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 GSX1400 K2
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France/Holland '05
 Head2Spain '06

"The Final Edition of the GSX1400 has got muscles like a power lifter and now howls through the Yoshimura exhaust"
 - Suzuki GB


www.GSX1400FE.com

GSX1400 Service manual & Parts Book

This is the Manuals downloads page, The manuals are free for you to download. It is the actual genuine service and parts manuals. The hard copy books are available from Suzuki dealers, Please use the right click and "save as" to save directly to your computer as repeated downloads use up my bandwidth. You will need an Adobe PDF file reader to view. 

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New GSX1400 Manuals On CD £3.50 or Download here
You can now buy a CD of all manuals below on this page for £3.50 + £1.50 P&P, you can pay by pay pal email me. Proceeds to towards the upkeep of this site dave@gsx1400fe.co.uk

**NEW for 2008** Download Individual Sections of the Service manual - K2 to K5 (PDF)
These individual manuals (below) are the most advanced PDF manuals available (see Screenshot, left), I have spent numerous hours making these and are fully interactive with bookmarks for ease of use to go direct to the part you want within its section, I've split up the manual into the sections/chapters to download separately, making it simpler to use and quicker download. click on the Red & Blue links below, I've listed underneath the links the contents of what is in the relevant sections as a description of each chapter  

Section 0 Index<< click to download (291kb)
Cover, forward and Index


Section 1 - General Information <<click to download (2.1mb)
CONTENTS OF THIS SECTION

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

Section 2 - Periodic Maintenance <<click to download (2.1mb)

PERIODIC MAINTENANCE SCHEDULE......................................... 2- 2

PERIODIC MAINTENANCE CHART............................................. 2- 2

LUBRICATION POINTS................................................................. 2- 3

MAINTENANCE AND TUNE-UP PROCEDURES ............................ 2- 4

AIR CLEANER ............................................................................... 2- 4

SPARK PLUG ................................................................................ 2- 5

VALVE CLEARANCE..................................................................... 2- 6

ENGINE OIL AND OIL FILTER ..................................................... 2-13

FUEL HOSE ................................................................................... 2-14

ENGINE IDLE SPEED ................................................................... 2-14

THROTTLE VALVE SYNCHRONIZATION ..................................... 2-15

THROTTLE CABLE PLAY ............................................................. 2-15

CLUTCH ......................................................................................... 2-16

DRIVE CHAIN ................................................................................ 2-17

BRAKE........................................................................................... 2-19

TIRE ............................................................................................... 2-22

STEERING ..................................................................................... 2-23

FRONT FORK ................................................................................ 2-24

REAR SUSPENSION..................................................................... 2-24

EXHAUST PIPE BOLT AND NUT ................................................. 2-24

CHASSIS BOLT AND NUT............................................................ 2-25

COMPRESSION PRESSURE CHECK ............................................. 2-27

OIL PRESSURE CHECK .................................................................. 2-28

Section 3 - Engine <<click to download (9.0mb)

ENGINE COMPONENTS REMOVABLE WITH

THE ENGINE IN PLACE ................................................................... 3- 2

ENGINE REMOVAL AND INSTALLATION ....................................... 3- 3

ENGINE REMOVAL ....................................................................... 3- 3

ENGINE INSTALLATION ............................................................... 3- 8

ENGINE DISASSEMBLY .................................................................. 3-11

ENGINE COMPONENTS INSPECTION AND SERVICE ................. 3-22

PAIR VALVE ................................................................................... 3-22

CYLINDER HEAD COVER ............................................................ 3-23

CAMSHAFT ................................................................................... 3-23

CAM CHAIN TENSION ADJUSTER.............................................. 3-25

CAM CHAIN TENSIONER/CAM CHAIN GUIDE ........................... 3-25

CYLINDER HEAD AND VALVE ..................................................... 3-26

CYLINDER ..................................................................................... 3-34

PISTON AND PISTON RING ......................................................... 3-35

CLUTCH ......................................................................................... 3-37

GEARSHIFT SYSTEM................................................................... 3-39

GENERATOR ................................................................................. 3-40

OIL PUMP ...................................................................................... 3-40

OIL PRESSURE REGULATOR/OIL STRAINER .......................... 3-41

CRANK BALANCER ..................................................................... 3-41

TRANSMISSION ............................................................................ 3-42

CRANKSHAFT AND CONROD..................................................... 3-45

CRANKCASE/OIL PAN ................................................................. 3-53

ENGINE REASSEMBLY ................................................................... 3-56

Section 4 - F.I. System (Fuel Injection) <<click to download (4.0mb)

PRECAUTIONS IN SERVICING ....................................................... 4- 2

FI SYSTEM TECHNICAL FEATURES .............................................. 4- 8

INJECTION TIME ........................................................................... 4- 8

COMPENSATION OF INJECTION TIME....................................... 4- 9

INJECTION STOP CONTROL....................................................... 4- 9

FUEL DELIVERY SYSTEM ........................................................... 4-10

FUEL PUMP................................................................................... 4-11

FUEL PRESSURE REGULATOR.................................................. 4-12

FUEL INJECTOR ........................................................................... 4-12

FUEL PUMP CONTROL SYSTEM ................................................ 4-13

ECM (FI CONTROL UNIT)............................................................. 4-14

INJECTION TIMING ....................................................................... 4-14

SENSORS ...................................................................................... 4-15

FI SYSTEM PARTS LOCATION ....................................................... 4-19

FI SYSTEM DIAGRAM...................................................................... 4-21

FI SYSTEM WIRING DIAGRAM........................................................ 4-22

SELF-DIAGNOSIS FUNCTION......................................................... 4-23

USER MODE.................................................................................. 4-23

DEALER MODE ............................................................................. 4-24

FAIL-SAFE FUNCTION..................................................................... 4-26

FI SYSTEM TROUBLESHOOTING................................................... 4-27

CUSTOMER COMPLAINT ANALYSIS ......................................... 4-27

SELF-DIAGNOSTIC PROCEDURES ............................................ 4-28

SELF-DIAGNOSIS RESET PROCEDURE.................................... 4-28

MALFUNCTION CODE AND DEFECTIVE CONDITION .............. 4-29

“C11” CMP SENSOR CIRCUIT MALFUNCTION ......................... 4-31

“C12” CKP SENSOR CIRCUIT MALFUNCTION ......................... 4-32

“C13” IAP SENSOR CIRCUIT MALFUNCTION ........................... 4-33

“C14” TP SENSOR CIRCUIT MALFUNCTION............................. 4-35

“C15” EOT SENSOR CIRCUIT MALFUNCTION.......................... 4-37

“C21” IAT SENSOR CIRCUIT MALFUNCTION ........................... 4-38

“C22” AP SENSOR CIRCUIT MALFUNCTION ............................ 4-39

“C23” TO SENSOR CIRCUIT MALFUNCTION ............................ 4-41

“C24” or “C25” IGNITION SYSTEM MALFUNCTION ................. 4-42

“C28” STV ACTUATOR CIRCUIT MALFUNCTION...................... 4-42

“C29” STP SENSOR CIRCUIT MALFUNCTION .......................... 4-43

“C31” GEAR POSITION SWITCH CIRCUIT MALFUNCTION ..... 4-45

“C32”, “C33”, “C34” or “C35” FUEL INJECTION

MALFUNCTION ............................................................................. 4-46

“C41” FP RELAY CIRCUIT MALFUNCTION................................ 4-47

“C42” IG SWITCH CIRCUIT MALFUNCTION .............................. 4-47

FUEL SYSTEM.................................................................................. 4-48

FUEL TANK REMOVAL ................................................................. 4-48

FUEL TANK INSTALLATION ......................................................... 4-48

FUEL PRESSURE INSPECTION .................................................. 4-49

FUEL PUMP INSPECTION ........................................................... 4-50

FUEL PUMP RELAY INSPECTION .............................................. 4-51

FUEL PUMP AND FUEL FILTER REMOVAL ............................... 4-51

FUEL MESH FILTER INSPECTION AND CLEANING ................. 4-52

FUEL PUMP AND FUEL MESH FILTER INSTALLATION ........... 4-53

THROTTLE BODY AND STV ACTUATOR ....................................... 4-54

CONSTRUCTION........................................................................... 4-54

THROTTLE BODY REMOVAL....................................................... 4-55

THROTTLE BODY DISASSEMBLY .............................................. 4-56

THROTTLE BODY CLEANING ..................................................... 4-59

INSPECTION ................................................................................. 4-59

THROTTLE BODY REASSEMBLY ............................................... 4-59

STP SENSOR ADJUSTMENT ...................................................... 4-62

TP SENSOR ADJUSTMENT ......................................................... 4-64

THROTTLE BODY INSTALLATION .............................................. 4-64

FUEL INJECTOR INSPECTION.................................................... 4-64

FUEL INJECTOR REMOVAL ........................................................ 4-64

FUEL INJECTOR INSTALLATION ................................................ 4-64

FAST IDLE INSPECTION .............................................................. 4-65

FAST IDLE ADJUSTMENT ........................................................... 4-65

THROTTLE VALVE SYNCHRONIZATION .................................... 4-66

THROTTLE CABLE ADJUSTMENT ............................................. 4-66

SENSORS .................................................................................... 4-67

IAP SENSOR INSPECTION .......................................................... 4-67

IAP SENSOR REMOVAL/INSTALLATION.................................... 4-67

TP SENSOR INSPECTION ........................................................... 4-67

TP SENSOR REMOVAL/INSTALLATION ..................................... 4-67

STP SENSOR INSPECTION ......................................................... 4-67

STP SENSOR REMOVAL/INSTALLATION................................... 4-67

CKP SENSOR INSPECTION ........................................................ 4-67

CKP SENSOR REMOVAL/INSTALLATION .................................. 4-67

CMP SENSOR INSPECTION ........................................................ 4-68

CMP SENSOR REMOVAL/INSTALLATION.................................. 4-68

IAT SENSOR INSPECTION........................................................... 4-68

IAT SENSOR REMOVAL/INSTALLATION .................................... 4-68

EOT SENSOR INSPECTION......................................................... 4-68

EOT SENSOR REMOVAL/INSTALLATION .................................. 4-68

AP SENSOR INSPECTION ........................................................... 4-68

AP SENSOR REMOVAL/INSTALLATION..................................... 4-68

TO SENSOR INSPECTION ........................................................... 4-68

TO SENSOR REMOVAL/INSTALLATION..................................... 4-68

Section 5 - Oil Cooling & Lubrication System <<click to download (1.6mb)

OIL COOLING SYSTEM/LUBRICATION SYSTEM ......................... 5- 2

CYLINDER HEAD OIL COOLING CIRCUIT ................................. 5- 2

CYLINDER HEAD COOLING SYSTEM CHART .......................... 5- 3

ENGINE LUBRICATION CIRCUIT ................................................ 5- 4

ENGINE LUBRICATION SYSTEM CHART .................................. 5- 6

OIL COOLER AND OIL HOSE ......................................................... 5- 7

OIL COOLER REMOVAL .............................................................. 5- 7

OIL COOLER INSPECTION AND CLEANING ............................. 5- 7

OIL HOSE/OIL PIPE INSPECTION............................................... 5- 8

OIL COOLER INSTALLATION ...................................................... 5- 8

COOLING FAN .................................................................................. 5- 8

REMOVAL ...................................................................................... 5- 8

INSPECTION ................................................................................. 5- 9

INSTALLATION .............................................................................. 5- 9

COOLING FAN THERMO-SWITCH .................................................. 5- 9

REMOVAL ...................................................................................... 5- 9

INSPECTION ................................................................................. 5-10

INSTALLATION .............................................................................. 5-10

OIL TEMPERATURE SENSOR......................................................... 5-11

REMOVAL ...................................................................................... 5-11

INSPECTION ................................................................................. 5-11

INSTALLATION .............................................................................. 5-11

OIL PRESSURE ................................................................................ 5-12

OIL FILTER........................................................................................ 5-12

OIL STRAINER.................................................................................. 5-12

OIL JET ............................................................................................. 5-12

OIL PUMP.......................................................................................... 5-12

OIL PRESSURE SWITCH................................................................. 5-12

Section 6 - Chassis<<click to download (4.8mb)

EXTERIOR PARTS............................................................................ 6- 2

CONSTRUCTION........................................................................... 6- 2

REMOVAL ...................................................................................... 6- 3

REMOUNTING ............................................................................... 6- 4

FASTENER REMOVAL AND REINSTALLATION ......................... 6- 5

FRONT WHEEL ................................................................................. 6- 6

CONSTRUCTION........................................................................... 6- 6

REMOVAL ...................................................................................... 6- 7

INSPECTION AND DISASSEMBLY.............................................. 6- 7

REASSEMBLY AND REMOUNTING ............................................ 6- 9

FRONT FORK ................................................................................... 6-12

CONSTRUCTION........................................................................... 6-12

REMOVAL AND DISASSEMBLY .................................................. 6-13

INSPECTION ................................................................................. 6-16

REASSEMBLY AND REMOUNTING ............................................ 6-17

SUSPENSION SETTING ............................................................... 6-22

STEERING AND HANDLEBARS ..................................................... 6-23

CONSTRUCTION........................................................................... 6-23

REMOVAL AND DISASSEMBLY .................................................. 6-24

INSPECTION AND DISASSEMBLY.............................................. 6-27

REASSEMBLY AND REMOUNTING ............................................ 6-28

STEERING TENSION ADJUSTMENT .......................................... 6-31

REAR WHEEL ................................................................................... 6-32

CONSTRUCTION........................................................................... 6-32

REMOVAL ...................................................................................... 6-33

INSPECTION AND DISASSEMBLY.............................................. 6-34

REASSEMBLY AND REMOUNTING ............................................ 6-36

REAR SHOCK ABSORBER ............................................................. 6-40

CONSTRUCTION........................................................................... 6-40

REMOVAL ...................................................................................... 6-41

INSPECTION ................................................................................. 6-42

REAR SHOCK ABSORBER SCRAPPING PROCEDURE........... 6-42

REMOUNTING ............................................................................... 6-42

SUSPENSION SETTING ............................................................... 6-43

REAR SWINGARM ........................................................................... 6-44

CONSTRUCTION........................................................................... 6-44

REMOVAL ...................................................................................... 6-45

INSPECTION AND DISASSEMBLY.............................................. 6-46

REASSEMBLY ............................................................................... 6-47

REMOUNTING ............................................................................... 6-48

FINAL INSPECTION AND ADJUSTMENT ................................... 6-48

FRONT BRAKE ................................................................................. 6-49

CONSTRUCTION........................................................................... 6-49

BRAKE PAD REPLACEMENT ...................................................... 6-50

BRAKE FLUID REPLACEMENT................................................... 6-50

CALIPER REMOVAL AND DISASSEMBLY ................................. 6-51

CALIPER INSPECTION ................................................................ 6-52

CALIPER REASSEMBLY AND REMOUNTING ........................... 6-52

BRAKE DISC INSPECTION .......................................................... 6-53

MASTER CYLINDER REMOVAL AND DISASSEMBLY .............. 6-54

MASTER CYLINDER INSPECTION.............................................. 6-55

MASTER CYLINDER REASSEMBLY AND REMOUNTING ........ 6-55

REAR BRAKE ................................................................................... 6-57

CONSTRUCTION........................................................................... 6-57

BRAKE PAD REPLACEMENT ...................................................... 6-58

BRAKE FLUID REPLACEMENT................................................... 6-58

CALIPER REMOVAL AND DISASSEMBLY ................................. 6-59

CALIPER INSPECTION ................................................................ 6-60

CALIPER REASSEMBLY AND REMOUNTING ........................... 6-60

MASTER CYLINDER REMOVAL AND DISASSEMBLY .............. 6-61

MASTER CYLINDER INSPECTION.............................................. 6-62

MASTER CYLINDER REASSEMBLY AND REMOUNTING ........ 6-62

CLUTCH RELEASE CYLINDER AND MASTER CYLINDER.......... 6-64

CONSTRUCTION........................................................................... 6-64

CLUTCH FLUID REPLACEMENT................................................. 6-65

CLUTCH RELEASE CYLINDER REMOVAL AND DISASSEMBLY.. 6-65

CLUTCH RELEASE CYLINDER INSPECTION............................ 6-66

CLUTCH RELEASE CYLINDER REASSEMBLY AND

REMOUNTING ............................................................................... 6-66

CLUTCH MASTER CYLINDER REMOVAL AND DISASSEMBLY ... 6-67

CLUTCH MASTER CYLINDER INSPECTION.............................. 6-68

CLUTCH MASTER CYLINDER REASSEMBLY AND

REMOUNTING ............................................................................... 6-69

TIRE AND WHEEL ............................................................................ 6-70

TIRE REMOVAL............................................................................. 6-70

INSPECTION ................................................................................. 6-70

VALVE INSTALLATION ................................................................. 6-71

TIRE INSTALLATION .................................................................... 6-71
 

Section 7 - Electrical <<click to download (2.1mb)

CAUTIONS IN SERVICING ............................................................... 7- 2

LOCATION OF ELECTRICAL COMPONENTS ............................... 7- 4

CHARGING SYSTEM ....................................................................... 7- 6

TROUBLESHOOTING ................................................................... 7- 6

INSPECTION ................................................................................. 7- 7

STARTER SYSTEM AND SIDE-STAND/IGNITION

INTERLOCK SYSTEM ...................................................................... 7-11

TROUBLESHOOTING ................................................................... 7-11

STARTER MOTOR REMOVAL AND DISASSEMBLY .................. 7-12

STARTER MOTOR INSPECTION ................................................. 7-13

STARTER MOTOR REASSEMBLY ............................................... 7-13

STARTER RELAY INSPECTION ................................................... 7-14

SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS

INSPECTION ................................................................................. 7-15

IGNITION SYSTEM ........................................................................... 7-18

TROUBLESHOOTING ................................................................... 7-18

INSPECTION ................................................................................. 7-20

COMBINATION METER.................................................................... 7-23

REMOVAL AND DISASSEMBLY .................................................. 7-23

INSPECTION ................................................................................. 7-24

LAMPS .............................................................................................. 7-28

RELAYS............................................................................................. 7-29

SWITCHES ........................................................................................ 7-29

BATTERY........................................................................................... 7-31

SPECIFICATIONS.......................................................................... 7-31

INITIAL CHARGING ...................................................................... 7-31

SERVICING .................................................................................... 7-32

RECHARGING OPERATION......................................................... 7-33

Section 8 - Servicing Information <<click to download (1.8mb)

TROUBLESHOOTING ...................................................................... 8- 2

FI SYSTEM MALFUNCTION CODE AND

DEFECTIVE CONDITION .............................................................. 8- 2

ENGINE.......................................................................................... 8- 4

COOLING SYSTEM....................................................................... 8- 9

CHASSIS........................................................................................ 8-10

BRAKES ........................................................................................ 8-11

ELECTRICAL................................................................................. 8-12

BATTERY ....................................................................................... 8-13

WIRING DIAGRAM ........................................................................... 8-14

FI SYSTEM WIRING DIAGRAM........................................................ 8-15

WIRE HARNESS, CABLE AND HOSE ROUTING........................... 8-16

WIRE HARNESS ROUTING.......................................................... 8-16

HIGH-TENSION CORD ROUTING ................................................ 8-17

ENGINE ELECTRICAL PARTS SET-UP ....................................... 8-18

CLUTCH HOSE ROUTING............................................................ 8-19

THROTTLE CABLE ROUTING ..................................................... 8-20

FUEL PUMP/FUEL LEVEL GAUGE SET-UP ............................... 8-21

FRONT BRAKE HOSE ROUTING ................................................ 8-22

REAR BRAKE HOSE ROUTING .................................................. 8-23

SIDE-STAND SET-UP .................................................................... 8-24

CENTER STAND SET-UP.............................................................. 8-24

SEAT LOCK CABLE ROUTING AND

LUGGAGE HOOK SET-UP............................................................ 8-25

BRAKE PEDAL SET-UP................................................................ 8-25

FUEL HOSE ROUTING ................................................................. 8-26

FUEL TANK SET-UP ...................................................................... 8-27

THROTTLE BODY SET-UP ........................................................... 8-28

PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING.......................... 8-29

SPECIAL TOOLS .............................................................................. 8-30

TIGHTENING TORQUE..................................................................... 8-33

SERVICE DATA ................................................................................. 8-37


Section 9 - GSX1400 K3 Supplement manual (334kb)
 

SPECIFICATIONS................................................................................ 9- 2

ENGINE ................................................................................................ 9- 3

GEARSHIFT CAM........................................................................ 9- 3

CHASSIS.............................................................................................. 9- 3

STEERING ................................................................................... 9- 3

WIRING DIAGRAM .............................................................................. 9- 4

WIRE HARNESS ROUTING ................................................................ 9- 5

SERVICE DATA ................................................................................... 9- 6



Section 10 - GSX1400 K4 Supplement Manual  (123kb)

SPECIFICATIONS ............................................................................. 10- 2

SERVICE DATA ................................................................................ 10- 3

PERIODIC MAINTENANCE CHART ................................................ 10-12

WIRING DIAGRAM ........................................................................... 10-13



Section 11 - GSX1400 K5 > supplement Manual (709kb)

SPECIFICATIONS ............................................................................. 11- 2

SERVICE DATA ................................................................................ 11- 3

IMMOBILIZER ................................................................................... 11-12

EXHAUST PIPE/MUFFLER INSTALLATION ................................... 11-14

CENTRE STAND INSTALLATION ................................................... 11-15

WIRE HARNESS ROUTING ............................................................. 11-16

WIRING DIAGRAM ........................................................................... 11-17


 

PDF GSX1400 Service Manuals

 Click here for GSX1400 complete Service manual K2, 24 Mb

Click here for GSX1400 owners Handbook K2, 12.4mb
This Handbook is the one that comes with the bike, I have made this interactive with bookmarks for all sections in the book, it is quite a large file size so be patient on downloading

GSX1400 Parts Manual

Click here for GSX1400 parts manual (PDF)  58 Mb (Very Large File size not suitable for slow connection speeds)
 

To save right click on links and click "save target as"

 

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