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Manuals
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Suzuki Manuals
Motorcycle
GSF 400 BANDIT
Service manual
Suzuki GSF 400 BANDIT Service Manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Index
View of Suzuki Gsf400/Bandit
General Information
Serial Number Location
Fuel, Oil and Coolant Recommendation
Engine Oil Recommendation
Brake Fluid Recommedation
Front Fork Oil Recommendation
Coolant/Water for Mixing/Anti-Freeze Recommendation
Liquid Amount of Water/Coolant
Break-In Procedures
Cylinder Identification
Special Materials
Precautions and General Instructions
Replacement Parts
Asbestos Information
Specifications
Country or Area Symbols
Exterior Parts Removal
Seats Removal
Frame Covers Removal
Air Cleaner Side Covers Removal
Periodic Maintenance and Tune-Up Procedures
Periodic Maintenance Schedule
Lubrication Points
Maintenance and Tune-Up Procedures
Battery Maintenance
Cylinder Head Nuts and Exhaust Pipe Bolts Maintenance
Exhaust Pipe and Muffler Maintenance
Air Cleaner Maintenance
Valve Clearance Maintenance
Spark Plugs Maintenance
Engine Oil and Oil Filter Maintenance
Necessary Amout of Engine Oil
Fuel Line Maintenance
Carburetors Maintenance
Engine Idling Speed
Throttle Cable Play
Cooling System/Coolant Level
Clutch Maintenance
Coolant Change
Drive Chain Maintenance
Drive Chain Checking/Adjusting/Cleaning/Lubricating
Brake Fluid Level Check
Brake Pads Check
Brake Pedal Height
Brake Light Switches Adjustment
Air Bleeding the Brake Fluid Circuit
Tires Maintenance
Tire Tread Condition
Steering Maintenance
Tire Pressure
Front Forks Check
Rear Suspension Check
Chassis Bolts and Nuts Check
Engine
Compression Pressure Check
Compression Test Procedure
Oil Pressure Check/Test Procedure
Engine Components Removable with Engine in Place
Engine Center
Engine Removal
Engine Reinstallation
Engine Disassembly
Engine Components Inspection and Service
Cylinder Head Inspection
Cylinder Head Distortion Check
Valve Stem Runout Check
Valve Head Radial Runout Check
Valve Race Wear Check
Valve Stem Deflection/Wear Check
Valve Guide Servicing
Valve Seat Width/Servicing
Valve Stem End Condition
Valve Springs
Valve Reassembly
Camshaft
Cam Wear
Camshaft Journal Wear
Camshaft Runout
Cam Sprocket
Camshaft Reassembly
Cam Chain Tensioner/20-Pitch Length
Cam Chain Guide
Cylinder Distortion/Bore
Piston Diameter
Piston-Cylinder Clearance
Piston Ring-Groove Clearance
Piston Ring Free End Gap and Piston Ring End Gap
Piston Pin and Pin Bore
Conrod Small End ID/Big End Side Clearance
Conrod-Crank Pin Bearing Selection
Conrod ID Specification
Crank Pin OD Specification
Bearing Thickness
Bearins Assembly
Crankcase-Crankshaft Bearing Selection
Bearing Selection Table
Crankcase ID Specification
Crankshaft Journal OD Specification
Crankshaft Thrust Clearance
Crankshaft Runout
Thrust Bearing Selection Table
Clutch Drive and Driven Plates
Clutch Spring Free Length
Clutch Release Bearing
Oil Pump
Transmission Diagram
Transmission Disassembly
Transmission Reassembly
Gearshift Fork-Groove Clearance
Engine Reassembly
Clutch Diagram
Breather Cover Servicing
Fuel and Lubrication System
Fuel System
Fuel Tank and Fuel Cock Removal
Fuel Cock Inspection/Cleaning
Carburetor Diagram and Parts List
Carburetor Specifications
ID no Location
Diaphragm and Piston Operation
Slow System
Main System
Starter System
Float System
Carburetor Inspection and Asjustment
Needle Valve Inspection
Float Height Adjustment
Reassembly and Remounting
Balance of Carburetors
Calibrating each Gauge
Balancing Carburetors
Lubrication System
Oil Sump Filter
Lubrication System Chart
Cooling System
Cooling System Description
Cooling System Diagram and Parts List
Cooling Solution
Cooling System Removal and Disassembly
Radiator Removal
Cooling Fan Removal
Water Thermo-Switch and Cooling Fan Thermo-Switch Removal
Thermostat Removal
Water Pump Removal
Radiator Inspection/Installation
Water Thermo-Switch Inspection/Reassembly
Cooling Fan Inspection
Cooling Fan Thermo-Switch Inspection/Reassembly
Thermostat Inspection/Reassembly
Water Pump Inspection/Reassembly
Electrical System
Charging System Description
Function of Regulator
Electrical System Inspection
Charging Output Check
AC Generator No-Load Performance/Continuity Check
Regulator/Rectifier Check
Ignition System (Digital Ignitor) Description
Ignition System Inspection
Ignition Coil Checking with Electro Tester
Signal Generator Checking with Pocket Tester
Spark Plug Check/Recommended Spark Plug
Ignitor Unit Checking
Starter System Description/Removal/Disassembly
Starter System Inspection
Carbon Brush Check
Commutator Check
Armature Coil Check
Oil Seal Check
Starter System Reassembly
Starter Relay Inspection
Side-Stand/Ignition Interlock System Description
Side-Stand/Ignition Interlock System Inspection
Diode Check
Neutral Switch Check
Side-Stand/Ignition Interlock Relay Check
Combination Meter Removal and Disassembly
Combination Meter Inspection
Lamps: Headlight/Tail/Brake Light Diagrams
Turn Signal Light Diagram
Switches
Oil Pressure Switch
Turn Signal Relay
Battery Specifications
Battery Initial Charging
Battery Servicing
Battery Recharging Operation
Chassis
Front Wheel Diagram/Removal
Wheel Bearings Inspection
Axle Shaft Inspection
Wheel Inspection
Wheel Reassembly and Remounting
Brake Disc Inspection
Speedometer Gearbox Inspection
Axle Shaft Tightening
Brake Caliper Tightening
Front Brake Diagram
Front Brake Pad Replacement
Caliper Removal and Disassembly
Caliper and Disc Inspection
Piston/Rubber Parts Inspection
Disc Inspection
Caliper Reassembly and Remounting
Caliper Bolts Tightening
Master Cylinder Removal and Disassembly
Master Cylinder Inspection/Reassembly/Remounting
Front Fork Diagram/Removal
Front Fork Disassembly
Damper Rod Ring Inspection
Inner and Outer Tubes Inspection
Fork Spring Inspection
Front Fork Reassembly and Remounting
Fork Oil
Front Fork Reinstallation/Clamp Bolts
Steering Diagram
Steering Removal/Disassembly
Steering Inspection/Reassembly/Remounting
Steering Tension Adjustment
Ignition Switch Removal/Installation
Rear Brake Diagram
Rear Brake Pad Replacement
Rear Brake Caliper Removal and Disassembly
Rear Brake Caliper Reassembly and Remounting
Rear Master Cylinder Removal and Disassembly
Rear Master Cylinder Ispection
Rear Master Cylinder Reassembly and Remounting
Rear Wheel Diagram/Removal
Rear Wheel Inspection and Disassembly
Rear Wheel and Sprocket Drum Bearings Inspection
Rear Axle Shaft Check
Rear Wheel/Sprocket Check
Damper Inspection
Rear Wheel Reassembly and Remounting
Rear Brake Disc Check
Tire and Wheel
Tire Removal
Wheel and Tire Inspection
Valve Inspection after Tire Is Removed
Valve Installation in the Rim
Tire Mounting
Correct Inflation of the Tire
Rear Suspension
Swingarm Diagram
Shock Absorber and Cushion Lever Diagram
Shock Absorber and Cushion Lever Removal
Swingarm/Cushion Lever/Cushion Lever Rod/Shock Absorber Inspection
Swingarm Pivot Shaft Inspection
Swingarm Disassembly
Cushion Lever Disassembly
Cushion Lever Rod Disassembly
Rear Suspension Reassembly
Swingarm/Cushion Lever/Cushion Lever Rod Remounting
Rear Suspension and Rear Wheel Final Inspection and Adjustment
Shock Absorber Spring Pre-Load Adjustment
Servicing Information
Engine - Troubleshooting
Radiator - Troubleshooting
Carburetor - Troubleshooting
Electrical - Troubleshooting
Battery - Troubleshooting
Chassis - Troubleshooting
Brakes - Troubleshooting
Wiring Diagram for USA and Canada Models
Wiring Diagram for W. Germany Models
Wiring Diagram for Other Models
Wire Harnes, Cable and Hose Routing
Wire Routing Diagram
Cable Routing Diagram
Speedometer Cable Routing Diagram
High Tension Cord Routing Diagram
Radiator Hose Routing
Fuel Hose, Vacuum Hose and Air Vent Hose Routing Diagram
Front Brake House Routing Diagram
Center Stand Spring and Side-Stand Spring Diagrams
Special Tools Diagrams
Tightening Torque - Engine
Tightening Torque - Chassis
Tightening Torque Chart for Other Bolts and Nuts Not Listed Previously
Service Data - Valve + Guide
Service Data - Camshaft + Cylinder Head
Service Data - Cylinder + Piston + Piston Ring
Service Data - Conrod + Crankshaft
Service Data - Oil Pump/Clutch/Thermostat + Radiator + Fan/Transmission + Drive Chain
Service Data - Carburetor
Service Data - Electrical/Wattage
Service Data - Brake + Wheel
Service Data - Suspension/Tire Pressure/Fuel + Oil + Coolant
Emission Control Information
Emission Control Carburetor Components
Evaporative Emission Control System (Only for California Model)
Canister Hose Routing (Only for California Model)
GSF400N ('92-Model)
GSF400N Specifications
GSF400N Service Data - Valve + Guide
GSF400N Service Data - Camshaft + Cylinder Head/Cylinder + Piston + Piston Ring
GSF400N Service Data - Conrod + Crankshaft
GSF400N Service Data - Oil Pump/Clutch/Thermostat + Radiator + Fan/Transmission + Drive Chain
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Table of
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Table of Contents
Troubleshooting
Engine - Troubleshooting
202
Radiator - Troubleshooting
204
Carburetor - Troubleshooting
205
Electrical - Troubleshooting
206
Battery - Troubleshooting
207
Chassis - Troubleshooting
208
Brakes - Troubleshooting
209
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Summary of Contents for Suzuki GSF 400 BANDIT
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