NOTE:
( 3.2 / 2.6 US/Imp qt)
E-02: England
Front fork oil type Mixture ratio SAE 1OW/30: A.T.F. = 1 : 1
E-04: France
Front fork oil capacity (each leg) 145 ml E-16: Norway
E-22 28
( 4.90 / 5.11 US/Imp oz) E-22: W. Germany
150 ml E-24: Australia
E-O2 04
( 5.07 / 5.28 US/Imp oz) E-26: Denmark
Brake fluid type E-28: Canada
SAE J1703, DOT3 or DOT4
SUSPENSION Unit: mm (in) TIRE PRESSURE

ITEM STANDARD LIMIT SPEC.
Front fork stroke 140
( 5.5 COLD INFLATION
SOLORIDING DUALRIDING SOLORIDING DUALRIDING
TIRE PRESSURE
Front fork spring free length 496 —————————————————
I I
( 19.5 kPa 2
kg/cm psi kPa 2
kg/cm psi kPa 2
kg/cm psi kPa 2
kg/cm psi
Front fork oil level 197 E 22 28 FRONT 175 1.75 25 175 1.75 25 200 2.00 28 200 2.00 28
( 7.8 ) -‘
186 REAR 200 2.00 j28 225 2.25 32[ 225 2.25 32 250 2.50 36
E-02,04
Rear wheel travel 100

( 3.9
Swinging arm pivot shaft runout 0.3
( 0.012) WATTAGE (W)
SPECIFICATION
ITEM
E-02 E-O4 E-22 E-28 E-24 E-16 E-26
Headlight HI 35 36 45 50 45
FUEL + OIL LO 35 36 40 35 45 40
ITEM SPECIFICATION SPEC. Parking or city light 3.4 4 ÷- —
_— 4
Fuel type Use gasoline with an octane number of Tail/Brake light 5/21 - - 8/23 5/21
90 or higher (Research Method), pre
ferably unleaded or low-lead. Turn signal light 21 23 - 21
Fuel tank including reserve 14.5 L Speedometer light 3.4 ÷-
( 3.8 / 3.2 US/Imp gal) Tachometer light 3.4 ÷- ÷-
reserve 3.0 L Turn signal indicator light 3.4 ÷- ÷-
( 3.2 / 2.6 US/Imp qt)

High beam indicator light 3.4 ÷-

Neutral indicator light 3.4 —
Engine oil capacity 2600 ml

Ch ange Oil pressure indicator light 3.4
( 2.7 / 2.3 US/Imp qt) -
Filter 2900 ml Gear position indicator light 1.1 —

3000 ml
Overhaul NOTE:
( 3.2 / 2.6 US/Imp qt)
E-02: England
Front fork oil type Mixture ratio SAE 1OW/30: A.T.F. = 1 : 1
E-04: France
Front fork oil capacity (each leg) 145 ml E-16: Norway
E-22 28
( 4.90 / 5.11 US/Imp oz) E-22: W. Germany
150 ml E-24: Australia
E-O2 04
( 5.07 / 5.28 US/Imp oz) E-26: Denmark
Brake fluid type E-28: Canada
r
GSX400S
GSX400S is a variation model of GSX400E. The differences from GSX400E are equipped
with sporty fairing and steel ball type steering.
Except for the items in this section, p/ease refer to the section GSX400E for servicing.
CONTENTS
VIEW OF SUZUKI GSX400S 57
SPECIFICATIONS 58
STEERING STEM 60
FAIRING 62
r
GSX400S
GSX400S is a variation model of GSX400E. The differences from GSX400E are equipped
with sporty fairing and steel ball type steering.
Except for the items in this section, p/ease refer to the section GSX400E for servicing.
CONTENTS
VIEW OF SUZUKI GSX400S 57
SPECIFICATIONS 58
STEERING STEM 60
FAIRING 62
57 GSX400S GSX400S 58
VIEW OF SUZUKI GSX400S SPECI Fl CATI ONS

Overall length 2 065 mm
Overall width 710mm
Overall height 1 230 mm
Wheelbase 1 385 mm
Ground clearance 155mm
Dry mass 175 kg
ENGINE
Bore 67.0 mm
Stroke 56.6 mm
3
Compression ratio 10.0:1
Starter system . Electric
Lubrication system Wet sump
RIGHT SIDE
TRANSMISSION
Primary reduction 2.7 14 (76/28)
**
Final reduction 2.750 (44/16)
Gear, ratios, Low 2.46 1 (32/13)
2nd 1.777 (32/18)
3rd 1.380(29/21)
I
4th 1.125 (27/24)
LI 5th 0.96 1 (25/26)
Top 0.851 (23/27)
Drive chain DAIDO D.I.D. 5OUB, 104 links

and after June, 1981 [2.812 (45/16)1
LEFT SIDE
•1
57 GSX400S GSX400S 58
VIEW OF SUZUKI GSX400S SPECI Fl CATI ONS

Overall length 2 065 mm
Overall width 710mm
Overall height 1 230 mm
Wheelbase 1 385 mm
Dry mass 175 kg
ENGINE
Bore 67.0 mm
Stroke 56.6 mm
3
Compression ratio 10.0:1
Starter system . Electric
RIGHT SIDE
TRANSMISSION
**
Gear, ratios, Low 2.46 1 (32/13)
2nd 1.777 (32/18)
3rd 1.380(29/21)
I
4th 1.125 (27/24)
LI 5th 0.96 1 (25/26)
Top 0.851 (23/27)
Drive chain DAIDO D.I.D. 5OUB, 104 links

and after June, 1981 [2.812 (45/16)1
LEFT SIDE
•1
GSX400S 60
STEERING STEM
CHASSIS REMOVAL AND DISASSEMBLY
Front suspension .
Telescopic, oil dampened
Rear suspension Swing arm, oil dampened, spring
5-way adjustable
Caster 62° 00’
Trail 105 mm
Turning radius 2.4 m
Front tire size 3.00S18 4PR
©
ELECTRICAL
Ignition type Transistorized
Ignition timing 20° B.T.D.C. below 1,650 r/min and
40° B.T.D.C. above 3,500 r/min
Spark plug NGK DR8ES-L or
NIPPON DENSO X24ESR-lJ
Battery 12V l2Ah (43.2 kC)/10 Hours
Generator Three-phase A.C. generator
Fuse 15A
CAPACITI ES
Fuel tank including reserve 14.5 L (3.2 Imp gal)
reserve 3.0 L (2.6 In’ip qt)
Engine oil when changing 2.6 L (2.3 Imp qt)
Front fork oil 145 ml (5.11 Imp oz) in each leg
Handlebar clamp
® Steering stem bearing (Lower)
© Steering stem lower bracket
Tightening torque
N.m kg-rn
12—20 1.2—2.0
© 36—52 3.6—5.2
© 15—25 1.5—2.5
© 20—30 2.0—3.0
© 25—40 2.5—4.0
GSX400S 60
STEERING STEM
CHASSIS REMOVAL AND DISASSEMBLY
Front suspension .
Telescopic, oil dampened
Rear suspension Swing arm, oil dampened, spring
5-way adjustable
Caster 62° 00’
Trail 105 mm
Front tire size 3.00S18 4PR
©
ELECTRICAL
Ignition timing 20° B.T.D.C. below 1,650 r/min and
40° B.T.D.C. above 3,500 r/min
Spark plug NGK DR8ES-L or
NIPPON DENSO X24ESR-lJ
Battery 12V l2Ah (43.2 kC)/10 Hours
Generator Three-phase A.C. generator
Fuse 15A
CAPACITI ES
Fuel tank including reserve 14.5 L (3.2 Imp gal)
reserve 3.0 L (2.6 In’ip qt)
Engine oil when changing 2.6 L (2.3 Imp qt)
Front fork oil 145 ml (5.11 Imp oz) in each leg
Handlebar clamp
© Steering stem lower bracket
Tightening torque
N.m kg-rn
12—20 1.2—2.0
© 36—52 3.6—5.2
© 15—25 1.5—2.5
© 20—30 2.0—3.0
© 25—40 2.5—4.0
9
61 GSX400S GSX400S 62
FAIRING
• For inspection and adjustment, please refer to
the page 6-36 through 6-41 of GSX25O
service manual.
• Take the following steps for mounting the
handlebars on the steering stem upper
bracket.
HANDLEBARS
Secure the each handlebars clamp in such a

way that the clearances ® ahead of and behind
the handlebars are equalized.
L Tightening torque
12—20N.m
(1.2 2.0 kg-rn)
—
Steering stem upper bracket
REMOVAL • Loosen two bolts 2 located right and left

• Loosen a bolt (I) located under fairing. sides of fairing and remove fairing.
I;
9
61 GSX400S GSX400S 62
FAIRING
• For inspection and adjustment, please refer to
the page 6-36 through 6-41 of GSX25O
service manual.
• Take the following steps for mounting the
handlebars on the steering stem upper
bracket.
HANDLEBARS
Secure the each handlebars clamp in such a

way that the clearances ® ahead of and behind
the handlebars are equalized.
L Tightening torque
12—20N.m
(1.2 2.0 kg-rn)
—
Steering stem upper bracket
REMOVAL • Loosen two bolts 2 located right and left

• Loosen a bolt (I) located under fairing. sides of fairing and remove fairing.
I;
CONTENTS
VIEW OF SUZUKI GSX400L 65

SPECIFICATIONS 66
FUEL SYSTEM 68
COMBINATION METER 69
LAMPS 72
FRONT WHEEL 74
STEERING STEM 75
FRONT BRAKE 76
WIRING DIAGRAM 80
WIRE ROUTING 83
CABLE ROUTING 86
SERVICE DATA 87
CONTENTS
VIEW OF SUZUKI GSX400L 65

SPECIFICATIONS 66
FUEL SYSTEM 68
COMBINATION METER 69
LAMPS 72
FRONT WHEEL 74
STEERING STEM 75
FRONT BRAKE 76
WIRING DIAGRAM 80
WIRE ROUTING 83
CABLE ROUTING 86
SERVICE DATA 87
65 GSX400L GSX400L 66
VIEW OF SUZUKI GSX400L SPECI Fl CATI ONS

Overall length 2090mm
Overall width
Overall height 1245mm
Wheelbase 1385mm
Ground clearance
Dry mass
ENGINE
Bore 67.0 mm
Stroke 56.6 mm
3
Starter system Electric
J
TRANSMI SSI ON
RIGHT SIDE Clutch Wet multi-plate type
**Final reduction 2.687 (43/16)
Gear ratios, Low 2.461 (32/13)
2nd 1.777 (32/18)
3rd 1.380(29/21)
4th 1.125 (27/24)
5th 0.961 (25/26)
Top 0.851 (23/27)
**Drive chain DAIDO D.l.D. 5OUB, 104 links
**Modifications of Rear sprocket and Drive chain for

manufactured on and after June, 1981 12.562 (41/16)
L102 links
LEFT SIDE
I
65 GSX400L GSX400L 66
VIEW OF SUZUKI GSX400L SPECI Fl CATI ONS

Overall length 2090mm
Overall width
Overall height 1245mm
Wheelbase 1385mm
Ground clearance
Dry mass
ENGINE
Bore 67.0 mm
Stroke 56.6 mm
3
J
TRANSMI SSI ON
RIGHT SIDE Clutch Wet multi-plate type
**Final reduction 2.687 (43/16)
2nd 1.777 (32/18)
3rd 1.380(29/21)
4th 1.125 (27/24)
5th 0.961 (25/26)
Top 0.851 (23/27)
**Drive chain DAIDO D.l.D. 5OUB, 104 links
**Modifications of Rear sprocket and Drive chain for

manufactured on and after June, 1981 12.562 (41/16)
L102 links
LEFT SIDE
I
67 GSX400L GSX400L 68
FUEL SYSTEM
CHASSIS FUEL COCK
Front suspension oil dampened The construction of the diaphragm type auto
Rear suspension arm, oil dampened, cock is shown at right. When the engine is not
spring 5-way adjustable running with the l,er in the ON or RES posi
Steering angle 42° (right & left) tion, the valve is kept in the closed position by
Caster 600 30’ applying pressure utilizing a spring so that no
Trail ..123mm fuel will flow to the carburetors. When the
Turning radius .2.4m engine is engaged, a negative pressure is
Front brake Disc brake generated in the diaphragm chamber through
Rear brake Internal expanding the vacuum (negative pessure) pipe which is
Front tire size connected to the carburetors, and builds up a
Rear tire size negative pressure which is higher than the spring
Front tire presure pressure so that the diaphragm is forced to open
)
2 the valve and thus allow the fuel to flow to the
carburetors. When the lever is set at the PRI
ELECTRICAL (which stands for priming to supply the fuel to
Ignition type Transistorized the carburetors) position, the fuel flows to the
Ignition timing 20° B.T.D.C. below 1 650 r/min and carburetors not via the diaphragm unit but
400 B.T.D.C. above 3 500 r/min directly through the RES (reserve) pipe.
Spark plug NGK DR8ES-L or ON: Normally used. Functions as auto
NIPPON DENSO X24ESR-U cock.
Battery 12V 43.2 kC (l2Ah)/1OHR RES: Reserve fuel is used. Functions as auto
Generator Three-phase A.C. generator cock.
Fuse 15A PRI: Fuel is directly supplied. Does not
Headlight 12V45/40W function as auto cock.
For France and West Germany The PRI position is used when the carburetors
12V 45/45W have little or no fuel, for example, when filling 1. Spring 5. Vacuum pipe
For England the fuel tank for the first time, or when the 2. Valve 6. To carburetor
Tail/Brake light 12V5/21W motorcycle has been left unused for a long time, 3. Fuel tank 7. Negative pressure from
4. Diaphragm carburetor
Turn signal light 12V21W or when the carburetors have been disassembled
8. Priming passage
Parking light 12V3.4W and repaired. Shift the lever to the ON position
For England when the engine begins to run smoothly.
12V 4W
For France and West Germany
Speedometer light 12V 3.4W
Tachometer light 12V 3.4W
Neutral indicator light . 12V 3.4W
High beam indicator light 12V 3.4W
Turn signal indicator light 12V 3.4W
Oil pressure indicator light 12V 3.4W
CAPACITIES
Fuel tank including reserve 11 L (2.4 Imp gal)
reserve 2.0 L (1.8 Imp qt.)
Engine oil when changing 2.6 L (2.3 Imp qt.)
Front fork oil 145 ml (5.11 Impoz.)
*
67 GSX400L GSX400L 68
FUEL SYSTEM
CHASSIS FUEL COCK
Front suspension oil dampened The construction of the diaphragm type auto
Rear suspension arm, oil dampened, cock is shown at right. When the engine is not
spring 5-way adjustable running with the l,er in the ON or RES posi
Steering angle 42° (right & left) tion, the valve is kept in the closed position by
Caster 600 30’ applying pressure utilizing a spring so that no
Trail ..123mm fuel will flow to the carburetors. When the
Turning radius .2.4m engine is engaged, a negative pressure is
Front brake Disc brake generated in the diaphragm chamber through
Rear brake Internal expanding the vacuum (negative pessure) pipe which is
Front tire size connected to the carburetors, and builds up a
Rear tire size negative pressure which is higher than the spring
Front tire presure pressure so that the diaphragm is forced to open
)
2 the valve and thus allow the fuel to flow to the
carburetors. When the lever is set at the PRI
ELECTRICAL (which stands for priming to supply the fuel to
Ignition type Transistorized the carburetors) position, the fuel flows to the
Ignition timing 20° B.T.D.C. below 1 650 r/min and carburetors not via the diaphragm unit but
400 B.T.D.C. above 3 500 r/min directly through the RES (reserve) pipe.
Spark plug NGK DR8ES-L or ON: Normally used. Functions as auto
NIPPON DENSO X24ESR-U cock.
Battery 12V 43.2 kC (l2Ah)/1OHR RES: Reserve fuel is used. Functions as auto
Generator Three-phase A.C. generator cock.
Fuse 15A PRI: Fuel is directly supplied. Does not
Headlight 12V45/40W function as auto cock.
For France and West Germany The PRI position is used when the carburetors
12V 45/45W have little or no fuel, for example, when filling 1. Spring 5. Vacuum pipe
For England the fuel tank for the first time, or when the 2. Valve 6. To carburetor
Tail/Brake light 12V5/21W motorcycle has been left unused for a long time, 3. Fuel tank 7. Negative pressure from
4. Diaphragm carburetor
Turn signal light 12V21W or when the carburetors have been disassembled
8. Priming passage
Parking light 12V3.4W and repaired. Shift the lever to the ON position
For England when the engine begins to run smoothly.
12V 4W
For France and West Germany
Neutral indicator light . 12V 3.4W
CAPACITIES
Fuel tank including reserve 11 L (2.4 Imp gal)
reserve 2.0 L (1.8 Imp qt.)
Front fork oil 145 ml (5.11 Impoz.)
*
69 GSX400L GSX400L 70
COMBINATION METER
REMOVAL Remove mounting bolts and take off com
Remove seat. bination meter.
Set the fuel cock lever “ON” or “RES” position DISASSEMBLY

and remove fuel and vacuum hoses.
Take off fuel tank.
Disconnect combination meter lead wires from

main wiring harness.
I
,
Disconnect speedometer cable and tachometer

cable.
69 GSX400L GSX400L 70
COMBINATION METER
REMOVAL Remove mounting bolts and take off com
Remove seat. bination meter.
Set the fuel cock lever “ON” or “RES” position DISASSEMBLY

and remove fuel and vacuum hoses.
Take off fuel tank.
Disconnect combination meter lead wires from

main wiring harness.
I
,
Disconnect speedometer cable and tachometer

cable.
LLGX4OOL GSX400L 72
INSPECTION
LAMPS
HEADLIGHT
Adjust the headlight vertically after reassembling.
TAIL/BRAKE LIGHT
CAUTION: Do not overtighten the lens fitting screws.
Using pocket tester, check the Continuity

between lead wires in the above diagram.
If the continuity measured is incorrect, replace
the respective part.
NOTE:
When making this test, it is not necessary
to remove the combination meter.
I
LLGX4OOL GSX400L 72
INSPECTION
LAMPS
HEADLIGHT
Adjust the headlight vertically after reassembling.
TAIL/BRAKE LIGHT
CAUTION: Do not overtighten the lens fitting screws.
Using pocket tester, check the Continuity

between lead wires in the above diagram.
If the continuity measured is incorrect, replace
the respective part.
NOTE:
When making this test, it is not necessary
to remove the combination meter.
I
73 GSX400L GSX400L 74
FRONT WHEEL
TURN SIGNAL LIGHT
CONSTRUCTI ON
L CAUTION: Do not overtighten the lens fitting screws.
REAR
40
iD Axle spacer
® Cover
® Bearing spacer
® Bearing
® Spacer
® Bearing
® Front brake disc
® Dust seal
® Speedometer gear box
Tightening torque
N•m kg-rn lb-ft
36 — 52 3.6 — 5.2 26.0 — 37.5
FRONT --
if0—18.O
15—25 1.5—2.5
73 GSX400L GSX400L 74
FRONT WHEEL
TURN SIGNAL LIGHT
CONSTRUCTI ON
L CAUTION: Do not overtighten the lens fitting screws.
REAR
40
iD Axle spacer
® Cover
® Bearing spacer
® Bearing
® Spacer
® Bearing
® Front brake disc
® Dust seal
® Speedometer gear box
Tightening torque
N•m kg-rn lb-ft
36 — 52 3.6 — 5.2 26.0 — 37.5
FRONT --
if0—18.O
15—25 1.5—2.5
75 GSX400L GSX400L 76
STEERING STEM FRONT BRAKE

MASTER CYLINDER
Handlebar clamp
® Steering stem lower bracket
® Front fork cover
Tightening torque
N-rn kg-m lb-ft
® 12—20 1.2 —2.0 8.5— 14.5
® 36 — 52 3.6 — 5.2 26.0 — 37.5
© 15 — 25 1.5 — 2.5 1 1.0 — 18.0
© 20 —30 2.0 — 3.0 14.5 —21.5
© 40 — 50 4.0 — 5.0 29.5 — 36.0
® 25 —40 2.5 — 4.0 18.0 — 29.0
75 GSX400L GSX400L 76
STEERING STEM FRONT BRAKE

MASTER CYLINDER
Handlebar clamp
® Steering stem lower bracket
® Front fork cover
Tightening torque
N-rn kg-m lb-ft
® 12—20 1.2 —2.0 8.5— 14.5
® 36 — 52 3.6 — 5.2 26.0 — 37.5
© 15 — 25 1.5 — 2.5 1 1.0 — 18.0
© 20 —30 2.0 — 3.0 14.5 —21.5
© 40 — 50 4.0 — 5.0 29.5 — 36.0
® 25 —40 2.5 — 4.0 18.0 — 29.0
77 GSX400L GSX400L 78
MASTER CYLINDER REMOVAL

AND DISASSEMBLY
Take off front brake light switch and remove Pull out the reservoir and 0 ring.
front brake lever.
Place a rag underneath the union bolt on the Draw out dust seal boot.
master cylinder to catch spilled drops of brake
fluid. Unscrew the union bolt and disconnect
the brake hose/master cylinder joint.
CAUTION:
Completely wipe off any brake fluid
adhering to any part of motorcycle.
The fluid react chemically with paint,
plastics, rubber matericals, etc.
I I
Remove master cylinder assembly after remov Remove circlip by using special tool.
ing two fitting bolts.
09900-06108 Snapringpliers
]
Remove filler cap and drain brake fluid. Pull out piston, primary cup and spring.
L
77 GSX400L GSX400L 78
MASTER CYLINDER REMOVAL

AND DISASSEMBLY
Take off front brake light switch and remove Pull out the reservoir and 0 ring.
front brake lever.
Place a rag underneath the union bolt on the Draw out dust seal boot.
master cylinder to catch spilled drops of brake
fluid. Unscrew the union bolt and disconnect
the brake hose/master cylinder joint.
CAUTION:
Completely wipe off any brake fluid
adhering to any part of motorcycle.
The fluid react chemically with paint,
plastics, rubber matericals, etc.
I I
Remove master cylinder assembly after remov Remove circlip by using special tool.
ing two fitting bolts.
09900-06108 Snapringpliers
]
Remove filler cap and drain brake fluid. Pull out piston, primary cup and spring.
L
GSX400L 80
79 GSX400L
WIRING DIAGRAM
For ENGLAND
MASTER CYLINDER INSPECTION 2
ZO
c=z
Inspect the cylinder bore wall for any scratch 2
0
2
or other damage. C— I
C
2
os_n
2
I
C,
Inspect the piston surface for scratch or other

damage.
Inspect the primary cup, secondary cup and
dust seal boot for damage.
>
MASTER CYLINDER REASSEMBLY

Reassemble the master cylinder in the reverse
orders of disassembly and by taking the follow
ing steps:
• — . • .
m
CAUTION:
C
Wash the master cylinder components
with fresh brake fluid before reassembly.
00
Never use cleaning solvent or gasoline to
wash them. o
Apply brake fluid to the cylinder bore

and all the internals to be inserted into
the bore.
When remount the master cylinder to the

OQQG)W
hancilebars, first tighten the clamp bolt for 0
upside as shown. C • • • •
. .
up 0 0. 0. 0.
CAUTION: C
I
Adjust the front brake light switch after
installation.
Bleeding the air after reassembling master
cylinder.
Clearance
A
GSX400L 80
79 GSX400L
WIRING DIAGRAM
For ENGLAND
MASTER CYLINDER INSPECTION 2
ZO
c=z
Inspect the cylinder bore wall for any scratch 2
0
2
or other damage. C— I
C
2
os_n
2
I
C,
Inspect the piston surface for scratch or other

damage.
Inspect the primary cup, secondary cup and
dust seal boot for damage.
>
MASTER CYLINDER REASSEMBLY

Reassemble the master cylinder in the reverse
orders of disassembly and by taking the follow
ing steps:
• — . • .
m
CAUTION:
C
Wash the master cylinder components
with fresh brake fluid before reassembly.
00
Never use cleaning solvent or gasoline to
wash them. o
Apply brake fluid to the cylinder bore

and all the internals to be inserted into
the bore.
When remount the master cylinder to the

OQQG)W
hancilebars, first tighten the clamp bolt for 0
upside as shown. C • • • •
. .
up 0 0. 0. 0.
CAUTION: C
I
Adjust the front brake light switch after
installation.
Bleeding the air after reassembling master
cylinder.
Clearance
A
-J
CD
CD WIRE COLOR
B Black Br/R • Brown with Red tracer
><
C)) BI Blue GIBI Green with Blue tracer
Br Brown GIW Green with White tracer
G Green G/Y • • Green with Yellow tracer
A ENGINE KILL SWITCH Gr Gray 01W • • Orange with White tracer
TACHOMETER LIGHT B STARTER BUtTON IGNITION COIL
C FRONT BRAKE LIGHT SWITCH Lbl Light blue R/B • Red with Black tracer
Lg Light green WIBI • White with Blue tracer
T
B
TURN SIGNAL NDICAT0a LIGHT
if 0.. Orange WIG • White with Green tracer
P OIL PRESSURE INDICATOR LIGHT R.... Red WIR • White with Red tracer
N NEUTRAL INDICATOR LIGHT W White White with Yellow tracer
W/Y •
Y Yellow V fBI • Yellow with Blue tracer
8/W BlackwithWhitetracer Y/G Yellow with Green tracer
BATTERY B/Y Black with Yellow tracer
TURN SIGNAL LIGHT (RI
FRONT TURN SIGNAL LIGHT ILl
TURN SIGNAL LIGHT ILl
STARTER DISCONNECT SWITCH
z
C-)
0
U-
WIRE COLOR
B Black
•
BrIR • Brown with Red tracer
B STARTER BUTTON
BI Blue • G/BI • Green with Blue tracer
Br • Brown GIW • Green with White tracer
TURN SIGNAL INDICATOR LIGHT G Green • GIY • Green with Yellow tracer
B HIGH BEAN INDICATOR LIGHT
P OIL PRESSURE INDICATOR LIGII Gr Gray • 0/W • Orange with White tracer
Lbl Light blue
• • • RIB • Red with Black tracer
Lg Light green
• • W/Bl • White with Blue tracer
I
0.... Orange White with Green tracer
j I I R.... Red
WIG
W/R
•
•
.
White with Red tracer
SPEEDONETER W White W/Y • White with Yellow tracer
Y Yellow
... Y/Bl • Yellow with Blue tracer
BIW Black with White tracer
. , Y/G • Yellow with Green tracer
FRONT TURN SIGNAL LIGHT (RI BATTERY
REAR BRAKE LIGHT SWITCH REAR TURN SIGNAL LIGHT WI
HEADLIGHT LIGHT
>-
z
TURN SIGNAL ‘LIGHT
ILl
uJ REAR TURN SIGNAL LIGHT ILl
I
U)
w
SIGNAL GENERATOR
OIL PRESSURE SWITCH
STARTER NOTOR
z STARTER RELAY
FUSE ISAI
REGULATOR/RECTIFIER
w AC. GENERATOR
IGNITOR
-J C.) TURN SIGNAL RELAY
CD
CD z
(o
C.D U
I
0
U-
-J
CD
CD WIRE COLOR
><
C)) BI Blue GIBI Green with Blue tracer
Br Brown GIW Green with White tracer
A ENGINE KILL SWITCH Gr Gray 01W • • Orange with White tracer
TACHOMETER LIGHT B STARTER BUtTON IGNITION COIL
C FRONT BRAKE LIGHT SWITCH Lbl Light blue R/B • Red with Black tracer
Lg Light green WIBI • White with Blue tracer
T
B
TURN SIGNAL NDICAT0a LIGHT
if 0.. Orange WIG • White with Green tracer
P OIL PRESSURE INDICATOR LIGHT R.... Red WIR • White with Red tracer
N NEUTRAL INDICATOR LIGHT W White White with Yellow tracer
W/Y •
Y Yellow V fBI • Yellow with Blue tracer
8/W BlackwithWhitetracer Y/G Yellow with Green tracer
BATTERY B/Y Black with Yellow tracer
TURN SIGNAL LIGHT (RI
FRONT TURN SIGNAL LIGHT ILl
TURN SIGNAL LIGHT ILl
STARTER DISCONNECT SWITCH
z
C-)
0
U-
WIRE COLOR
B Black
•
BrIR • Brown with Red tracer
B STARTER BUTTON
BI Blue • G/BI • Green with Blue tracer
Br • Brown GIW • Green with White tracer
TURN SIGNAL INDICATOR LIGHT G Green • GIY • Green with Yellow tracer
B HIGH BEAN INDICATOR LIGHT
P OIL PRESSURE INDICATOR LIGII Gr Gray • 0/W • Orange with White tracer
Lbl Light blue
• • • RIB • Red with Black tracer
Lg Light green
• • W/Bl • White with Blue tracer
I
0.... Orange White with Green tracer
j I I R.... Red
WIG
W/R
•
•
.
White with Red tracer
SPEEDONETER W White W/Y • White with Yellow tracer
Y Yellow
... Y/Bl • Yellow with Blue tracer
BIW Black with White tracer
. , Y/G • Yellow with Green tracer
FRONT TURN SIGNAL LIGHT (RI BATTERY
REAR BRAKE LIGHT SWITCH REAR TURN SIGNAL LIGHT WI
HEADLIGHT LIGHT
>-
z
TURN SIGNAL ‘LIGHT
ILl
uJ REAR TURN SIGNAL LIGHT ILl
I
U)
w
SIGNAL GENERATOR
OIL PRESSURE SWITCH
STARTER NOTOR
z STARTER RELAY
FUSE ISAI
REGULATOR/RECTIFIER
w AC. GENERATOR
IGNITOR
-J C.) TURN SIGNAL RELAY
CD
CD z
(o
C.D U
I
0
U-
m c,J
x
C) —
CD
Cl)
Clamp Clamp
-4’
0
-‘0
C
m -
Cl)
- z
m
-<
Clamp Clamp
Main wiring harness Gear position indicator light harness
Left handlebar switch harness
ground
co
/
0
Clamp Transistor unit

- /
NTurn signal relay
/
Starter relay
Guide
Clamp
Clamp -4i
ch lead) 0
-I
Brake hose
Neutral indicato
oO
m
g harness to C’,
m
Make sure that the
Clamp—/ Clutch cable should not block air deane
47 Clamp
Tachometer cable \ To meter inlet.
To right handlebar switch z
-<
To left handlebar switch
Wiring harness Wiring harness
Clamp (Neutral indicator lead
—Brake hose
clamp
Regulator/Rectifier
0 Transistor unit
Clamping direction “k— - Ground
Neutral
indicator lead Ground
Clamp
Fuse
Brake hose
Turn signal relay
Clamp
Tachometer cable Clamp (generator lead) (Signal generator lead)
Clamp
Starter motor lead ‘\ o battery holder bolt
To starter relay
(Generator lead 0
00
To crankcase bolt
Wiring harness
Battery
Clamp
Secure with battery hollt

m c,J
x
C) —
CD
Cl)
Clamp Clamp
-4’
0
-‘0
C
m -
Cl)
- z
m
-<
Clamp Clamp
Main wiring harness Gear position indicator light harness
Left handlebar switch harness
ground
co
/
0
Clamp Transistor unit

- /
NTurn signal relay
/
Starter relay
Guide
Clamp
Clamp -4i
ch lead) 0
-I
Brake hose
Neutral indicato
oO
m
g harness to C’,
m
Make sure that the
Clamp—/ Clutch cable should not block air deane
47 Clamp
Tachometer cable \ To meter inlet.
To right handlebar switch z
-<
To left handlebar switch
Wiring harness Wiring harness
Clamp (Neutral indicator lead
—Brake hose
clamp
Regulator/Rectifier
0 Transistor unit
Clamping direction “k— - Ground
Neutral
indicator lead Ground
Clamp
Fuse
Brake hose
Turn signal relay
Clamp
Tachometer cable Clamp (generator lead) (Signal generator lead)
Clamp
Starter motor lead ‘\ o battery holder bolt
To starter relay
(Generator lead 0
00
To crankcase bolt
Wiring harness
Battery
Clamp
Secure with battery hollt

(0
-J a)
-o
C)
>(
(ID
CD
-c
C-)
4-,
C-, a)
-o
C-)
-c
C.)
4-,
a)
C-,
0
2
I
D
0
a)
U,
0
LU a)
-J
C-)
a)
U,
a)
L.
0.
0
CU
0
4-’
CU
a)
a) U)
, .
0) CU
0
E
CU
C-,
0
-J
>(
(I)
CD
LCD
- EEr - — -
-
(0
-J a)
-o
C)
>(
(ID
CD
-c
C-)
4-,
C-, a)
-o
C-)
-c
C.)
4-,
a)
C-,
0
2
I
D
0
a)
U,
0
LU a)
-J
C-)
a)
U,
a)
L.
0.
0
CU
0
4-’
CU
a)
a) U)
, .
0) CU
0
E
CU
C-,
0
-J
>(
(I)
CD
LCD
- EEr - — -
-
7 GSX400L GSX400L 88
SERVICE DATA
VALVE + GUIDE Unit: mm CAMSHAFT + CYLINDER HEAD Unit: mm (in)
ITEM STANDARD ITEM STANDARD LIMIT
Valve diam. 23 * Cam height 34.650 34.690 34.350
IN.
—
IN.
0.90 ( 1.3642— 1.3657) ( 1.3524)
20 34.650 34.690 34.350
EX.
—
EX
0.78 . (1.3642—1.3657) (1.3524)
* Valve lift 7.0 Camshaft journal oil clearance 0.032 0.066 0.150
IN. IN.&EX. i
—
0.28 ( 0.0013 — 0.0026) ( 0.0059)

7.0 Camshaft journal holder l.D. IN. & EX. 22.012 22.025
EX.
—
0.28 (_0.8666_— 0.867 1

Valve clearance 0.08— 0.13 Camshaft journal O.D. 21.959 — 21.980
IN. & EX. IN. & EX.
(when cold) ( 0.003— 0.005 (_0.8645 — 0.8654)
Valve guide to Valve stem 0.025 0.052 0.090 Camshaft runout 0.10
IN. IN. & EX.
—
clearance ( 0.0010— 0.0020) ( 0.0035) ( 0.004

0.040 0.067 0.100 Cam chain 20 pitch length 157.80
EX.
—
( 0.0016— 0.0026) (0.0039) ( 6.213

Valve guide I.D. 5.500 5.512 Cam chain pin (at arrow “3”)
IN. & EX. 20th pin
—
( 0.2165— 0.2170)
ValvestemO.D. 5.460 5.475 Rocker arm l.D. 12.000— 12.018
IN. IN. & EX.
—
(0.2150—0.2156) ( 0.4724— 0.4731

5.445 5.460 Rocker arm shaft O.D. 11.973 11.984 —
EX. IN. & EX.

—
(0.2144—0.2150) ( 0.4714— 0.4718)

Valve stem runout 0.05 Cylinder head distortion 0.10
—
IN. & EX.

( 0.002 ( 0.004
Valve head thickness 0.5
IN. & EX.
( 0.02
IN. & EX.
( 0.14 *
Only for E-22 Unit: mm (in)
Valve seat width 0.9— 1.1 ITEM STANDARD LIMIT
IN. & EX.
( 0.035 —0.043 33.350 33.390 33.050
Cam height IN.
—
Valve head radial runout 0.03 ( 1.3130— 1.3146) ( 1.3012)

IN. & EX.
( 0.001 33.350 33.390
— 33.050
Valve spring free length EX
INNER 31.9 . (1.3130—1.3146) (1.3012)
(IN.&EX.) ( 1.26 Valve lift 4.8
IN. 0.19
OUTER (
( 1.40 4.8
Valve spring tension 4.4 6.4 kg EX
—
. ( 0.19
(IN. & Ex.) INNER ( 9.7— 14.1 Ibs)
6.5— 8.9 kg
OUTER ( 14.3— 19.6 Ibs)
7 GSX400L GSX400L 88
SERVICE DATA
VALVE + GUIDE Unit: mm CAMSHAFT + CYLINDER HEAD Unit: mm (in)
ITEM STANDARD ITEM STANDARD LIMIT
Valve diam. 23 * Cam height 34.650 34.690 34.350
IN.
—
IN.
0.90 ( 1.3642— 1.3657) ( 1.3524)
20 34.650 34.690 34.350
EX.
—
EX
0.78 . (1.3642—1.3657) (1.3524)
* Valve lift 7.0 Camshaft journal oil clearance 0.032 0.066 0.150
IN. IN.&EX. i
—
0.28 ( 0.0013 — 0.0026) ( 0.0059)

7.0 Camshaft journal holder l.D. IN. & EX. 22.012 22.025
EX.
—
0.28 (_0.8666_— 0.867 1

Valve clearance 0.08— 0.13 Camshaft journal O.D. 21.959 — 21.980
IN. & EX. IN. & EX.
(when cold) ( 0.003— 0.005 (_0.8645 — 0.8654)
Valve guide to Valve stem 0.025 0.052 0.090 Camshaft runout 0.10
IN. IN. & EX.
—
clearance ( 0.0010— 0.0020) ( 0.0035) ( 0.004

0.040 0.067 0.100 Cam chain 20 pitch length 157.80
EX.
—
( 0.0016— 0.0026) (0.0039) ( 6.213

Valve guide I.D. 5.500 5.512 Cam chain pin (at arrow “3”)
IN. & EX. 20th pin
—
( 0.2165— 0.2170)
ValvestemO.D. 5.460 5.475 Rocker arm l.D. 12.000— 12.018
IN. IN. & EX.
—
(0.2150—0.2156) ( 0.4724— 0.4731

5.445 5.460 Rocker arm shaft O.D. 11.973 11.984 —
EX. IN. & EX.

—
(0.2144—0.2150) ( 0.4714— 0.4718)

Valve stem runout 0.05 Cylinder head distortion 0.10
—
IN. & EX.

( 0.002 ( 0.004
Valve head thickness 0.5
IN. & EX.
( 0.02
IN. & EX.
( 0.14 *
Valve seat width 0.9— 1.1 ITEM STANDARD LIMIT
IN. & EX.
( 0.035 —0.043 33.350 33.390 33.050
Cam height IN.
—
Valve head radial runout 0.03 ( 1.3130— 1.3146) ( 1.3012)

IN. & EX.
( 0.001 33.350 33.390
— 33.050
Valve spring free length EX
INNER 31.9 . (1.3130—1.3146) (1.3012)
(IN.&EX.) ( 1.26 Valve lift 4.8
IN. 0.19
OUTER (
( 1.40 4.8
Valve spring tension 4.4 6.4 kg EX
—
. ( 0.19
(IN. & Ex.) INNER ( 9.7— 14.1 Ibs)
6.5— 8.9 kg
OUTER ( 14.3— 19.6 Ibs)
GSX400L GSX400L 90
PISTON + RING + CYLINDER Unit: mm (in)

CONROD + CRANKSHAFT + BALANCER
ITEM 1 STANDARD LIMIT
—
18.040
(0.7089—0.7092) (0.7102)
—
0.30
( 0.004 0.008 )
— ( 0.012
Conrod big end width 22.95 — 23.00
( 0.904 — 0.906
( 0.909—0.911
Conrod big end oil clearance 0.024 — 0.048 0.080
( 0.0009—0.0019) ( 0.0031
Crank pin O.D. 33.976 — 34.000
( 1.3376—_1.3386)
Crankshaft journal oil clearance 0.020 — 0.044 0.080
( 0.0008— 0.0017) ( 0.0031
Crankshaft journal O.D. 31.976 — 32.000
( 1.2589— 1.2598)
Crankshaft thrust bearing thickness 2.95 — 2.98 2.85
( 0.116—0.117 ) ( 0.112
( 0.002
Ba lancer journal oil clearance 0.020 0.044
—
0.080
(0.0008—0.0017) ( 0.0031
—
( 1.2592— 1.2598)
OIL PUMP
ITEM r STANDARD LIMIT
Oil pump reduction ratio
Oil pressure (at 60° C, 140° F)
T 2.07 1 ( 76 / 28 x 29 / 38
Above
3.0 2
kg/cm
( 43 psi)
5.5 2
kg/cm
Below 78 psi)
at 3000 r/min.
GSX400L GSX400L 90
PISTON + RING + CYLINDER Unit: mm (in)

CONROD + CRANKSHAFT + BALANCER
ITEM 1 STANDARD LIMIT
—
18.040
(0.7089—0.7092) (0.7102)
—
0.30
( 0.004 0.008 )
— ( 0.012
Conrod big end width 22.95 — 23.00
( 0.904 — 0.906
( 0.909—0.911
Conrod big end oil clearance 0.024 — 0.048 0.080
( 0.0009—0.0019) ( 0.0031
Crank pin O.D. 33.976 — 34.000
( 1.3376—_1.3386)
Crankshaft journal oil clearance 0.020 — 0.044 0.080
( 0.0008— 0.0017) ( 0.0031
Crankshaft journal O.D. 31.976 — 32.000
( 1.2589— 1.2598)
Crankshaft thrust bearing thickness 2.95 — 2.98 2.85
( 0.116—0.117 ) ( 0.112
( 0.002
Ba lancer journal oil clearance 0.020 0.044
—
0.080
(0.0008—0.0017) ( 0.0031
—
( 1.2592— 1.2598)
OIL PUMP
ITEM r STANDARD LIMIT
Oil pump reduction ratio
Oil pressure (at 60° C, 140° F)
T 2.07 1 ( 76 / 28 x 29 / 38
Above
3.0 2
kg/cm
( 43 psi)
5.5 2
kg/cm
Below 78 psi)
at 3000 r/min.
91 GSX400L GSX400L 92
CLUTCH Unit: mm (in) TRANSMISSION + DRIVE CHAIN Unit: mm (in)

Clutch cable play 4.0 Primary reduction ratio 2.7 14 ( 76 / 28
( 0.16
Final reduction ratio 2.687 ( 43 / 16
Clutch release screw ¼ — 1/2
Gear ratios Low 2.461 ( 32 / 13
turn back
2nd 1.777 ( 32 / 18
Drive plate thickness 2.9 3.1
— 2.6
( 0.11—0.12 ) ( 0.10 3rd 1.380 ( 29 / 21
Drive plate claw width 15.8 — 16.0 15.0 4th 1.125 ( 27 / 24
( 0.62 — 0.63 ) ( 0.59 5th 0.961 ( 25 / 26
Driven plate thickness 1.60 ± 0.06 23 27
Top 0.851 ( /
( 0.063± 0.002
Driven plate distortion 0.1
clearance ( 0.004 — 0.012 ) ( 0.020
(0.004
Shift fork groove width 5.5 — 5.6
Clutch spring free length 38.4
( 0.217—0.220
( 1.51
Shift fork thickness 5.3 — 5.4
( 0.209—0.213
Countershaft length 1 14.7 ±
(Low to 2nd) ( 4.52 ± 0.004
Drive chain
Type D.l.D.: 50 UB
Links 104
324.3
20 pitch length
.
( 12.77
Drive chain slack 20 30 —
( 0.8—1.2
91 GSX400L GSX400L 92
CLUTCH Unit: mm (in) TRANSMISSION + DRIVE CHAIN Unit: mm (in)

Clutch cable play 4.0 Primary reduction ratio 2.7 14 ( 76 / 28
( 0.16
Clutch release screw ¼ — 1/2
Gear ratios Low 2.461 ( 32 / 13
turn back
2nd 1.777 ( 32 / 18
Drive plate thickness 2.9 3.1
— 2.6
( 0.11—0.12 ) ( 0.10 3rd 1.380 ( 29 / 21
Drive plate claw width 15.8 — 16.0 15.0 4th 1.125 ( 27 / 24
( 0.62 — 0.63 ) ( 0.59 5th 0.961 ( 25 / 26
Driven plate thickness 1.60 ± 0.06 23 27
Top 0.851 ( /
( 0.063± 0.002
Driven plate distortion 0.1
clearance ( 0.004 — 0.012 ) ( 0.020
(0.004
Shift fork groove width 5.5 — 5.6
Clutch spring free length 38.4
( 0.217—0.220
( 1.51
Shift fork thickness 5.3 — 5.4
( 0.209—0.213
Countershaft length 1 14.7 ±
(Low to 2nd) ( 4.52 ± 0.004
Drive chain
Type D.l.D.: 50 UB
Links 104
324.3
20 pitch length
.
( 12.77
Drive chain slack 20 30 —
( 0.8—1.2
93 GSX400L GSX400L 94
CARBURETOR Unit: mm (in) ELECTRICAL Unit: mm (in)
ITEM
[ SPECIFICATION ITEM SPECIFICATION
Ignition timing 20° B.T.D.C. Below 1650 ± 100 r/min and
E—02, and the others Only for E-22 Only for E-28
L 35° B.T.D.C. Above 3500 ± 100 r/min.
Carburetor type MIKUNI BS34SS - 4—
20° B.T.D.C. Below 1650 ± 100 r/min and Transistorized
Bore size 34 (1.34) — 4-- 40° B.T.D.C. Above 3500 ± 100 r/min. ignition type
44202 44220 Firingorder 1,2
l.D. No. 44201
Spark plug I NGK: DR8ES-L
Idle r/min. 1100 ± 50r/min. 4-- 4-- Type
N. D.: X24ESR-U
Fuel level 5.0 ± 0.5 0.6 0.7
Gap
—
(0.20 0.02)
‘-
± 0.028
4- 4-
(__0.024 —
Float height 22.4 ± 1.0 Spark performance Over 8 (0.3) at 1 atm

(0.88 ± 0.04) 4- 4-
Contact point gap 0.30 0.40 —
E-28
Main jet (M.J.) #117.5 4-- 4-- - ( 0.012 0.016
—
Main air jet (M.A.J.) 0.6 -

Dwell angle KOKUSAN 190° E-28
•1 Condenser capacity KOKUSAN_[
Jet needle (J.N.) 5D69-4 4- 4- 0.25 ± 0.03 F E-28
Br —B/W Except for
Needle jet (N.J.) 0-9 P-i P-2 —
G/W—B/W E-28
r
Pilot jet (P.J.) #42.5 Ignition doil resistance 01W W or B/Y Except for
Primary
—
I
Approx. 3.5 4.5 &2 E-28
(B.P.) 0.9, 0.8, 0.8
—
By pass 4- 4-
Plug cap W or B/Y Except for

Secondary
—
Pilot outlet (P.O.) 0.8 4- 4- .
Approx. 23 — 25 k2 E-28
Valve seat (V.S.) 2.0 4-- 4-
01W W or B
Primary
—
Approx. E-28
Starter jet (G.S.) #32.5 4-- 4- 3 — 5
Plug cap W or B
(P.S.) Secondary
—
Pilot screw 11/2 4- 4-- E-28

Approx.
-
21 — 25 kcz
Pilotairjet (P.A.J.) #125 4-
Generator No-Load voltage More than 75V (AC) at 5000 r/min.
Throttle calbe play 0.5 — 1.0 4- Regulated voltage 14— 15V at 5000 r/min.
(0.02 0.04) 4-
I I
Starter motor
—
9
:1 Brush length N.D. I Limit:
( 0.4
Commutator under cut 0.2

Limit:
( 0.008)
Starter relay resistance Approx. 3 4 2 —
Battery - Type I YB1OL-A2

designation I
Standard elec
trolyte S.G.
1.28 at 20°C (68°F)
Fuse ize Main iSA
93 GSX400L GSX400L 94
CARBURETOR Unit: mm (in) ELECTRICAL Unit: mm (in)
ITEM
[ SPECIFICATION ITEM SPECIFICATION
Ignition timing 20° B.T.D.C. Below 1650 ± 100 r/min and
E—02, and the others Only for E-22 Only for E-28
L 35° B.T.D.C. Above 3500 ± 100 r/min.
Carburetor type MIKUNI BS34SS - 4—
20° B.T.D.C. Below 1650 ± 100 r/min and Transistorized
Bore size 34 (1.34) — 4-- 40° B.T.D.C. Above 3500 ± 100 r/min. ignition type
44202 44220 Firingorder 1,2
l.D. No. 44201
Spark plug I NGK: DR8ES-L
Idle r/min. 1100 ± 50r/min. 4-- 4-- Type
N. D.: X24ESR-U
Fuel level 5.0 ± 0.5 0.6 0.7
Gap
—
(0.20 0.02)
‘-
± 0.028
4- 4-
(__0.024 —
Float height 22.4 ± 1.0 Spark performance Over 8 (0.3) at 1 atm

(0.88 ± 0.04) 4- 4-
Contact point gap 0.30 0.40 —
E-28
Main jet (M.J.) #117.5 4-- 4-- - ( 0.012 0.016
—
Main air jet (M.A.J.) 0.6 -

Dwell angle KOKUSAN 190° E-28
•1 Condenser capacity KOKUSAN_[
Jet needle (J.N.) 5D69-4 4- 4- 0.25 ± 0.03 F E-28
Br —B/W Except for
Needle jet (N.J.) 0-9 P-i P-2 —
G/W—B/W E-28
r
Pilot jet (P.J.) #42.5 Ignition doil resistance 01W W or B/Y Except for
Primary
—
I
Approx. 3.5 4.5 &2 E-28
(B.P.) 0.9, 0.8, 0.8
—
By pass 4- 4-
Plug cap W or B/Y Except for

Secondary
—
Pilot outlet (P.O.) 0.8 4- 4- .
Approx. 23 — 25 k2 E-28
Valve seat (V.S.) 2.0 4-- 4-
01W W or B
Primary
—
Approx. E-28
Starter jet (G.S.) #32.5 4-- 4- 3 — 5
Plug cap W or B
(P.S.) Secondary
—
Pilot screw 11/2 4- 4-- E-28

Approx.
-
21 — 25 kcz
Pilotairjet (P.A.J.) #125 4-
Generator No-Load voltage More than 75V (AC) at 5000 r/min.
Throttle calbe play 0.5 — 1.0 4- Regulated voltage 14— 15V at 5000 r/min.
(0.02 0.04) 4-
I I
Starter motor
—
9
:1 Brush length N.D. I Limit:
( 0.4
Commutator under cut 0.2

Limit:
( 0.008)
Starter relay resistance Approx. 3 4 2 —
Battery - Type I YB1OL-A2

designation I
Standard elec
trolyte S.G.
1.28 at 20°C (68°F)
Fuse ize Main iSA
95 GSX400L 96
GSX400L
BRAKE + WHEEL Unit: mm (in) SUSPENSION Unit: mm (in)
Rear brake pedal free travel 20 — 30 Front fork stroke 140

( 0.8 — 1.2 ) I
Rear brake pedal height 20 Front fork spring free length 506
( 0.8 ( 19.9
Brake drum l.D.
160.7 Front fork oil level 207
Rear
( 6.33 ( 8.1
__________________
]____________________
Brake lining thickness 1.5 Rear wheel travel 100

0.06 ( 3.9
5.0 0.1 4.5 Swinging arm pivot shaft runout 0.3

Brake disc thickness Front
±
( 0.20 ± 0.004 ) ( 0.18 ( 0.012)
Brakediscrunout 0.30
( 0.012
FUEL + OIL
Master cylinder bore 14.000— 14.043
Front ITEM SPECIFICATION
(0.5512—0.5529)
Master cylinder piston diam. 13.957 — 13.984 Fuel type Use gasoline with an octane number of 90
Front or higher (Research Method), preferably
( 0.5495 — 0.5506
unleaded or low-lead.
Brake caliper cylinder bore 42.850 42.926—
Front Fuel tank including reserve 11 L

( 1.6870— 1.6900)
( 2.9 / 2.4 US/Imp gal)
42.770 42.820 —
Rear reserve 2.0 L

( 1.6839— 1.6858)
( 2.1 / 1.8 US/Imp gal)
Wheel rim runout • 2.0
Axial 0.08 Engine oil type SAE 1OW/40
(
2.0 Engine oil capacity 2600 ml
Radial Ch ange
( 0.08 Cu
( 2.7 / 2.3 US/Imp qt)
Wheel axle runout 0.25 Filter 2900 ml

Front change ( 3.1 / 2.6 US/Imp qt)
( 0.010
0.25 3000 ml
Rear ( o.oo Overhaul
( 3.2 / 2.6 US/Imp qt)
ii
Tire size Front fork oil type Mixture ratio SAE 1OW/30: A.T.F. = 1 : 1
Front 3.60S19 4PR
Front fork oil capacity (each leg) 145 ml
( 4.90 / 5.11 US/Imp oz)
Rear 4.60S164PR
Brake fluid type
Tire tread depth 1.6
Front 0.06
(
2.0
Rear 0.08
(
95 GSX400L 96
GSX400L
Rear brake pedal free travel 20 — 30 Front fork stroke 140

( 0.8 — 1.2 ) I
Rear brake pedal height 20 Front fork spring free length 506
( 0.8 ( 19.9
Brake drum l.D.
160.7 Front fork oil level 207
Rear
( 6.33 ( 8.1
__________________
]____________________
Brake lining thickness 1.5 Rear wheel travel 100

0.06 ( 3.9
5.0 0.1 4.5 Swinging arm pivot shaft runout 0.3

Brake disc thickness Front
±
( 0.20 ± 0.004 ) ( 0.18 ( 0.012)
Brakediscrunout 0.30
( 0.012
FUEL + OIL
Master cylinder bore 14.000— 14.043
Front ITEM SPECIFICATION
(0.5512—0.5529)
Master cylinder piston diam. 13.957 — 13.984 Fuel type Use gasoline with an octane number of 90
Front or higher (Research Method), preferably
( 0.5495 — 0.5506
Brake caliper cylinder bore 42.850 42.926—
Front Fuel tank including reserve 11 L

( 1.6870— 1.6900)
( 2.9 / 2.4 US/Imp gal)
42.770 42.820 —
Rear reserve 2.0 L

( 1.6839— 1.6858)
( 2.1 / 1.8 US/Imp gal)
Wheel rim runout • 2.0
Axial 0.08 Engine oil type SAE 1OW/40
(
2.0 Engine oil capacity 2600 ml
Radial Ch ange
( 0.08 Cu
( 2.7 / 2.3 US/Imp qt)
Wheel axle runout 0.25 Filter 2900 ml

Front change ( 3.1 / 2.6 US/Imp qt)
( 0.010
0.25 3000 ml
Rear ( o.oo Overhaul
( 3.2 / 2.6 US/Imp qt)
ii
Tire size Front fork oil type Mixture ratio SAE 1OW/30: A.T.F. = 1 : 1
Front 3.60S19 4PR
( 4.90 / 5.11 US/Imp oz)
Rear 4.60S164PR
Brake fluid type
Front 0.06
(
2.0
Rear 0.08
(
97 GSX400L
TIRE PRESSURE

COLD INFLA11ON
SOLO RIDING DUAL RIDING SOLO RIDING DUAL RIDING
kPa 2
kg/cm psi kPa 2
kg/cm psi kPa 2
kg/cm psi kPa 2
kg/cm psi CONTENTS
FRONT 175 1.75 25 175 1.75 25 200 2.00 28 200 2.00 28

VIEW OF SUZUKI GSX400E/S 99
REAR 200 2.00 28 225 2.25 32 225 2.25 32 250 2.50 36
SPECIFICATIONS ioo
SERVICE DATA 102
WATTAGE (W)
SPECI FICATION
ITEM
E-28 E-O2 E-O4 E-22
Headlight HI 45
LO 40 45 40
Parking or city light 3.4 4
Tail/Brake light 8/23 5/21
Turn signal light 23 21
Speedometer light 3.4 -
Tachometer light 3.4 -
Turn signal indicator light 3.4 -
High beam indicator light 3.4 -
Neutral indicator light 3.4 -
Oil pressure indicator light 3.4 —

97 GSX400L
TIRE PRESSURE

COLD INFLA11ON
kPa 2
kg/cm psi kPa 2
kg/cm psi kPa 2
kg/cm psi kPa 2
kg/cm psi CONTENTS
FRONT 175 1.75 25 175 1.75 25 200 2.00 28 200 2.00 28

VIEW OF SUZUKI GSX400E/S 99
REAR 200 2.00 28 225 2.25 32 225 2.25 32 250 2.50 36
SPECIFICATIONS ioo
SERVICE DATA 102
WATTAGE (W)
SPECI FICATION
ITEM
E-28 E-O2 E-O4 E-22
Headlight HI 45
LO 40 45 40
Speedometer light 3.4 -
Tachometer light 3.4 -
Turn signal indicator light 3.4 -
High beam indicator light 3.4 -
Neutral indicator light 3.4 -
Oil pressure indicator light 3.4 —

GSX400E/S 100
99 GSX400E!S
VIEW OF SUZUKI GSX400E/S SPECI Fl CATI ONS

Overall length 075 mm E type
— Model
2 065 mm S type
— Model
Overall width mm E type
— Model
7lOmm—Stype Model
Overall height type Model
1 230 mm S type
— Model
Wheelbase
Ground clearance
Seat height Model
805 mm—S type Model
Dry mass 175 kg
ENGINE
Number of cylinders. 2
Bore 67.0 mm
Stroke 56.6 mm
3
Compression ratio . 10.0: 1
GSX400E Lubrication system Wet sump
TRANSMI SSI ON
Transmission • . . 6-speed constant mesh
Primary reduction . 2.714(76/28)
Final reudction 2.812 (45/16)
2nd 1.777 (32/18)
3rd 1.380(29/21)
4th 1.125 (27/24)
5th 0.961 (25/26)
Top 0.851 (23/27)
Drive chain DAIDO D.l.D. 5OUB, 104 links
A
GSX400S
GSX400E/S 100
99 GSX400E!S
VIEW OF SUZUKI GSX400E/S SPECI Fl CATI ONS

Overall length 075 mm E type
— Model
2 065 mm S type
— Model
Overall width mm E type
— Model
7lOmm—Stype Model
Overall height type Model
1 230 mm S type
— Model
Wheelbase
Ground clearance
Seat height Model
805 mm—S type Model
Dry mass 175 kg
ENGINE
Number of cylinders. 2
Bore 67.0 mm
Stroke 56.6 mm
3
Compression ratio . 10.0: 1
GSX400E Lubrication system Wet sump
TRANSMI SSI ON
Transmission • . . 6-speed constant mesh
Primary reduction . 2.714(76/28)
Final reudction 2.812 (45/16)
2nd 1.777 (32/18)
3rd 1.380(29/21)
4th 1.125 (27/24)
5th 0.961 (25/26)
Top 0.851 (23/27)
A
GSX400S
GSX400E/S 102
101 GSX400E/S
CHASSIS SERVICE DATA

Front suspension Telescopic, oil dampened Unit: mm (in)
VALVE + GUIDE
Rear suspension Swing arm, oil dampened, spring LIMIT
ITEM STANDARD
5-way adjustable
23 —______
Steering angle 42° (right & left) Valve diam. IN.

-
( 0.90
Caster 62° 00’
20
Trail 105 mm EX.
( 0.78
7.0
Front brake Disc brake *
Valve lift IN.
( 0.28
7,0
Front tire size 3.00S18 4PR EX.
( 0.28
3.75S18 4PR (for W. Germany) Valve clearance or tappet clearance
0.080.13
(when cold) IN. & EX. 0.003—0.005
ELECTRI CAL
Ignition timing 200 B.T.D.C. below 1 650 r/min and 0.025—0.052 0.35
Valve guide to valve stem clearance —
IN.
40° B.T.D.C. above 3 500 r/min 0.00100.0020 ) ( 0.014
Spark plug NGK DR8ES-L or 0.040—0.067 0.35
EX.
NIPPON DENSO X24ESR-U ( 0.0016—0.0026 ) ( 0.014
Battery 12V 43.2 kC (l2Ah)/10 Hours 5.500—5.512
Valve guide I.D. ,. & EX.
Generator Three-phase A.C. generator 0.2165—0.2170
Fuse 15A 5.460— 5.47 5
Valve stem O.D. IN.
Headlight 12V 35/35W England ( 0.2150—0.2156
12V 36/36W France 5.445— 5.460
EX.
12V 45/45W Australia 0.2144—0.2150
12V 45/40W The others 0.05
Valve stem runout IN. & EX.
Tail /Brake light . 12V 8/23W Australia ( 0.002
Valve head thickness IN. & EX.
Turn signal light ‘12V 23W Australia ( 0.02
12V 21W The others 3.6
Valve stem end length IN. & EX.
Parking light 12V 3.4W England ( 0.14
12V 4W The others 0.9—1.1
Valve seat width IN. & EX.
Speedometer light 12V 3.4W 00350043
Tachometer light 12V 3.4W 0.03
Valve head radial runout
-
Neutral indicator light . 12V3.4W IN. & EX. ( 0.001

High beam indicator light 12V 3.4W 31.9
Valve spring free length INNER
Turn signal indicator light 12V 3.4W ( 1.26
(IN. & EX.) I
Oil pressure indicator light 12V 3.4W 35.5
OUTER ( 1.40
CAPACITI ES
Fuel tank including reserve 14.5 L (3.2 Imp gal) 4.4—6.4 kg
Valve spring tension
reserve 3.0 L (2.6 Imp qt) INNER 9,7—14.1 lbs)
(IN. & EX.)
Engine oil when changing 2.6 L (2.3 Imp qt) at length2s.5mm( 1.12 in)
Frontfork oil 145 ml (5.11 Imp oz) — E-22, 26 6.5—8.9 kg
E type Model OUTER ( 14.3—19.6 lbs)
148 ml (5.21 Imp oz) — E-02, 04, 22 at length32.omm ( 1.26 in)
S type Model
150 ml (5.28 Imp oz) — E-02, 04, 16, 24
E type Model
I
GSX400E/S 102
101 GSX400E/S
CHASSIS SERVICE DATA

Front suspension Telescopic, oil dampened Unit: mm (in)
VALVE + GUIDE
Rear suspension Swing arm, oil dampened, spring LIMIT
ITEM STANDARD
5-way adjustable
23 —______
Steering angle 42° (right & left) Valve diam. IN.

-
( 0.90
Caster 62° 00’
20
Trail 105 mm EX.
( 0.78
7.0
Front brake Disc brake *
Valve lift IN.
( 0.28
7,0
Front tire size 3.00S18 4PR EX.
( 0.28
3.75S18 4PR (for W. Germany) Valve clearance or tappet clearance
0.080.13
(when cold) IN. & EX. 0.003—0.005
ELECTRI CAL
Ignition timing 200 B.T.D.C. below 1 650 r/min and 0.025—0.052 0.35
Valve guide to valve stem clearance —
IN.
40° B.T.D.C. above 3 500 r/min 0.00100.0020 ) ( 0.014
Spark plug NGK DR8ES-L or 0.040—0.067 0.35
EX.
NIPPON DENSO X24ESR-U ( 0.0016—0.0026 ) ( 0.014
Battery 12V 43.2 kC (l2Ah)/10 Hours 5.500—5.512
Valve guide I.D. ,. & EX.
Generator Three-phase A.C. generator 0.2165—0.2170
Fuse 15A 5.460— 5.47 5
Valve stem O.D. IN.
Headlight 12V 35/35W England ( 0.2150—0.2156
12V 36/36W France 5.445— 5.460
EX.
12V 45/45W Australia 0.2144—0.2150
Tail /Brake light . 12V 8/23W Australia ( 0.002
Valve head thickness IN. & EX.
Turn signal light ‘12V 23W Australia ( 0.02
12V 21W The others 3.6
Valve stem end length IN. & EX.
Parking light 12V 3.4W England ( 0.14
12V 4W The others 0.9—1.1
Valve seat width IN. & EX.
Speedometer light 12V 3.4W 00350043
Tachometer light 12V 3.4W 0.03
Valve head radial runout
-
Neutral indicator light . 12V3.4W IN. & EX. ( 0.001

High beam indicator light 12V 3.4W 31.9
Valve spring free length INNER
Turn signal indicator light 12V 3.4W ( 1.26
(IN. & EX.) I
Oil pressure indicator light 12V 3.4W 35.5
OUTER ( 1.40
CAPACITI ES
Fuel tank including reserve 14.5 L (3.2 Imp gal) 4.4—6.4 kg
Valve spring tension
reserve 3.0 L (2.6 Imp qt) INNER 9,7—14.1 lbs)
(IN. & EX.)
Engine oil when changing 2.6 L (2.3 Imp qt) at length2s.5mm( 1.12 in)
Frontfork oil 145 ml (5.11 Imp oz) — E-22, 26 6.5—8.9 kg
E type Model OUTER ( 14.3—19.6 lbs)
148 ml (5.21 Imp oz) — E-02, 04, 22 at length32.omm ( 1.26 in)
S type Model
150 ml (5.28 Imp oz) — E-02, 04, 16, 24
E type Model
I
103 GSX400E/S GSX400EIS 104
CRANKSHAFT + CYLINDER HEAD Unit: mm (in) CYLINDER + PISTON + PISTON RING Unit: mm (in)
*
Cam height 34.650—34.690 34.350 Compression pressure
lO — 14 2
kg/cm 8 2
kg/cm
IN.
( 1.3642—1.3657 ) ( 1.3524) , ( 142 — 199 psi) ( 114 psi)
34.650—34.690 34.350 Compression pressure difference

2 2
kg/cm
EX.
( 1.3642—1.3657 ) ( 1.3524) ( 28.4__psi)
Camshaft journal oil clearance 0.032—0.066 0.150 Piston to cylinder clearance
0.050—0.060 0.120
IN. & EX.
( 0.0013—0.0026 ) ( 0.0059) ( 0.0020—0.0024 ) ( 0.0047)
22.012—22.025 Cylinder bore 67.000—67.015 67.080
Camshaft journal holder l.D.
IN. & EX. 2.6410)
(_0.8666—0.8671 ( 2.6378—2.6384 ) (
Camshaft journal 0.D. 21.959—21.980 Piston diam.

66.945 66.960
r.& EX. —
66.880
(_0.8645—0.8654 ( 2.6356—2.6362
0.10 ( 2.6331
Camshaft runout
IN. & EX. Measure at thel 5.0( 0.59 ) from skirt end.
( 0.004
1 57.80 Cylinder 0.10
Cam chain 20 pitch length distortion
( 6.213) — (0.004)
9.5 7.6
Cam chain pin (at arrow “3”) 20 th pin Piston ring free end gap
N Approx.
( 0.37 ) ( 0.30
12.000—12.018 1st —________________
Rocker arm l.D.

IN. & EX. 9.5 7.6
( 0.4724—0.4731 R Approx.
( 0.37 ) ( 0.30
Rocker arm shaft O.D. 11.973—11.984 10.0 8.0
IN. & EX. N Approx.
( 0.4714—0.4718 0.39 ) ( 0.31
(
0.10 2nd
R Approx
(_0.004 ( 0.39 ) ( 0.31
0.10—0.30 0.7
Piston ring end gap 1st
( 0.004—0.012 ) ( 0.03
0.10—0.30 0.7
*
Only for E-22 Unit: 2nd
mm (in)
( 0.004—•0.012 ) ( 0.03
ITEM STANDARD LIMIT Piston ring to groove clearance
0.180
1 St
Cam height 33.350—33.390 33.050 (0.0071)
IN. 0.150
(1.3130—1.3146) (1.3012)
2nd
33.350—33.390 33.050 (_0.0059)
EX. 1.21 —1.23
(1.3130—1.3146) (1.3012) Piston ring groove width 1 St
Valve lift 4.8 ( 0.047—0.048
IN.
(0.19) 1.21—1.23
2nd
4.8 (__0.047— 0.048
EX.
(0.19) 2.51 —2.53
Oil
(__0.099—0.100
1.175—1.190
Piston ring thickness
1st
(_0.0463—0.0469
1 .1 70—1 .190
2nd
( 0.0461—0.0469
18.002—18.008 18.030
Piston pin bore
( 0.7087—0.7090 ) ( 0.7098)
17.99618.000 17.980
Piston pin O.D.
—
( 0.7085—0.7087 ) ( 0.7079)
CRANKSHAFT + CYLINDER HEAD Unit: mm (in) CYLINDER + PISTON + PISTON RING Unit: mm (in)
*
Cam height 34.650—34.690 34.350 Compression pressure
lO — 14 2
kg/cm 8 2
kg/cm
IN.
( 1.3642—1.3657 ) ( 1.3524) , ( 142 — 199 psi) ( 114 psi)
34.650—34.690 34.350 Compression pressure difference

2 2
kg/cm
EX.
( 1.3642—1.3657 ) ( 1.3524) ( 28.4__psi)
Camshaft journal oil clearance 0.032—0.066 0.150 Piston to cylinder clearance
0.050—0.060 0.120
IN. & EX.
( 0.0013—0.0026 ) ( 0.0059) ( 0.0020—0.0024 ) ( 0.0047)
22.012—22.025 Cylinder bore 67.000—67.015 67.080
Camshaft journal holder l.D.
IN. & EX. 2.6410)
(_0.8666—0.8671 ( 2.6378—2.6384 ) (
Camshaft journal 0.D. 21.959—21.980 Piston diam.

66.945 66.960
r.& EX. —
66.880
(_0.8645—0.8654 ( 2.6356—2.6362
0.10 ( 2.6331
Camshaft runout
IN. & EX. Measure at thel 5.0( 0.59 ) from skirt end.
( 0.004
1 57.80 Cylinder 0.10
Cam chain 20 pitch length distortion
( 6.213) — (0.004)
9.5 7.6
Cam chain pin (at arrow “3”) 20 th pin Piston ring free end gap
N Approx.
( 0.37 ) ( 0.30
12.000—12.018 1st —________________
Rocker arm l.D.

IN. & EX. 9.5 7.6
( 0.4724—0.4731 R Approx.
( 0.37 ) ( 0.30
Rocker arm shaft O.D. 11.973—11.984 10.0 8.0
IN. & EX. N Approx.
( 0.4714—0.4718 0.39 ) ( 0.31
(
0.10 2nd
R Approx
(_0.004 ( 0.39 ) ( 0.31
0.10—0.30 0.7
Piston ring end gap 1st
( 0.004—0.012 ) ( 0.03
0.10—0.30 0.7
*
Only for E-22 Unit: 2nd
mm (in)
( 0.004—•0.012 ) ( 0.03
ITEM STANDARD LIMIT Piston ring to groove clearance
0.180
1 St
Cam height 33.350—33.390 33.050 (0.0071)
IN. 0.150
(1.3130—1.3146) (1.3012)
2nd
33.350—33.390 33.050 (_0.0059)
EX. 1.21 —1.23
(1.3130—1.3146) (1.3012) Piston ring groove width 1 St
Valve lift 4.8 ( 0.047—0.048
IN.
(0.19) 1.21—1.23
2nd
4.8 (__0.047— 0.048
EX.
(0.19) 2.51 —2.53
Oil
(__0.099—0.100
1.175—1.190
Piston ring thickness
1st
(_0.0463—0.0469
1 .1 70—1 .190
2nd
( 0.0461—0.0469
18.002—18.008 18.030
Piston pin bore
( 0.7087—0.7090 ) ( 0.7098)
17.99618.000 17.980
Piston pin O.D.
—
( 0.7085—0.7087 ) ( 0.7079)
105 GSX400E/S GSX400E/S 106
CONROD + CRANKSHAFT + BALANCER Unit: mm (in)

I CLUTCH Unit: mm (in
Conrod small end l.D. 18.006—18.014 18.040 Clutch cable play 4.0
. ( 0.7089—0.7092 ) (0.7102) (__0.16
Conrod big end thrust clearance 0.10—0.20 0.30 Clutch release screw Turn back
( 0.004—0.008 ) ( 0.012
Conrod big end width 22.95—23.00 Drive plate thickness 2.9—3.1 2.6
(__0.904—0.906 ( 0.11—0.12 ) ( 0.10
Crank pin width 23.10—23.15 Drive plate claw width 1 5.8—16.0 1 5.0
( 0.909—0.91 1 ( 0.62—0.63 ) ( 0.59
Conrod big end oil clearance 0.024—0.048 0.080 Driven plate thickness 1 .60 ± 0.06
( 0.0009—0.0019 ) ( 0.0031) (__0.063 ± 0.002
Crank pin O.D. 33.976—34.000 Driven plate distortion 0.1
( 1.3376—1.3386 (_0.004
Crankshaft journal oil clearance 0.020—0.044 0.080 Clutch spring free length 38.4
( 0.0008—0.0017 ) ( 0.0031 (__1.51
Crankshaft journal O.D. 31.976—32.000
( 1.2589—1.2598 TRANSMISSION + DRIVE CHAIN Unit: mm (in)
Crankshaft thrust bearing thickness 2.95—2.98 2.85 ITEM STANDARD LIMIT
( 0.116—0.117 ) ( 0.112 Primary reduction ratio 2.714 ( 76 / 28
( 0.002 Final reduction ratio 2.812 ( 45/16
Balancer journal oil clearance 0.020—0.044 0.080 Gear ratios Low 2.461 ( 32 / 13
( 0.0008—0.0017 ) ( 0.0031
2nd 1.777 ( 32/18
Balancer journal O.D. 31.984—32.000
( 1.2592—1.2598 3rd 1.380 ( 29/21
4th 1.125 ( 27/ 24
5th 0.961 ( 25/26

OIL PUMP
ITEM STANDARD
Top 0.851 ( 23 / 27
LIMIT
Oil pump reduction ratio Shift fork to groove clearance 0.10 0.30 0.50
2.071 ( 76 / 28 x 29 / 38
( 0.004 0.01 2 — ) ( 0.020
Oil pressure (at 60°C, 140° F) 3.0 kg/cm
2 5.5 5.6
Above Shift fork groove width —
( 43 psi) (_0.217—0.220
5.5 2
kg/cm 5.3 5.4
Below Shift fork thickness —
( 78 psi) (__0.209—0.213
at 3000 r/min.
Counter shaft length 1 14.7 ±
(Low to 2nd) ( 4.52 ± 0.004 )
Drivechain Type D.l.D.: 5OUB
Links 104
I 324.3
20 pitch length
( 1 2.77
Drive chain slack 20—30
( 0.8—1.2
105 GSX400E/S GSX400E/S 106

I CLUTCH Unit: mm (in
Conrod small end l.D. 18.006—18.014 18.040 Clutch cable play 4.0
. ( 0.7089—0.7092 ) (0.7102) (__0.16
Conrod big end thrust clearance 0.10—0.20 0.30 Clutch release screw Turn back
( 0.004—0.008 ) ( 0.012
Conrod big end width 22.95—23.00 Drive plate thickness 2.9—3.1 2.6
(__0.904—0.906 ( 0.11—0.12 ) ( 0.10
Crank pin width 23.10—23.15 Drive plate claw width 1 5.8—16.0 1 5.0
( 0.909—0.91 1 ( 0.62—0.63 ) ( 0.59
Conrod big end oil clearance 0.024—0.048 0.080 Driven plate thickness 1 .60 ± 0.06
( 0.0009—0.0019 ) ( 0.0031) (__0.063 ± 0.002
Crank pin O.D. 33.976—34.000 Driven plate distortion 0.1
( 1.3376—1.3386 (_0.004
Crankshaft journal oil clearance 0.020—0.044 0.080 Clutch spring free length 38.4
( 0.0008—0.0017 ) ( 0.0031 (__1.51
( 1.2589—1.2598 TRANSMISSION + DRIVE CHAIN Unit: mm (in)
Crankshaft thrust bearing thickness 2.95—2.98 2.85 ITEM STANDARD LIMIT
( 0.116—0.117 ) ( 0.112 Primary reduction ratio 2.714 ( 76 / 28
( 0.002 Final reduction ratio 2.812 ( 45/16
Balancer journal oil clearance 0.020—0.044 0.080 Gear ratios Low 2.461 ( 32 / 13
( 0.0008—0.0017 ) ( 0.0031
2nd 1.777 ( 32/18
Balancer journal O.D. 31.984—32.000
( 1.2592—1.2598 3rd 1.380 ( 29/21
4th 1.125 ( 27/ 24
5th 0.961 ( 25/26

OIL PUMP
ITEM STANDARD
Top 0.851 ( 23 / 27
LIMIT
Oil pump reduction ratio Shift fork to groove clearance 0.10 0.30 0.50
2.071 ( 76 / 28 x 29 / 38
( 0.004 0.01 2 — ) ( 0.020
Oil pressure (at 60°C, 140° F) 3.0 kg/cm
2 5.5 5.6
Above Shift fork groove width —
( 43 psi) (_0.217—0.220
5.5 2
kg/cm 5.3 5.4
Below Shift fork thickness —
( 78 psi) (__0.209—0.213
at 3000 r/min.
(Low to 2nd) ( 4.52 ± 0.004 )
Drivechain Type D.l.D.: 5OUB
Links 104
I 324.3
20 pitch length
( 1 2.77
( 0.8—1.2
CARBURETOR
Unit: mm (in)
SPEC I F I CATI ON ELECTRI CAL Unit: mm (in)
ITEM Only for E-22
E-02, and the others - ITEM SPECIFICATION NOTE
Ignition timing 20° B.T.D.C. Below 1650± 100 r/min and

Carburetor type MIKUNI BS34SS
40° B.T.D.C. Above3500 ± 100 r/min.
Bore size 34 NGK D8EA
Spark plug Type
44220 NIPPON DENSO X24ES—U Only for
I. D. No. 44202
0.6—0.7 E-24
Gap
Idler/mm. 1100 ± 50 r/min. ( 0.024—0.028
Fuel level 5.0 ± Q5 NGK DR8ES-L
0.20 ± 0.02 Type NIPPON DENSO X24ESR-U
(
22.4 ± 1.0 The others

Float height 0.6 0.7
Gap
—
(__0.88 ± 0.04 ( 0.024 — 0.028

Main jet (M.J.) # 117.5 Spark performance Over 8 (0.3) at 1 atm
Main air jet (M. A. J.) 0.6 Signal coil resistance Approx. 80 Br—BIW
60
GIW— BIW
—
Jet needle (J. N.) 5D 69-4 Ignition coil resistance 01W W or B

Primary —
P-2 Approx. 3—5 £2

Needlejet (N.J.) P—i
Plug cap 0/WorW
Secondary
—
Pilotjet (P.J.) # 42.5 Approx. 21 25 k2 —
By pass (B. P.) 0.9, 0.8, 0.8 Generator no-load voltage More than 75 V (AC) at 5000 r/min.
Regulated voltage i 15 V at 5000 r/min.

Pilot outlet (P. o) 0.8 —
Starter motor
I 9
Valve seat (V. S.) 2.0 Brush Iength N. D.
I Limit: ( 0.4
Commutatorundercut 0.2
Starter jet (G.S.) # 32.5 Limit: (0.008)
Pilot screw (P. S.) 1 1/2 turn out Starter relay resistance Approx. 3 4 £2—
Pilotairjet (P.A.J.) # 125 Battery Type designation YB1 OL-A2
Throttle cable play 0.5 1 .0 Capacity 1 2V 43.2 kC

0.02 0.04 (1 2Ah)/1 OHR
( —
Standard
1.28 at 20°C (68°F)
electrolyte S. G.
Fuse size Main 15 A
CARBURETOR
Unit: mm (in)
SPEC I F I CATI ON ELECTRI CAL Unit: mm (in)
ITEM Only for E-22
E-02, and the others - ITEM SPECIFICATION NOTE
Ignition timing 20° B.T.D.C. Below 1650± 100 r/min and

Carburetor type MIKUNI BS34SS
40° B.T.D.C. Above3500 ± 100 r/min.
Bore size 34 NGK D8EA
Spark plug Type
44220 NIPPON DENSO X24ES—U Only for
I. D. No. 44202
0.6—0.7 E-24
Gap
Idler/mm. 1100 ± 50 r/min. ( 0.024—0.028
Fuel level 5.0 ± Q5 NGK DR8ES-L
0.20 ± 0.02 Type NIPPON DENSO X24ESR-U
(
22.4 ± 1.0 The others

Float height 0.6 0.7
Gap
—
(__0.88 ± 0.04 ( 0.024 — 0.028

Main jet (M.J.) # 117.5 Spark performance Over 8 (0.3) at 1 atm
Main air jet (M. A. J.) 0.6 Signal coil resistance Approx. 80 Br—BIW
60
GIW— BIW
—
Jet needle (J. N.) 5D 69-4 Ignition coil resistance 01W W or B

Primary —
P-2 Approx. 3—5 £2

Needlejet (N.J.) P—i
Plug cap 0/WorW
Secondary
—
Pilotjet (P.J.) # 42.5 Approx. 21 25 k2 —
By pass (B. P.) 0.9, 0.8, 0.8 Generator no-load voltage More than 75 V (AC) at 5000 r/min.
Regulated voltage i 15 V at 5000 r/min.

Pilot outlet (P. o) 0.8 —
Starter motor
I 9
Valve seat (V. S.) 2.0 Brush Iength N. D.
I Limit: ( 0.4
Commutatorundercut 0.2
Starter jet (G.S.) # 32.5 Limit: (0.008)
Pilot screw (P. S.) 1 1/2 turn out Starter relay resistance Approx. 3 4 £2—
Pilotairjet (P.A.J.) # 125 Battery Type designation YB1 OL-A2
Throttle cable play 0.5 1 .0 Capacity 1 2V 43.2 kC

0.02 0.04 (1 2Ah)/1 OHR
( —
Standard
1.28 at 20°C (68°F)
electrolyte S. G.
Fuse size Main 15 A
LQ GSX400E/S GSX400E/S 110
ITEM STANDARD LIMIT ITEM STANDARD LIMIT NOTE

20 30 Front fork stroke 140
Rear brake pedal free travel —
( 0.8 — 1 .2 ( s.s
496 E-02, 04,
Rear brake pedal height 20 Front fork spring free length 16,24
Etype
( 0.8 ( 19.5 ) Model
160.7 I 103
Brake drum I.D. Rear Upper E-22,26
( 6.33 ( 4.1
Etype
391
Brake lining thickness 1.5 Lower Model
0.06 ( 15.4
5.0±0.1 45 103
Brake disc thickness Upper
Front
1
( 0.20 ± 0.004 ) ( 0.18 ( 4.1 ) Stype
391 Model
Brake disc runout 0.30 Lower
( 0.012 ( 15.4
14.000—14.043 Front fork oil level 197 S type
Master cylinder bore
Front ( 7.8 ) Model
( 0.551 2—0.5529
186 E-02,04,
13.957—1 3.984 16 24
Master cylinder piston diam. Etyie
Front
( 0.5495—0.5506 ( 7.3 ) Model
42.850—42.926 197 E-22,26
Brake caliper cylinder bore E type
Front
1 ( 1 .6870—1 .6900 ( 7.8 ) Model
Brakecaliperpiston diam. 42.770—42.820 Rear wheel travel 100

Front
1.6839—1.6858 ( 3.9
Wheel rim runout 2.0 Swing arm pivot shaft runout 0.3
Axial
( 0.08 ( 0.012
2.0
Radial
( 0.08
Front
( 0.010 FUEL + OIL
0.25 NOTE
Rear ITEM SPECIFICATION
( 0.010
Fuel type
Tire size Use gasoline with an octane number of 85-
Front 3.OOS1 8 4PR
gOor higher (Research Method), preferably
Rear 3.50S184PR -___
Fuel tank including reserve 14.5 L

Only for
Rear 3.75S18 4PR ( 3.8 / 3.2 US/Imp_gal)
E-22
reserve 3.0 L
Front ( 3.2 / 2.6 US/Imp qt)
( 0.06
2.0 Engine oil type SAE 1OW/40
Rear
( 0.08 2600 ml
Engine oil capacity Change
I ( 2.7 / 2.3 US/Imp qt)
Filter 2900 ml
3000 ml I
Overhaul
( 3.2 / 2.6 US/Imp qt)
LQ GSX400E/S GSX400E/S 110
ITEM STANDARD LIMIT ITEM STANDARD LIMIT NOTE

20 30 Front fork stroke 140
Rear brake pedal free travel —
( 0.8 — 1 .2 ( s.s
496 E-02, 04,
Rear brake pedal height 20 Front fork spring free length 16,24
Etype
( 0.8 ( 19.5 ) Model
160.7 I 103
Brake drum I.D. Rear Upper E-22,26
( 6.33 ( 4.1
Etype
391
Brake lining thickness 1.5 Lower Model
0.06 ( 15.4
5.0±0.1 45 103
Brake disc thickness Upper
Front
1
( 0.20 ± 0.004 ) ( 0.18 ( 4.1 ) Stype
391 Model
Brake disc runout 0.30 Lower
( 0.012 ( 15.4
14.000—14.043 Front fork oil level 197 S type
Master cylinder bore
Front ( 7.8 ) Model
( 0.551 2—0.5529
186 E-02,04,
13.957—1 3.984 16 24
Master cylinder piston diam. Etyie
Front
( 0.5495—0.5506 ( 7.3 ) Model
42.850—42.926 197 E-22,26
Brake caliper cylinder bore E type
Front
1 ( 1 .6870—1 .6900 ( 7.8 ) Model
Brakecaliperpiston diam. 42.770—42.820 Rear wheel travel 100

Front
1.6839—1.6858 ( 3.9
Wheel rim runout 2.0 Swing arm pivot shaft runout 0.3
Axial
( 0.08 ( 0.012
2.0
Radial
( 0.08
Front
( 0.010 FUEL + OIL
0.25 NOTE
Rear ITEM SPECIFICATION
( 0.010
Fuel type
Tire size Use gasoline with an octane number of 85-
Front 3.OOS1 8 4PR
gOor higher (Research Method), preferably
Rear 3.50S184PR -___
Fuel tank including reserve 14.5 L

Only for
Rear 3.75S18 4PR ( 3.8 / 3.2 US/Imp_gal)
E-22
reserve 3.0 L
Front ( 3.2 / 2.6 US/Imp qt)
( 0.06
2.0 Engine oil type SAE 1OW/40
Rear
( 0.08 2600 ml
Engine oil capacity Change
I ( 2.7 / 2.3 US/Imp qt)
Filter 2900 ml
3000 ml I
Overhaul
( 3.2 / 2.6 US/Imp qt)
111 GSX400E/S
Unit: mm (in)
ITEM SPECIFICATION NOTE
Front fork oil type Mixture ratio SAE 1 OW/30 : A.T.F = 1 :1

145 ml E-22, 26 CONTENTS
Front fork oil capacity (each leg)
( 4.90 / 5.1 1 US/Imp oz) E type Model
VIEW OF SUZUKI GSX400T 113
148 ml E-02,04,22
( 5.00 / 5.21 US/Imp oz) S type Model SPECIFICATIONS 114
150 ml E-02, 04, 16,24 COMBINATION METER 116
. ( 5.07 / 5.28 US/Imp oz E type Model
WIRING DIAGRAM 117
Brake fluid type SAE Ji 703, DOT3 or DOT4
WIRE ROUTING 121
TIRE PRESSURE CABLE ROUTING 122

NORMAL RIDING CONTINUOUS HIGH SPEED RIDING SERVICE DATA 123
COLD INFLATION
TIRE PRESSURE
kPa 2
kg/cm psi kPa 2
kg/cm psi kPa 2
kg/cm Psi kPa 2
kg/cm Psi
FRONT 175 1.75 25 175 1.75 25 200 2.00 28 200 2.00 28
REAR 200 2.00 28 225 2.25 32 225 2.25 32 250 2.50 36
WATTAGE (W)
____________ SPECIFICATION
ITEM
E-02 E-04 E-16, 22,26 E-24
Headlight HI 35 36 45
LO 35 36 40 45
Speedometer light 3.4
Tachometer light 3.4
Turn signal indicator light 3.4
High beam indicator light 3.4
Neutral indicator light 3.4
Oil pressure indicator light 3.4
Gear position indicator light 1.1

111 GSX400E/S
Unit: mm (in)
ITEM SPECIFICATION NOTE
Front fork oil type Mixture ratio SAE 1 OW/30 : A.T.F = 1 :1

145 ml E-22, 26 CONTENTS
Front fork oil capacity (each leg)
( 4.90 / 5.1 1 US/Imp oz) E type Model
VIEW OF SUZUKI GSX400T 113
148 ml E-02,04,22
( 5.00 / 5.21 US/Imp oz) S type Model SPECIFICATIONS 114
150 ml E-02, 04, 16,24 COMBINATION METER 116
. ( 5.07 / 5.28 US/Imp oz E type Model
WIRING DIAGRAM 117
WIRE ROUTING 121
TIRE PRESSURE CABLE ROUTING 122

NORMAL RIDING CONTINUOUS HIGH SPEED RIDING SERVICE DATA 123
COLD INFLATION
TIRE PRESSURE
kPa 2
kg/cm psi kPa 2
kg/cm psi kPa 2
kg/cm Psi kPa 2
kg/cm Psi
FRONT 175 1.75 25 175 1.75 25 200 2.00 28 200 2.00 28
REAR 200 2.00 28 225 2.25 32 225 2.25 32 250 2.50 36
WATTAGE (W)
____________ SPECIFICATION
ITEM
E-02 E-04 E-16, 22,26 E-24
Headlight HI 35 36 45
LO 35 36 40 45
Tachometer light 3.4
Neutral indicator light 3.4
Oil pressure indicator light 3.4
Gear position indicator light 1.1

c
113 GSX400T GSX400T 114
VIEW OF SUZUKI GSX400T SPECI Fl CATI ONS
Overall length 2 100mm
Overall width 845 mm
Overall height 1145 mm
Wheelbase 1 375 mm
Dry mass 175 kg
ENGINE
Number-of cylinders 2
Bore 67.0 mm
Stroke 56.6 mm
3
Compression ratio 10.0: 1
TRANSMI SSI ON
RIGHT SIDE
2nd 1.777 (32/18)
3rd 1.380 (29/21)
4th 1.125(27/24)
)
5th 0.961 (25/26)
Top 0.851 (23/27)
LEFT SIDE
c
113 GSX400T GSX400T 114
VIEW OF SUZUKI GSX400T SPECI Fl CATI ONS
Overall length 2 100mm
Overall width 845 mm
Overall height 1145 mm
Wheelbase 1 375 mm
Dry mass 175 kg
ENGINE
Number-of cylinders 2
Bore 67.0 mm
Stroke 56.6 mm
3
Compression ratio 10.0: 1
TRANSMI SSI ON
RIGHT SIDE
2nd 1.777 (32/18)
3rd 1.380 (29/21)
4th 1.125(27/24)
)
5th 0.961 (25/26)
Top 0.851 (23/27)
LEFT SIDE
115 GSX400T GSX400T 116
COMBINATION METER
CHASSIS
Rear suspension Swing arm, oil dampened,
Steering angle 42° (right &left)
Caster 61° 00’
Trail 120mm
Turning radius 2.3m
Front tire size 90/90-19 52S
Reartiresize 110/90-17 60S
ELECTRI CAL
Ignition timing 20° B.T.D.C. below 1 650 r/m in and
40° B.T.D.C. above 3 500 r/min
Spark plug NGK D8EAor
NIPPON DENSO X24ES-U General market
NGK DR8ES-Lor
NIPPON DENSO X24ESR-U Other markets
Battery 12V 43.2 kC (l2Ah)/1OHR
Generator • . Three-phase A.C. generator
Fuse iSA
Headlight 12V 45/45W General market
12V 35/35W England
12V 45/40W Other markets
Tail/Brake light 12V 5/21W England
8/23W General market
Turn signal light 12V 21W England
23W General market
Parking light . .
12V 3.4W England
12V 4W France and West Germany
Neutral indicator light 12V 3.4W
CAPACITI ES
Fuel tank including reserve. .. 12 L (2.6 Imp gal)
reserve 4.0 L(3.5lmpqt.)
Front fork oil 148 ml (5.21 Imp oz.)
*
115 GSX400T GSX400T 116
COMBINATION METER
CHASSIS
Rear suspension Swing arm, oil dampened,
Steering angle 42° (right &left)
Caster 61° 00’
Trail 120mm
Turning radius 2.3m
Front tire size 90/90-19 52S
Reartiresize 110/90-17 60S
ELECTRI CAL
Ignition timing 20° B.T.D.C. below 1 650 r/m in and
40° B.T.D.C. above 3 500 r/min
Spark plug NGK D8EAor
NIPPON DENSO X24ES-U General market
NGK DR8ES-Lor
NIPPON DENSO X24ESR-U Other markets
Battery 12V 43.2 kC (l2Ah)/1OHR
Generator • . Three-phase A.C. generator
Fuse iSA
Headlight 12V 45/45W General market
12V 35/35W England
12V 45/40W Other markets
Tail/Brake light 12V 5/21W England
8/23W General market
Turn signal light 12V 21W England
23W General market
Parking light . .
12V 3.4W England
12V 4W France and West Germany
Neutral indicator light 12V 3.4W
CAPACITI ES
Fuel tank including reserve. .. 12 L (2.6 Imp gal)
reserve 4.0 L(3.5lmpqt.)
Front fork oil 148 ml (5.21 Imp oz.)
*
WIRE COLOR
Bl Blue G/Bl Green with Blue tracer
G Green G/Y Green with Yellow tracer
Gr Gray 0/W Orange with White tracer
Lbl Light blue R/B Red with Black tracer
0 Orange W/G White with Green tracer
R Red W/R White with Red tracer
B STARTER SUTTDN W White W/Y White with Yellow tracer
BlURT HANDLEBAR SWITCH Y Yellow Y/Bl Yellow with Blue tracer
• TURN SIUNUL INBICATOR LIGHT B/W Black with White tracer Y/G Yellow with Green tracer
RIGR BEAU INDICATOR LIGRT
P GIL PRESSURE INOICATOR LIGHT B/Y Black with Yellow tracer
N NEUTRAL INDICATOR LIGHT l-oI
AAWlGIWJBIIWI
—IIIII
BUTTERy
HEAR THRN SIGNAL LIGHT IRI
TAILIURAKE LIGHT
TURN SIGNAL LIGHT
ILl
SIGNAL GENERATOR
OIL PRESSURE SWITCH
STARTER MOTOR
FUSE SAl
REGULATUR/RECTIFIER
2 AC. GENERATOR
IGNITRR
TURN SIGNAL RELAY
-J
0
2
Lii
0
LI
p.
WIRE COLOR
B Black Br/R • • Brown with Red tracer
BI Blue G/Bl • Green with Blue tracer
Br Brown G/W • Green with White tracer
Gr Gray 0/W • Orange with White tracer
Lbl Light blue R/B • Red with Black tracer
0 Orange W/G • • White with Green tracer
R.... Red W/R • • White with Red tracer
U ENGINE BILL SWITCH
B STARTER BUTTON W White W/Y • White with Yellow tracer
RIGHT HANDLEBAR SWITCH Y. Yellow Y/Bl • • Yellow with Blue tracer
• TURN SIGNAL INDICATOR LIGHT B/W Black with White tracer Y/G • • Yellow with Green tracer
B HIGH BEAU INDICATOR LIGHT
P OIL PRESSURE INDICATOR LIGHT B/Y Black with Yellow tracer
N NEUTRAL INDICATOR LIGRT
I
I I I I I
SPEEDOMETER
FRONT TURN SIGNAL LIGHT (HI
REAR BRAKE LIGHT SWITCH REAR TURN SIGNAL LIGHr (RI
HEAULIURT
TURN SIGNAL LIGRT
LI
REAR TURN SIONAL LIORT IL)
—
C., iii
Q
— LEFT HANDLEBAR SWITCH
oLI
WIRE COLOR
Bl Blue G/Bl Green with Blue tracer
Lbl Light blue R/B Red with Black tracer
B STARTER SUTTDN W White W/Y White with Yellow tracer
BlURT HANDLEBAR SWITCH Y Yellow Y/Bl Yellow with Blue tracer
• TURN SIUNUL INBICATOR LIGHT B/W Black with White tracer Y/G Yellow with Green tracer
RIGR BEAU INDICATOR LIGRT
P GIL PRESSURE INOICATOR LIGHT B/Y Black with Yellow tracer
N NEUTRAL INDICATOR LIGHT l-oI
AAWlGIWJBIIWI
—IIIII
BUTTERy
HEAR THRN SIGNAL LIGHT IRI
TAILIURAKE LIGHT
TURN SIGNAL LIGHT
ILl
SIGNAL GENERATOR
OIL PRESSURE SWITCH
STARTER MOTOR
FUSE SAl
REGULATUR/RECTIFIER
2 AC. GENERATOR
IGNITRR
TURN SIGNAL RELAY
-J
0
2
Lii
0
LI
p.
WIRE COLOR
B Black Br/R • • Brown with Red tracer
BI Blue G/Bl • Green with Blue tracer
Gr Gray 0/W • Orange with White tracer
Lbl Light blue R/B • Red with Black tracer
0 Orange W/G • • White with Green tracer
R.... Red W/R • • White with Red tracer
U ENGINE BILL SWITCH
B STARTER BUTTON W White W/Y • White with Yellow tracer
RIGHT HANDLEBAR SWITCH Y. Yellow Y/Bl • • Yellow with Blue tracer
• TURN SIGNAL INDICATOR LIGHT B/W Black with White tracer Y/G • • Yellow with Green tracer
B HIGH BEAU INDICATOR LIGHT
P OIL PRESSURE INDICATOR LIGHT B/Y Black with Yellow tracer
N NEUTRAL INDICATOR LIGRT
I
I I I I I
SPEEDOMETER
FRONT TURN SIGNAL LIGHT (HI
REAR BRAKE LIGHT SWITCH REAR TURN SIGNAL LIGHr (RI
HEAULIURT
TURN SIGNAL LIGRT
LI
REAR TURN SIONAL LIORT IL)
—
C., iii
Q
— LEFT HANDLEBAR SWITCH
oLI
WIRE COLOR
81 Blue G/Bl Green with Blue tracer
ENGINE KILL SWITCH
STARTER HUtTON
W White W/Y White with Yellow tracer
B
Y Yellow Y/Bl Yellow with Blue tracer
B/W Black with White tracer Y/G Yellow with Green tracer
B HIGH REAM INUICATOR LIGHT B/Y Black with Yellow tracer
P OIl PRESSURE INDICATOR 11611’
FRONT TURN SIGNAL EIGHT HI
U,
-J
Lii
z
I-
LU
z
>-
LU
I...
0
LL
WIRE COLOR
BI Blue G/BI • Green with Blue tracer
G Green G/Y • Green with Yellow tracer
Gr Gray 01W • Orange with White tracer
Lbl Light blue RIB • Red with Black tracer
0 Orange WIG • White with Green tracer
R.. Red W/R • White with Red tracer
A - ENGINE KILL SWITCH W White W/Y • White with Yellow tracer
SHURTET BUTTON
Y Yellow Y/Bl • Yellow with Blue tracer
B/W Black with White tracer Y/G • Yellow with Green tracer
TURN SIGNAL INDICATOR LIGHT
B/Y Black with Yellow tracer
-
H - HIGH BEAM INOICATOH LIGHT
P OIL PRESSURE INRICATOR LIGIIT
N - NEUTRAL INDICATOR LIGHT
FRONT TARN SIGNAl LIGHT 101
TAILISRAKE LIGHT
PARKING OR ClOT LIGHT I
TURN SIGNAL LIGHT
III
D
Q
-J
LU
LEPT HANDLEBAR SWITCH
0
LL
WIRE COLOR
81 Blue G/Bl Green with Blue tracer
ENGINE KILL SWITCH
STARTER HUtTON
W White W/Y White with Yellow tracer
B
Y Yellow Y/Bl Yellow with Blue tracer
B/W Black with White tracer Y/G Yellow with Green tracer
B HIGH REAM INUICATOR LIGHT B/Y Black with Yellow tracer
P OIl PRESSURE INDICATOR 11611’
FRONT TURN SIGNAL EIGHT HI
U,
-J
Lii
z
I-
LU
z
>-
LU
I...
0
LL
WIRE COLOR
BI Blue G/BI • Green with Blue tracer
G Green G/Y • Green with Yellow tracer
Gr Gray 01W • Orange with White tracer
Lbl Light blue RIB • Red with Black tracer
0 Orange WIG • White with Green tracer
R.. Red W/R • White with Red tracer
A - ENGINE KILL SWITCH W White W/Y • White with Yellow tracer
SHURTET BUTTON
Y Yellow Y/Bl • Yellow with Blue tracer
B/W Black with White tracer Y/G • Yellow with Green tracer
TURN SIGNAL INDICATOR LIGHT
B/Y Black with Yellow tracer
-
H - HIGH BEAM INOICATOH LIGHT
P OIL PRESSURE INRICATOR LIGIIT
N - NEUTRAL INDICATOR LIGHT
FRONT TARN SIGNAl LIGHT 101
TAILISRAKE LIGHT
PARKING OR ClOT LIGHT I
TURN SIGNAL LIGHT
III
D
Q
-J
LU
LEPT HANDLEBAR SWITCH
0
LL
C,,
Handle S/W. R.L. ><
Meter ignition S/W QcD
ClampI
Clamp Clamp
Handle S/W L
Main wiring harness
Regulated rectifier Ground
Fuse Electric parts holder ground
Brake hose to Starter relay
to Battery
• to Fuse
holder bolt
Ignitor
© to Crankcase bolt
M am wiring harness
Turn signal relay
Brake hose
Main wiring harness Battery

Secure with crank case bolt
e
Starter relay
Tighten together with the battery holder retaining bolt

uide
C)
D
c
7
- ..e.
z
-I
CD
C)
I
I :xJ
0
C
CD
C
C)
C)
C)
0)
CD
6
o -,
C 0
Cn C
(0
0)
3
CD
-
CD
(0 0
0
CD
CD 0)
—
CD
C-,
C,,
N)
t’J
C,,
Handle S/W. R.L. ><
Meter ignition S/W QcD
ClampI
Clamp Clamp
Handle S/W L
Main wiring harness
Regulated rectifier Ground
Fuse Electric parts holder ground
Brake hose to Starter relay
to Battery
• to Fuse
holder bolt
Ignitor
© to Crankcase bolt
M am wiring harness
Turn signal relay
Brake hose
Main wiring harness Battery

Secure with crank case bolt
e
Starter relay
Tighten together with the battery holder retaining bolt

uide
C)
D
c
7
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-I
CD
C)
I
I :xJ
0
C
CD
C
C)
C)
C)
0)
CD
6
o -,
C 0
Cn C
(0
0)
3
CD
-
CD
(0 0
0
CD
CD 0)
—
CD
C-,
C,,
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i3 GSX400T GSX400T 124
SERVICE DATA CRANKSHAFT + CYLINDER HEAD Unit: mm (in)

VALVE + GUIDE Unit: mm (in) ITEM STANDARD — LIMIT
ITEM STANDARD LIMIT *
Cam height 34.650—34.690
IN. 34.350
Valve diam. 23 ( 1.3642—1.3657 ) ( 1.3524)
I N.
( 0.90 34. 350
EX.
20 1.3642—1.3657) ( 1.3524
EX.
( 0.78 Camshaft journal oil clearance 0.032—0.066 0.150
IN. & EX.
70 0.0013—0.0026 ) ( 0.0059)
Valve lift I N.
( 0.28 Camshaft journal holder I.D. 22.012—22.025
IN. & EX.
7.0 ( 0.8666—0.867 1 )
EX.
—______________
( 0.28 Camshaft journal O.D. 21.959—21.980

IN. & EX.
Valve clearance or tappet clearance ( 0.8645—0.8654
0.08—0.13 Camshaft runout 0.10
(when cold) IN. & EX. IN. & EX.
( 0.003—0.005
( 0.004
Cam chain 20 pitch length 157.80
0.025—0.052 0.35 ( 6.213
Valve guide to valve stem clearance IN.
( 0.0010—0.0020 ) ( 0.014 Cam chain pin (at arrow ‘3”) 20 th pin
0.040—0.067 0.35
EX. Rocker arm l.D. 12.000—12.018
( 0.0016—0.0026 ) ( 0.014 IN. & EX.
5.500—5.512
( 0.4724—0.4731
Valve guide I.D. IN.& EX. Rocker arm shaftO.D. 11.973—11.984
(_0.2165—0.2170 IN. & EX.
5.460—5.475
( 0.4714—0.4718)
Valve stem O.D. I N. Cylinder head distortion 0.10
(_0.2150—0.2156
5.445— 5.460 ( 0.004
EX.
(_0.2144—0.2150 .‘
0.05
(_0.002 *
0.5
Valve head thickness IN. & EX. ITEM STANDARD
(__0.02 LIMIT
3.6 Cam height 33.350—33.390 33.050
Valve stem end length IN.
IN. & EX. (1.3130—1.3146) (1.3012)
(__0.14
0.9—1.1 — 33.350—33.390 33.050
Valve seat width IN. & EX. EX.
(1.3130—1.3146) (1.3012)
(__0.035—0.043
0.03 Valve lift 4.8
Valve head radial runout IN. & EX. IN.
(_0.001 (0.19)
31.9 4.8
Valve spring free length INNER EX.
( 1.26 (0.19)
(IN.&EX.)
35.5
OUTER
(__1.40
Valve spring tension 4.4—6.4 kg
(IN. & EX.) INNER ( 9.7—14.1 Ibs)
at_length28.5mm_(_1.12_in)
6.5—8.9 kg
OUTER ( 14.3—19.6 Ibs)
at_Iength32.Omm_(_1.26_in)
i3 GSX400T GSX400T 124
SERVICE DATA CRANKSHAFT + CYLINDER HEAD Unit: mm (in)

VALVE + GUIDE Unit: mm (in) ITEM STANDARD — LIMIT
ITEM STANDARD LIMIT *
Cam height 34.650—34.690
IN. 34.350
Valve diam. 23 ( 1.3642—1.3657 ) ( 1.3524)
I N.
( 0.90 34. 350
EX.
20 1.3642—1.3657) ( 1.3524
EX.
( 0.78 Camshaft journal oil clearance 0.032—0.066 0.150
IN. & EX.
70 0.0013—0.0026 ) ( 0.0059)
Valve lift I N.
( 0.28 Camshaft journal holder I.D. 22.012—22.025
IN. & EX.
7.0 ( 0.8666—0.867 1 )
EX.
—______________
( 0.28 Camshaft journal O.D. 21.959—21.980

IN. & EX.
Valve clearance or tappet clearance ( 0.8645—0.8654
0.08—0.13 Camshaft runout 0.10
(when cold) IN. & EX. IN. & EX.
( 0.003—0.005
( 0.004
Cam chain 20 pitch length 157.80
0.025—0.052 0.35 ( 6.213
Valve guide to valve stem clearance IN.
( 0.0010—0.0020 ) ( 0.014 Cam chain pin (at arrow ‘3”) 20 th pin
0.040—0.067 0.35
EX. Rocker arm l.D. 12.000—12.018
( 0.0016—0.0026 ) ( 0.014 IN. & EX.
5.500—5.512
( 0.4724—0.4731
Valve guide I.D. IN.& EX. Rocker arm shaftO.D. 11.973—11.984
(_0.2165—0.2170 IN. & EX.
5.460—5.475
( 0.4714—0.4718)
Valve stem O.D. I N. Cylinder head distortion 0.10
(_0.2150—0.2156
5.445— 5.460 ( 0.004
EX.
(_0.2144—0.2150 .‘
0.05
(_0.002 *
0.5
Valve head thickness IN. & EX. ITEM STANDARD
(__0.02 LIMIT
3.6 Cam height 33.350—33.390 33.050
Valve stem end length IN.
IN. & EX. (1.3130—1.3146) (1.3012)
(__0.14
0.9—1.1 — 33.350—33.390 33.050
Valve seat width IN. & EX. EX.
(1.3130—1.3146) (1.3012)
(__0.035—0.043
0.03 Valve lift 4.8
Valve head radial runout IN. & EX. IN.
(_0.001 (0.19)
31.9 4.8
Valve spring free length INNER EX.
( 1.26 (0.19)
(IN.&EX.)
35.5
OUTER
(__1.40
Valve spring tension 4.4—6.4 kg
(IN. & EX.) INNER ( 9.7—14.1 Ibs)
at_length28.5mm_(_1.12_in)
6.5—8.9 kg
OUTER ( 14.3—19.6 Ibs)
at_Iength32.Omm_(_1.26_in)
125 GSX400T GSX400T 126
CYLINDER + PISTON + PISTON RING

Unit: mm (in)
LIMIT
ITEM STANDARD LIMIT
ITEM STANDARD
Conrod small end l.D. 18,00618,014 18.040
Compression pressure 10 — 14 kg/cm
2 8 kg/cm
2
( 0.7089—0.7092 ) ( 0.7102)
( 142 — 199 psi) ( 114 psi)
Conrod big end thrust clearance 0.10—0.20 0.30
Compression pressure difference 2 kg/cm
2
( 0.004—0.008 ) ( 0.012
(__28.4__psi)
Piston to cylinder clearance 0.050—0.060 0.120
( 0.904—0.906
( 0.0020—0.0024 ) ( 0.0047)
Crank pin width 23.10—23.15
Cylinder bore 67,000—67.01 5 67.080
( 0.909—0.91 1
( 2.6378-- 2.6384 ) ( 2.6410)
Conrod big end oil clearance 0.024—0.048 0.080
Piston diam. 66.945—66.960 66.880 ( 0.0009—0.00 1 9 ) ( 0.003 1)
4
( 2.6356—2.6362 ) ( 2.6331 Crank pin O.D. 33.976—34.000
( 1.3376—1.3386
Measure at thei 5.Q( 0.59 ) from skirt end.
Crankshaft journal oil clearance 0.020—0.044 0.080
Cylinder distortion 0.10
( 0.0008—0.0017 ) ( 0.0031)
(_0.004
Piston ring free end gap 95 7.6
N Approx. ( 1.2589—1.2598
( 0.37 ) ( 0.30
1st Crankshaft thrust bearing thickness 2.95—2.98 2.85
9.5 7.6
R Approx ( 0.116—0.117 ) ( 0.112
• 0.37 )( ( 0.30
10.0 8.0
N Approx (_0.002
( 0.39 ) ( 0.31
2nd —
Balancer journal oil clearance 0.020—0.044 0.080
10.0 8.0
R Approx ( 0.0008—0.0017 ) ( 0.0031
( 0.39 ) ( 0.31
Balancer journal O.D. 31 .984—32.000
Piston ring end gap 0.10—0.30 0.7
( 1.2592—1.2598
—
1st
( 0.004—0.012 ) ( 0.03
0.10—0.30 0.7
2nd
( 0.004—0.012 ) ( 0.03
Piston ring to groove clearance 0.180
1st OIL PUMP
(_0.0071
0.150 ITEM STANDARD LIMIT
2nd
(_0.0059) Oil pump reduction ratio 2.07 1 ( 76 / 28 x 29 / 38
Piston ring groove width 1 .21 —1 .23 3.0 kg/cm
2
1 St Oil pressure (at 60°C, 140°F)
(__0.047—0.048 Above
( 43 psi)
1.21—1.23 5.5 2
kg/cm
2nd Below
(__0.047—0.048 ( 78 psi)
2.51 —2.53 at 3000 r/min.
Oil
( 0.099—0.100
Piston ring thickness 1.175—1.190
1st
(_0.0463—0.0469
1.170—1.190
2nd
( 0.0461—0.0469
Piston pin bore 18.002—18.008 18.030
( 0.7087—0.7090 ) ( 0.7098
Piston pin O.D. 17.996—18.000 17.980
( 0.7085—0.7087 ) ( 0.7079)
125 GSX400T GSX400T 126
CYLINDER + PISTON + PISTON RING

Unit: mm (in)
LIMIT
ITEM STANDARD LIMIT
ITEM STANDARD
Conrod small end l.D. 18,00618,014 18.040
Compression pressure 10 — 14 kg/cm
2 8 kg/cm
2
( 0.7089—0.7092 ) ( 0.7102)
( 142 — 199 psi) ( 114 psi)
Conrod big end thrust clearance 0.10—0.20 0.30
Compression pressure difference 2 kg/cm
2
( 0.004—0.008 ) ( 0.012
(__28.4__psi)
Piston to cylinder clearance 0.050—0.060 0.120
( 0.904—0.906
( 0.0020—0.0024 ) ( 0.0047)
Crank pin width 23.10—23.15
Cylinder bore 67,000—67.01 5 67.080
( 0.909—0.91 1
( 2.6378-- 2.6384 ) ( 2.6410)
Conrod big end oil clearance 0.024—0.048 0.080
Piston diam. 66.945—66.960 66.880 ( 0.0009—0.00 1 9 ) ( 0.003 1)
4
( 2.6356—2.6362 ) ( 2.6331 Crank pin O.D. 33.976—34.000
( 1.3376—1.3386
Measure at thei 5.Q( 0.59 ) from skirt end.
Crankshaft journal oil clearance 0.020—0.044 0.080
Cylinder distortion 0.10
( 0.0008—0.0017 ) ( 0.0031)
(_0.004
Piston ring free end gap 95 7.6
N Approx. ( 1.2589—1.2598
( 0.37 ) ( 0.30
1st Crankshaft thrust bearing thickness 2.95—2.98 2.85
9.5 7.6
R Approx ( 0.116—0.117 ) ( 0.112
• 0.37 )( ( 0.30
10.0 8.0
N Approx (_0.002
( 0.39 ) ( 0.31
2nd —
Balancer journal oil clearance 0.020—0.044 0.080
10.0 8.0
R Approx ( 0.0008—0.0017 ) ( 0.0031
( 0.39 ) ( 0.31
Balancer journal O.D. 31 .984—32.000
Piston ring end gap 0.10—0.30 0.7
( 1.2592—1.2598
—
1st
( 0.004—0.012 ) ( 0.03
0.10—0.30 0.7
2nd
( 0.004—0.012 ) ( 0.03
Piston ring to groove clearance 0.180
1st OIL PUMP
(_0.0071
0.150 ITEM STANDARD LIMIT
2nd
(_0.0059) Oil pump reduction ratio 2.07 1 ( 76 / 28 x 29 / 38
Piston ring groove width 1 .21 —1 .23 3.0 kg/cm
2
1 St Oil pressure (at 60°C, 140°F)
(__0.047—0.048 Above
( 43 psi)
1.21—1.23 5.5 2
kg/cm
2nd Below
(__0.047—0.048 ( 78 psi)
2.51 —2.53 at 3000 r/min.
Oil
( 0.099—0.100
Piston ring thickness 1.175—1.190
1st
(_0.0463—0.0469
1.170—1.190
2nd
( 0.0461—0.0469
Piston pin bore 18.002—18.008 18.030
( 0.7087—0.7090 ) ( 0.7098
Piston pin O.D. 17.996—18.000 17.980
( 0.7085—0.7087 ) ( 0.7079)
127 GSX400T
GSX400T 128
CLUTCH Unit: mm (in)

CARBURETOR Unit: mm (in)
ITEM STANDARD LIMIT
SPEC I FICATION
Clutch cable play 4.0 ITEM
General and the others Only for E-22
(__0.16
Clutch release screw - Carburetortype MIKUNI BS34SS
Turn back
—
Bore size 34
Drive plate thickness 2.9—3.1 2.6
( 0.11—0.12 ) ( 0.10 I. D. No, 44202 44220
Drive plate claw width 1 5.8—16.0 1 5.0
Idler/mm. 1100 50 r/min.
Driven plate thickness

( 0.62—0.63
1 .60 ± 0.06
) ( 0.59
I Fuel level 5.0
±
± 0.5
(_0.063 ± 0.002 ( 0.20 ± 0.02
0.1 Float height 22.4 ± 1.0
Driven plate distortion
( 0.004) ( 0.88 ± 0.04
Clutch spring free length 38.4 Main jet (M. J.) # 1 1 7.5
( 1.51
Main air jet (M. A. J.) 0.6
TRANSMISSION + DRIVE CHAIN Unit: mm (in) Jet needle (J. N.) 5D69-4
ITEM STANDARD LIMIT
Needle jet (N. J.) P-i P-2
Primary reduction ratio 2.7 14 ( 76 / 28
Pilotjet (P.J.) # 42.5 C

By pass (B. P.) 0.9, 0.8, 08
Gear ratios Low 2.46 1 ( 32 / 13
Pilot outlet (P. 0.) 0.8 C
2nd 1.777 ( 32 / 18
Valve seat (V. S.) 2.0
3rd 1.380 ( 29 / 21
Starter jet (G.S.) # 32.5 C
4th 1.125 ( 27 / 24
Pilot screw (P. S.) 1 1/2 turn out
5th 0.961 ( 25 / 26
Pilotairjet (P.A.J.) # 125
Top 0.851 ( 23 / 27
Throttle cable play 0.5—1 .0
Shift fork to groove clearance 0.10—0.30 0.50 ( 0.02—0.04
( 0.004—0.012 ) ( 0.020
Shift fork groove width 5.5—5.6
(__0.217—0.220
Shift fork thickness 5.4
(__0.209—0.213
(Low to 2nd) ( 4.52 ± 0.004
Drive chain Type D.l.D.: 5OUB
Links 104
. 324.3
20 pitch length
( 1 2.77
( 0.8—1.2
127 GSX400T
GSX400T 128
CLUTCH Unit: mm (in)

CARBURETOR Unit: mm (in)
ITEM STANDARD LIMIT
SPEC I FICATION
Clutch cable play 4.0 ITEM
General and the others Only for E-22
(__0.16
Clutch release screw - Carburetortype MIKUNI BS34SS
Turn back
—
Bore size 34
Drive plate thickness 2.9—3.1 2.6
( 0.11—0.12 ) ( 0.10 I. D. No, 44202 44220
Drive plate claw width 1 5.8—16.0 1 5.0
Idler/mm. 1100 50 r/min.
Driven plate thickness

( 0.62—0.63
1 .60 ± 0.06
) ( 0.59
I Fuel level 5.0
±
± 0.5
(_0.063 ± 0.002 ( 0.20 ± 0.02
0.1 Float height 22.4 ± 1.0
Driven plate distortion
( 0.004) ( 0.88 ± 0.04
Clutch spring free length 38.4 Main jet (M. J.) # 1 1 7.5
( 1.51
Main air jet (M. A. J.) 0.6
TRANSMISSION + DRIVE CHAIN Unit: mm (in) Jet needle (J. N.) 5D69-4
ITEM STANDARD LIMIT
Needle jet (N. J.) P-i P-2
Primary reduction ratio 2.7 14 ( 76 / 28
Pilotjet (P.J.) # 42.5 C

By pass (B. P.) 0.9, 0.8, 08
Gear ratios Low 2.46 1 ( 32 / 13
Pilot outlet (P. 0.) 0.8 C
2nd 1.777 ( 32 / 18
Valve seat (V. S.) 2.0
3rd 1.380 ( 29 / 21
Starter jet (G.S.) # 32.5 C
4th 1.125 ( 27 / 24
Pilot screw (P. S.) 1 1/2 turn out
5th 0.961 ( 25 / 26
Pilotairjet (P.A.J.) # 125
Top 0.851 ( 23 / 27
Throttle cable play 0.5—1 .0
Shift fork to groove clearance 0.10—0.30 0.50 ( 0.02—0.04
( 0.004—0.012 ) ( 0.020
Shift fork groove width 5.5—5.6
(__0.217—0.220
Shift fork thickness 5.4
(__0.209—0.213
(Low to 2nd) ( 4.52 ± 0.004
Drive chain Type D.l.D.: 5OUB
Links 104
. 324.3
20 pitch length
( 1 2.77
( 0.8—1.2
129 GSX400T GSX400T 130
ITEM SPECIFICATION NOTE ITEM STANDARD LIMIT

200 B.T.D.C. Belowl65O± 100 r/min and
Rear brake pedal free travel
20—30
Ignition timing
40° B.T.D.C. Above 3500± 100 r/min. ( 0.8— 1.2
NGK D8EA Rear brake pedal height 15
Spark plug Type 0.6
NIPPON DENSO X24ES-U
General and E-25
0.6—0.7 Brake drum ID. 160.7
Gap Rear
( 0.024—0.028 ( 6.33
NGK DR8ES-L Onlyfor 180.7
Type Rear
NIPPON DENSO X24ESR-U E-02 ( 7.11
The others 1.5
0.6—0.7 Brake lining thickness
Gap
( 0.024—0.028 ( 0.06
Spark performance Over 8 (0.3) at 1 atm Front ( 0.20 ± 0.004 ) ( 0.18
Approx. 60 80 2 Br—B/W
Signal coil resistance —
GIW— B/W Brake disc runout 0.30

O/W—W or B ( 0.012
Ignition coil resistance Primary
Approx. 3 5 Master cylinder bore 14.000—14.043
Front
—
Plugcap WorB —
0.5512—0.5529
Secondary 13.957—13.984
Approx. 21 25 k2 Master cylinder piston diam. Front
—
0.5495—0.5506
Generator no-load voltage More than 75 V (AC) at 5000 r/min.
Brake caliper cylinder bore 42.850—42.926
Front
Regulated voltage 14 — 15 V at 5000 r/min. ( 1 .6870—1 .6900
Brake caliper piston diam. 42.770—42.820
Starter motor Brush length N. D. Limit: ( 04 Front
1.6839—1.6858
Commutatorundercut Limit: (o?ó8) Wheel rim runout 2.0
Axial
Approx.
( 0.08
Starter relay resistance 3 4
2.0
—
Radial
Battery Type designation YB1 OL-A2 ( 0.08
12V 43.2 kC Wheel axle runout 0.25
Capacity Front
(1 2Ah)/1 OHR ( 0.010
Standard 0.25
1.28 at2O°C(68°F) Rear
electrolyte S. G. ( 0.010
Fuse size Main 15 A Tire size 90!90—19 52S
Front
Rear 110/90—1760S

Front
( 0.06
2.0
Rear
( 0.08
129 GSX400T GSX400T 130
ITEM SPECIFICATION NOTE ITEM STANDARD LIMIT

200 B.T.D.C. Belowl65O± 100 r/min and
Rear brake pedal free travel
20—30
Ignition timing
40° B.T.D.C. Above 3500± 100 r/min. ( 0.8— 1.2
NGK D8EA Rear brake pedal height 15
Spark plug Type 0.6
NIPPON DENSO X24ES-U
General and E-25
0.6—0.7 Brake drum ID. 160.7
Gap Rear
( 0.024—0.028 ( 6.33
NGK DR8ES-L Onlyfor 180.7
Type Rear
NIPPON DENSO X24ESR-U E-02 ( 7.11
The others 1.5
0.6—0.7 Brake lining thickness
Gap
( 0.024—0.028 ( 0.06
Spark performance Over 8 (0.3) at 1 atm Front ( 0.20 ± 0.004 ) ( 0.18
Approx. 60 80 2 Br—B/W
Signal coil resistance —
GIW— B/W Brake disc runout 0.30

O/W—W or B ( 0.012
Ignition coil resistance Primary
Approx. 3 5 Master cylinder bore 14.000—14.043
Front
—
Plugcap WorB —
0.5512—0.5529
Secondary 13.957—13.984
Approx. 21 25 k2 Master cylinder piston diam. Front
—
0.5495—0.5506
Generator no-load voltage More than 75 V (AC) at 5000 r/min.
Brake caliper cylinder bore 42.850—42.926
Front
Regulated voltage 14 — 15 V at 5000 r/min. ( 1 .6870—1 .6900
Brake caliper piston diam. 42.770—42.820
Starter motor Brush length N. D. Limit: ( 04 Front
1.6839—1.6858
Commutatorundercut Limit: (o?ó8) Wheel rim runout 2.0
Axial
Approx.
( 0.08
Starter relay resistance 3 4
2.0
—
Radial
Battery Type designation YB1 OL-A2 ( 0.08
12V 43.2 kC Wheel axle runout 0.25
Capacity Front
(1 2Ah)/1 OHR ( 0.010
Standard 0.25
1.28 at2O°C(68°F) Rear
electrolyte S. G. ( 0.010
Fuse size Main 15 A Tire size 90!90—19 52S
Front
Rear 110/90—1760S

Front
( 0.06
2.0
Rear
( 0.08
GSX400T 132
131 GSX400T
TIRE PRESSURE
SUSPENSION Unit: mm (in)
ITEM STANDARD LIMIT NOTE
COLD INFLATION
140 TIRE PRESSURE SOLO RIDING DUAL RIDING SOLO RIDING DUAL RIDING
Front fork stroke
( 5.5
kPa 2
kg/cm psi kPa 2
kg/cm psi kPa 2
kg/cm PSi kPa 2
kg/cm Psi
Front fork spring free length 496
(__19.5 FRONT 150 1.50 21 175 1.75 25 175 1.75 25 200 2.00 28
Front fork oil level 198
REAR 175 1.75 25 225 2.25 32 175 1.75 25 250 2.50 36
( 7.8
Rear wheel travel

. ( 3.7
Swing arm pivot shaft runout 0.3
0.012 WATTAGE (W)
SPEC I FICATION
ITEM
E-01 E-02 E21,22,25
Headlight HI 45 35
FUEL + OIL
ITEM SPECIFICATION NOTE LO 45 35 40
Fuel type
Use gasoline with an octane number of Parking or city light 3.4 4
85-90 or higher (Research Method), Tail/Brake light 8/23 5/21
preferably unleaded or low-lead.
Fuel tank including reserve 12 L
(__3.2 / 2.6 US/Imp_gal)
reserve 4.0 L Tachometer light 3.4
( 4.2 / 3.5 US/Imp_qt)
ml
Engine oil capacity 2600
Change
(__2.7__/__2.3__US/Imp_qt) Neutral indicator light 3.4
Filter ml
2900
change (__3.1 / 2.6
US/Imp_qt) Oil pressure indicator light 3.4
3000 ml Gear position indicator light 1 .1
Overhaul
(__3.2__/__2.6 US/Imp_qt)
Front fork oil type Mixture ratio SAE 1 OW/3O : A.T.F = 1 : 1

(__5.00 /__5.21 US/Imp_oz)
GSX400T 132
131 GSX400T
TIRE PRESSURE
SUSPENSION Unit: mm (in)
ITEM STANDARD LIMIT NOTE
COLD INFLATION
140 TIRE PRESSURE SOLO RIDING DUAL RIDING SOLO RIDING DUAL RIDING
Front fork stroke
( 5.5
kPa 2
kg/cm psi kPa 2
kg/cm psi kPa 2
kg/cm PSi kPa 2
kg/cm Psi
Front fork spring free length 496
(__19.5 FRONT 150 1.50 21 175 1.75 25 175 1.75 25 200 2.00 28
Front fork oil level 198
REAR 175 1.75 25 225 2.25 32 175 1.75 25 250 2.50 36
( 7.8
Rear wheel travel

. ( 3.7
Swing arm pivot shaft runout 0.3
0.012 WATTAGE (W)
SPEC I FICATION
ITEM
E-01 E-02 E21,22,25
Headlight HI 45 35
FUEL + OIL
ITEM SPECIFICATION NOTE LO 45 35 40
Fuel type
Use gasoline with an octane number of Parking or city light 3.4 4
85-90 or higher (Research Method), Tail/Brake light 8/23 5/21
preferably unleaded or low-lead.
Fuel tank including reserve 12 L
(__3.2 / 2.6 US/Imp_gal)
reserve 4.0 L Tachometer light 3.4
( 4.2 / 3.5 US/Imp_qt)
ml
Engine oil capacity 2600
Change
(__2.7__/__2.3__US/Imp_qt) Neutral indicator light 3.4
Filter ml
2900
change (__3.1 / 2.6
US/Imp_qt) Oil pressure indicator light 3.4
3000 ml Gear position indicator light 1 .1
Overhaul
(__3.2__/__2.6 US/Imp_qt)
Front fork oil type Mixture ratio SAE 1 OW/3O : A.T.F = 1 : 1

(__5.00 /__5.21 US/Imp_oz)
Prepared by
SUZUKI MOTOR CO., LTD.
Service Department
Overseas Operations Division
3rd Ed. August, 1981
1st Ed. November, 1980
Manual No.: 99500-34000-OlE

Printed in Japan
Prepared by
SUZUKI MOTOR CO., LTD.
Service Department
Overseas Operations Division
3rd Ed. August, 1981
1st Ed. November, 1980
Manual No.: 99500-34000-OlE

Printed in Japan
SUZUKI MOTOR CON, LTD.
SUZUKI MOTOR CON, LTD.

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FOREWORD

SUZUKI MOTOR CO.,LTD.

Quoting, copying or otherwise using any part of this manual without ex

VIEW OF SUZUI(I GSX400E BREAKING-IN R/MIN

SPECI Fl CATI ONS

VIEW OF SUZUI(I GSX400E BREAKING-IN R/MIN

SPECI Fl CATI ONS

These specifications are subject to change without notice.

These specifications are subject to change without notice.

VALVE AND CAMSHAFT

IN.open Ex. close

20th pin 1St

VALVE AND CAMSHAFT

IN.open Ex. close

20th pin 1St

CYLINDER HEAD CYLINDER, PISTON AND RING

® with new one. REASSEMBLY

CYLINDER HEAD CYLINDER, PISTON AND RING

® with new one. REASSEMBLY

CRANKSHAFT AND CONNECTING ROD

I CRANKSHAFT AND COUNTER

GSX25O Service Manual page 3-43.)

STANDARD SIZE BEARING

UNDER-SIZE BEARING Tightening 90—110 N.m

CRANKSHAFT AND CONNECTING ROD

I CRANKSHAFT AND COUNTER

GSX25O Service Manual page 3-43.)

STANDARD SIZE BEARING

UNDER-SIZE BEARING Tightening 90—110 N.m

09913-80112 Bearing installer

• Check the springs for strength by measuring

Moty paste 14.2 mm I

• Pull out the counter balancer drive gear.

09913-80112 Bearing installer

• Check the springs for strength by measuring

Moty paste 14.2 mm I

• Pull out the counter balancer drive gear.

• Fix the washer (j, spacer ® and washer

• Fix two oil separater plate ® with 4 screws

• Seat washer and tighten oil pressure regulator

• Fix the washer (j, spacer ® and washer

• Fix two oil separater plate ® with 4 screws

• Seat washer and tighten oil pressure regulator

GEARSHIFT CAM AND FORK

• Place two “C” rings (fj and knock pin @J

• Be sure to install the bearing dowel pins

GEARSHIFT CAM AND FORK

• Place two “C” rings (fj and knock pin @J

• Be sure to install the bearing dowel pins

CLUTCH AND OIL PUMP

• Driven plate is the first to go into the sleeve

• Install primary driven gear and thrust washer

CLUTCH AND OIL PUMP

• Driven plate is the first to go into the sleeve

• Install primary driven gear and thrust washer

NOTE • Position new gasket to align two holes ©

09910-20115 Con rod stopper

torque (0.4 0.6 kg-rn)

• Apply grease to oil seal lip of the crankshaft.