Gixxer 400 cam timing? anyone?

Question

I've a cute 'lil suzy GSX-r 400 circa '85
It's a GK73a import so i can't get any info in english on the bike,even my local dealer won't touch it! the rotter..
Does anyone know how to set the cam chain timing up? do YOU know the all fabled secret to the mistical cam gear markings that will guide me to nobrokenvalveshire? or even better, do you know someone who hath the tome of guidance? (english workshop manual). and if ya have any bits for one, mail me plz!!

Answer 1

Rob,,,no solid info here.
Just some suggestions.

#1,,"Beggers cannot be Chosers"

Meaning ,,take what you can get.
Those are Scarce Bikes to begin with,,
and English Language info is even More scarce.
And they are getting fairly Old by now which only makes things harder to find.

The Jap Language manuals are worth having for the Pictures alone.
( I recall struggling to read old Brit Bike manuals due to the Language Barrier all we Yanks here in the US suffer,,LOL)

Seriously,,Jap Manual Photos are typically VERY useful.
And it's Not that difficult to find Translation Help from all sorts of sources,,especially if you're anywhere near a major city.

All the 4 cylinders' engines were basically the same thru all the different year-models.

A GSF Bandit 400 engine ,,,which began in 1989,,
is same basic engine as GSX-R400.

A Service Manual for a GSF 400 would cover most of the Basics of ENGINE/Trans/Clutch details.

I am Not certain about things like Carb Specs,,Generator Specs,,,,those are PROBABLY different.
Thus I would Not reccomend Relying on a GSF Manual as a Complete & Accurate Cross-Refference for a GSXR.

Most things like Basic Tear-Down & Re-Assembly on Clutch,Trans,Engine will be Identical to a GSXR.

CAM Installation & timing would be Identical for a GSF because it "IS"
a "GSX" engine.

VALVE CLEARANCE Procedures would be Identical.
But the particular Clearance Specs would Possibly,,Probably be Different.
Cuz of different Tuning Specs,,CamProfiles,etc

So,,a GSF Manual would only be a PARTIAL Source.
Though RELIABLE in the areas where it Does apply

I found a Jap Language manual on EBAY
In my opinion it's worth having.

The words and letters are in Japanese,,,
but in Most Cases any NUMBERS are written "English".
Various Dimensions,Clearances,Capacities,,Jet Sizes,Sprocket Tooth Count,,etc will most Likely be Readable.
I won't Swear to that,,,but I bet they are.


http://cgi.ebay.co.uk/Genuine-Suzuki-GSX-R400-manual-GK73A-J-FJ-RK-RFK_W0QQitemZ200102224071QQihZ010QQcategoryZ122275QQssPageNameZWDVWQQrdZ1QQcmdZViewItem
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Also,,just general info---
The GK73's did not appear till 1988.

'87 and earlier were -71x series.

First GK73a was the 1st model with a 4-into-2 Exhaust.
Having a silencer on each side of the bike.
All earlier than '88 GK73a had 4-into-1 w/ a single silencer.

'86's were only ones with Single Headlight

All '84,'85,'86's had wheels with 3 Pairs of "thin" Spokes,,,,total 6 separate spokes

'87 and Later had 3 wide,Solid spokes


Here's a GSF Service & parts Manual on CD.
This AIN'T Your Bike,,
But it IS Your ENGINE( or,basically so)

http://cgi.ebay.co.uk/Suzuki-GSF400-Bandit-Microfiche-Manual-CD_W0QQitemZ150113786391QQihZ005QQcategoryZ122276QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

...............................................................

I suppose I'm Stupid,,,I have NO Idea what an "Instruction Book " is.
I would assume an Operator's /Owner's Manual ???

You might contact these folks for specific details about Content & what all this covers???

http://cgi.ebay.com/Suzuki-GSX-R400-Instruction-book_W0QQitemZ220104308160QQihZ012QQcategoryZ9945QQrdZ1QQssPageNameZWD2VQQcmdZViewItem#ebayphotohosting


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As I said in the beginning,,not much actual info

Hopefully some of it may be of use to you.

Good Luck with it,,,hope you get it going good.

Answer 2

Not being familiar with that model I have to assume that the cam chain tensioner is automatic. If you have removed it or have already pulled the cams out the chain tensioner will have automatically extended. You MUST reset it before reinstallation, if you don't you could SERIOUSLY DAMAGE something, be sure to look into this.

Answer 3

--Remove cam chain chain tensioner.
--#1 piston @ TDC.
--Line up a flywheel mark at a pointer, or center of an inspection hole (I don't know what your bike looks like).
--#1 cam lobes pointing "away" from each other.
--Any markings on the cam sprocket should line up with the head surface.
--Push your finger through the tensioner hole to remove slack from the cam chain.
--Re-check all timing marks (flywheel - cam sprocket).
--Finger tighten sprocket bolts.
--Install tensioner.
--Re-check timing marks.
--Turn flywheel in direction of crankshaft rotation "slowly".
--If you feel any resistance, STOP turning. (valve may be hitting).
--Re-set timing if any problems.
--Tighten cam sprocket bolts.

Answer 4

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Answer 5

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Answer 6

align the dots or arrows which ever the gears have, also check to make sure piston is on the firing stroke