Suzuki GSF400 GSF 400 Bandit Complete OFFICIAL Factory Service / Repair / Workshop Manual 91-97
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Basic Information Identification Make: Suzuki Model: GSF400 Bandit Model Code: GSF400 Generation: GK75A (pre-1994), GK75B (1994 onwards) Engine Variant: 4-cylinder, inline, DOHC, 16-valve Introduction Market Position Market Segment: Naked sportbike, entry-level performance motorcycle. Competitive Analysis Key Competitors: Honda CB-1, Yamaha FZR400, Kawasaki ZZR-400. Key Features Vehicle Appeal: Compact size, nimble handling, lively inline-four engine, aggressive styling for its era. Manual Value Utility: Essential for owners undertaking their own maintenance and repairs, saving costs and ensuring proper procedures are followed. Delivery Method: Instant download, eliminating shipping costs and wait times. Manual Details Coverage Areas Applicable Model Years: 1991, 1992, 1993, 1994, 1995, 1996, 1997 Page Count Estimated Page Count: Approximately 300-500 pages (typical for comprehensive factory manuals) Manual Type Manual Type: Complete Official Factory Service / Repair / Workshop Manual Language Language: English (presumed, based on typical market distribution and product description) Format File Format: PDF Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, cylinder head, valve train (camshafts, valves, springs, seals), pistons, rings, connecting rods, crankshaft, bearings, oil pump, oil pan, lubrication system, cooling system (radiator, fan, hoses, thermostat). Fuel System: Carburetor(s) (assembly, disassembly, adjustment, cleaning), fuel pump, fuel lines, fuel filter, fuel tank. Ignition System: Ignition coils, spark plugs, spark plug wires, CDI unit, timing. Transmission Drivetrain: Clutch (operation, service, replacement), gearbox (internal components, shifting mechanism), final drive (chain, sprockets). Chassis Suspension: Front forks (disassembly, overhaul, oil levels, seals), rear shock absorber, swingarm, steering system (bearings, headstock). Braking System: Front and rear brakes (disc brakes), brake calipers, master cylinders, brake lines, brake pads, brake fluid specifications and changes. Electrical System: Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starter motor, lighting (headlights, taillights, turn signals, brake lights), instrumentation, sensors. Bodywork And Trim: Fairings, tank, seat, fenders, exhaust system (muffler, headers, gaskets). Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, tire pressure checks, spark plug replacement, coolant checks and changes, brake fluid changes, lubrication points. Major Repairs: Engine rebuilds, carburetor synchronization and tuning, suspension overhaul, brake system servicing, electrical component testing and replacement. Troubleshooting: Diagnostic procedures for common problems related to starting, running, electrical systems, and braking. Technical Specifications: Torque specifications for all fasteners, fluid capacities, engine timing marks, valve clearances, electrical resistance values. Technical Depth Depth Of Coverage: Comprehensive (covers everything from basic maintenance to complete engine and transmission rebuilds). Manual Specifications File Format Digital Format: PDF Download Print Quality Printable: Yes Zoom Functionality: Yes Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Engine Specifications Primary Engine Engine Type: Inline-four cylinder, 4-stroke, liquid-cooled, DOHC, 16 valves. Displacement: 398 cc (24.3 cu in) Bore X Stroke: 53.0 mm x 45.0 mm (estimated, common for this class) Performance Horsepower: Approximately 53 hp @ 11,000 rpm (varies slightly by market/year) Torque: Approximately 3.9 kgf·m (38 Nm; 28 lb·ft) @ 9,000 rpm (estimated) Fuel System Carburetion: Four Mikuni CV-type carburetors (e.g., VM29SS) Fuel Capacity: 15 Liters (3.9 US gal) Lubrication Oil Capacity With Filter: Approximately 2.8 Liters (2.9 US qt) Cooling System Cooling Type: Liquid-cooled Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-plate Features Final Drive: O-ring sealed chain Dimensions Exterior Length: Approximately 2,080 mm (81.9 in) Width: Approximately 745 mm (29.3 in) Height: Approximately 1,045 mm (41.1 in) Weights Dry Weight: Approximately 172 kg (379 lbs) Wet Weight: Approximately 185 kg (408 lbs) (estimated, with fluids) Wheels Tires Front Tire Size: 110/70ZR17M/C (54W) Rear Tire Size: 150/70ZR17M/C (69W) Front Brake Type: Dual hydraulic disc Rear Brake Type: Single hydraulic disc Safety Features Ratings Safety Features: Standard motorcycle safety features, ABS was not commonly available on this model. Technology Features Infotainment Infotainment Features: Basic analogue instrumentation (speedometer, tachometer, fuel gauge, warning lights). No advanced infotainment systems present. Driver Assistance Driver Assistance Features: None. Primarily rider-controlled. Connectivity Connectivity Options: None. Maintenance Service Intervals Oil Change Interval: Every 4,000 km (2,500 miles) or 6 months, whichever comes first. Valve Check Interval: Every 12,000 km (7,500 miles) or 12 months. Spark Plug Replacement Interval: Every 12,000 km (7,500 miles). Fluid Specifications Engine Oil Type: API SE, SF or SG, JASO MA certified, viscosity SAE 10W-40 or 20W-50 (refer to manual for precise recommendation). Coolant Type: Ethylene glycol-based antifreeze with water (50/50 mix). Brake Fluid Type: DOT 4. Known Issues Common Wear Items: Clutch wear, fork seal leaks, carburetor float bowl gaskets, exhaust system corrosion. Electrical Issues: Aging wiring harness components, regulator/rectifier failures can be more common on older Japanese motorcycles. Vehicle History Brand Heritage Suzuki Legacy: Suzuki has a long history of producing reliable and performance-oriented motorcycles, particularly in the sportbike and standard categories. Model Evolution Bandit Lineage: The Bandit series started with the larger GSF600 Bandit and was later expanded to include the 400cc version, offering a more accessible entry point into the Bandit's blend of performance and practicality. Production Production Period:...
Approximately 185 kg (408 lbs) (estimated, with fluids)
Wheels Tires
Front Tire Size:
110/70ZR17M/C (54W)
Rear Tire Size:
150/70ZR17M/C (69W)
Front Brake Type:
Dual hydraulic disc
Rear Brake Type:
Single hydraulic disc
Safety Features
Ratings
Safety Features:
Standard motorcycle safety features, ABS was not commonly available on this model.
Technology Features
Infotainment
Infotainment Features:
Basic analogue instrumentation (speedometer, tachometer, fuel gauge, warning lights). No advanced infotainment systems present.
Driver Assistance
Driver Assistance Features:
None. Primarily rider-controlled.
Connectivity
Connectivity Options:
None.
Maintenance
Service Intervals
Oil Change Interval:
Every 4,000 km (2,500 miles) or 6 months, whichever comes first.
Valve Check Interval:
Every 12,000 km (7,500 miles) or 12 months.
Spark Plug Replacement Interval:
Every 12,000 km (7,500 miles).
Fluid Specifications
Engine Oil Type:
API SE, SF or SG, JASO MA certified, viscosity SAE 10W-40 or 20W-50 (refer to manual for precise recommendation).
Coolant Type:
Ethylene glycol-based antifreeze with water (50/50 mix).
Brake Fluid Type:
DOT 4.
Known Issues
Common Wear Items:
Clutch wear, fork seal leaks, carburetor float bowl gaskets, exhaust system corrosion.
Electrical Issues:
Aging wiring harness components, regulator/rectifier failures can be more common on older Japanese motorcycles.
Vehicle History
Brand Heritage
Suzuki Legacy:
Suzuki has a long history of producing reliable and performance-oriented motorcycles, particularly in the sportbike and standard categories.
Model Evolution
Bandit Lineage:
The Bandit series started with the larger GSF600 Bandit and was later expanded to include the 400cc version, offering a more accessible entry point into the Bandit's blend of performance and practicality.
Production
Production Period:
Produced throughout the 1990s, with this manual covering the 1991-1997 period.
Awards & Recognition
Recognitions
Motorcycle Reviews:
Generally well-regarded for its performance and handling for its displacement class, often praised for being a more affordable and user-friendly alternative to 600cc sportbikes.
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