Suzuki GSX1400 User manual

99500-39222-01E
GSX1400
www.GSX1400FE.com

GROUP INDEX
1
FOREWORD
This manual contains an introductory description
on the SUZUKI GSX1400 and procedures for its
inspection/service and overhaul of its main com-
ponents.
Other information considered as generally known
is not included.
Read the GENERAL INFORMATION section to fa-
miliarize yourself with the motorcycle and its main-
tenance. Use this section as well as other sections
to use as a guide for proper inspection and service.
This manual will help you know the motorcycle bet-
ter so that you can assure your customers of fast
and reliable service.
!
Inexperienced mechanics or mechanics with-
out the proper tools and equipment may not
be able to properly perform the services de-
scribed in this manual. Improper repair may
result in injury to the mechanic and may ren-
der the motorcycle unsafe for the rider and
passenger.
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GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FI SYSTEM
OIL COOLING AND
LUBRICATION SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
GSX1400K3 (’03-MODEL)
GSX1400K4 (’04-MODEL)
GSX1400K5/UDK5 (’05-MODEL)
* This manual has been prepared on the basis
of the latest specifications at the time of pub-
lication. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual motorcycle.
* Illustrations in this manual are used to show
the basic principles of operation and work pro-
cedures. They may not represent the actual
motorcycle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI motor-
cycles. If you do not have the proper knowl-
edge and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2001
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GENERAL INFORMATION 1-1
1
GENERAL INFORMATION
CONTENTS
WARNING/CAUTION/NOTE ............................................................. 1- 2
GENERAL PRECAUTIONS .............................................................. 1- 2
SUZUKI GSX1400K2 (2002-MODEL) .............................................. 1- 4
SERIAL NUMBER LOCATION ......................................................... 1- 4
FUEL AND OIL RECOMMENDATION .............................................. 1- 5
FUEL .............................................................................................. 1- 5
ENGINE OIL ................................................................................... 1- 5
BRAKE FLUID ............................................................................... 1- 5
FRONT FORK OIL ......................................................................... 1- 5
BREAK-IN PROCEDURES ............................................................... 1- 6
CYLINDER IDENTIFICATION ........................................................... 1- 6
INFORMATION LABELS .................................................................. 1- 7
SPECIFICATIONS ............................................................................. 1- 8
COUNTRY AND AREA CODES ....................................................... 1-10
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1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.
#
Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN-
INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you
are unsure about how to perform a particular service operation, ask a more experienced mechanic for ad-
vice.
GENERAL PRECAUTIONS
#
* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the motorcycle.
* When 2 or more persons work together, pay attention to the safety of each other.
* When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.
* When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer’s instructions.
* Never use gasoline as a cleaning solvent.
* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system until
they have cooled.
* After servicing the fuel, oil, engine coolant, exhaust or brake systems, check all lines and fit-
tings related to the system for leaks.
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GENERAL INFORMATION 1-3

* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-
lent.
* When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order.
* Be sure to use special tools when instructed.
* Make sure that all parts used in reassembly are clean. Lubricate them when specified.
* Use the specified lubricant, bond, or sealant.
* When removing the battery, disconnect the negative cable first and then the positive cable.
* When reconnecting the battery, connect the positive cable first and then the negative cable,
and cover the positive terminal with the terminal cover.
* When performing service to electrical parts, disconnect the battery negative cable unless the
service procedure requires the battery power.
* When tightening cylinder head and crankcase bolts and nuts, tighten the larger sizes first.
Always tighten the bolts and nuts diagonally from the inside working out and to the specified
tightening torque.
* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts,
cotter pins, circlips, and certain other parts as specified, be sure to replace them with new
ones. Also, before installing these new parts, be sure to remove any left over material from the
mating surfaces.
* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread is smeared with them.
* After reassembling, check parts for tightness and proper operation.
* To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and
other fluids: batteries, and tires.
* To protect the earth’s natural resources, properly dispose of used motorcycles and parts.
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1-4 GENERAL INFORMATION
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number)
Ais stamped on the right side of the steering head pipe. The
engine serial number Bis located on the rear side of the crank-
case. These numbers are required especially for registering the
machine and ordering spare parts.
* Difference between photograph and actual motorcycle depends on the markets.
RIGHT SIDE
SUZUKI GSX1400K2 (2002-MODEL)
LEFT SIDE
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GENERAL INFORMATION 1-5
FUEL AND OIL RECOMMENDATION
FUEL
Gasoline used should be graded 91 octane (Research Method) or higher. An unleaded gasoline is recom-
mended.
ENGINE OIL
Use a premium quality 4-stroke motor oil to ensure longer ser-
vice life of your motorcycle. Use only oils which are rated SF or
SG under the API service classification.
The recommended viscosity is SAE 10W-40. If an SAE 10W-40
motor oil is not available, select an alternative according to the
following chart.
BRAKE FLUID
Use DOT4 brake fluid.
#
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufac-
turer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid
for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period.
FRONT FORK OIL
Use fork oil L01 or an equivalent fork oil.
MULTIGRADE
TEMP.
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1-6 GENERAL INFORMATION
BREAK-IN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very
high standard but it is still necessary to allow the moving parts to “BREAK-IN”before subjecting the engine to
maximum stresses. The future performance and reliability of the engine depends on the care and restraint
exercised during its early life. The general rules are as follows.
•Keep to these break-in procedures:
Initial 800 km ( 500 miles): Below 4 500 r/min
Up to 1 600 km (1 000 miles): Below 6 700 r/min
Over to 1 600 km (1 000 miles): Below 9 000 r/min
•Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle
operation. However, do not exceed 9 000 r/min at any time.
CYLINDER IDENTIFICATION
The four cylinders of this engine are identified as No.1, No.2, No.3
and No.4 cylinder, as counted from left to right (as viewed by the
rider on the seat).
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GENERAL INFORMATION 1-7
INFORMATION LABELS
GSX1400 GSX1400UD
1Noise label For E-24
2Fuel caution label For E-02, 24
3Tire pressure label
4Warning safety label
5ID plate For E-02, 19, 24
6Loading capacitiy
Rear fender
unit: mm
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1-8 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ................................................................ 2 160 mm (85.0 in)
Overall width ................................................................. 810 mm (31.9 in)
Overall height ................................................................ 1 140 mm (44.9 in)
Wheelbase .................................................................... 1 520 mm (59.8 in)
Ground clearance ......................................................... 130 mm (5.1 in)
Seat height .................................................................... 790 mm (31.1 in)
Dry mass ....................................................................... 228 kg (502 lbs)
ENGINE
Type............................................................................... Four-stroke, air-cooled with SACS, DOHC
Number of cylinders ...................................................... 4
Bore .............................................................................. 81.0 mm (3.189 in)
Stroke ............................................................................ 68.0 mm (2.677 in)
Piston displacement ..................................................... 1 402 cm3(85.5 cu. in)
Compression ratio......................................................... 9.5 : 1
Fuel system .................................................................. Fuel injection system
Air cleaner ..................................................................... Non-woven fabric element
Starter system............................................................... Electric
Lubrication system ........................................................ Wet sump
Idle speed ..................................................................... 1 100 ± 100 r/min
TRANSMISSION
Clutch ............................................................................ Wet multi-plate type
Transmission ................................................................. 6-speed constant mesh
Gearshift pattern ........................................................... 1-down, 5-up
Primary reduction ratio ................................................. 1.509 (83/55)
Gear ratios, Low ............................................................ 2.916 (35/12)
2nd ............................................................ 1.937 (31/16)
3rd ............................................................. 1.526 (29/19)
4th .............................................................. 1.285 (27/21)
5th .............................................................. 1.136 (25/22)
Top ............................................................. 1.000 (24/24)
Final reduction ratio ...................................................... 2.277 (41/18)
Drive chain .................................................................... RK GB50GSVZ3, 116 links
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