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Suzuki GSF400 Bandit 1994 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Suzuki Model: GSF400 Bandit Year: 1994 Generation Model Generation: GK75A (Second Generation) Codes Chassis Code: GK75A 👋 Introduction Market Position Segment: Middleweight Naked Sportbike /...
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🏷️ Basic Information
Identification
Make:
Suzuki
Model:
GSF400 Bandit
Year:
1994
Generation
Model Generation:
GK75A (Second Generation)
Codes
Chassis Code:
GK75A
👋 Introduction
Market Position
Segment:
Middleweight Naked Sportbike / Standard Motorcycle
Target Audience:
Enthusiasts seeking performance, versatility, and a classic sportbike aesthetic
Competitive Analysis
Key Competitors Era:
Kawasaki Zephyr 400, Honda CB-1, Yamaha XJR400, Kawasaki ZRX400
Unique Selling Points:
Compact, high-revving inline-four engine; sharp styling; balanced handling
Key Features
Engine Configuration:
Liquid-cooled, DOHC, inline-four cylinder
Design Philosophy:
Sporty performance packaged in a user-friendly, aesthetically pleasing naked bike format
Target Market Focus:
Primarily focused on the Japanese domestic market (JDM) with its strong demand for smaller displacement inline-fours.
📋 Manual Details
Coverage Areas
Title:
Suzuki GSF400 Bandit 1994 Factory Service Repair Manual
Covered Models:
Suzuki GSF400 Bandit (GK75A chassis)
Primary Market:
Japan (home market model); Limited availability in other markets
Page Count
Estimated Page Count:
Approx. 300-400 pages (typical for factory service manuals of this era)
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
Japanese (original factory); English translations may be available separately
Format
Format:
Digital (likely PDF), Printable
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, inspection, repair, carburetor tuning, lubrication system
Fuel System:
Carburetor specifications, fuel pump, fuel lines, tank inspection and cleaning
Transmission:
Clutch operation, gearbox disassembly, inspection, reassembly, gear shift mechanism
Electrical System:
Ignition system (CDI), lighting, charging system (stator, regulator/rectifier), starting system, wiring diagrams, diagnostic procedures
Brakes:
Hydraulic system, brake caliper inspection and overhaul, master cylinder, brake fluid specifications, bleeding procedures
Suspension:
Front fork (telescopic, oil type, levels, seal replacement), rear shock absorber (preload adjustment, damping), swingarm inspection
Cooling System:
Liquid cooling system, radiator, water pump, thermostat operation, coolant specifications
Chassis And Frame:
Frame inspection, steering head bearing service, wheel bearing replacement, general chassis component checks
Bodywork And Fairings:
Removal and installation of body panels, seat, fuel tank, minor cosmetic repair guidance
Procedures Included
Maintenance:
Routine maintenance checks, oil changes, filter replacements, spark plug replacement, chain adjustment, brake pad inspection
Troubleshooting:
Diagnostic charts for common performance issues, electrical faults, starting problems
Repair:
Detailed step-by-step instructions for component disassembly, repair, and reassembly
Installation:
Guidance for installing new parts or components
Adjustments:
Carburetor synchronization, idle speed adjustment, clutch and throttle cable free play adjustment
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds
Diagnostic Level:
Advanced diagnostics with detailed wiring diagrams and fault finding procedures
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Text-searchable for quick information retrieval
Print Quality
Resolution:
High-resolution for clear diagrams and text
Scalability:
Scalable for detailed viewing of diagrams
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, DOHC, inline-four
Displacement:
398 cc
Bore X Stroke:
53.0 mm x 46.8 mm
Compression Ratio:
11.5:1
Valvetrain:
DOHC, 4 valves per cylinder
Performance
Horsepower:
Approx. 53 PS (39 kW) @ 12,000 rpm (JDM spec, often lower for export markets due to restrictions)
Torque:
Approx. 3.8 kg-m (37 Nm) @ 10,000 rpm (JDM spec)
Fuel System
Carburetion:
Mikuni CVKD32 x 4 (Constant Velocity, Down-draft, Keihin-type with butterfly valve)
Fuel Capacity:
15 Liters (3.3 Gallons)
Lubrication System
Oil Capacity:
3.2 Liters (with filter change)
Oil Type Recommendation:
API SG/SH, JASO MA, SAE 10W-40
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet multi-plate
Final Drive:
O-ring sealed chain
Features
Gear Ratios:
Specific ratios detailed in manual, typically optimized for spirited riding.
Transmission Fluid Type:
Refer to engine oil specification (shared sump)
📐 Dimensions
Exterior
Length:
Approx. 2,080 mm (81.9 in)
Width:
Approx. 760 mm (29.9 in)
Height:
Approx. 1,050 mm (41.3 in)
Wheelbase:
Approx. 1,420 mm (55.9 in)
Weights
Dry Weight:
Approx. 168 kg (370 lbs)
Curb Weight:
Approx. 186 kg (410 lbs) (with all fluids)
Load Capacity:
Refer to manual for rider and luggage limits
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle safety ratings not standardized in this era)
Active Features
Braking System Front:
Dual hydraulic disc brakes
Braking System Rear:
Single hydraulic disc brake
Tire Specification Front:
110/70-17 M/C 54H
Tire Specification Rear:
150/70-17 M/C 69H
Passive Features
Lighting:
Halogen headlight, LED tail light (typical for the era)
Instrumentation:
Analog speedometer, tachometer, fuel gauge, temperature gauge, warning lights
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic motorcycle instrumentation)
Driver Assistance
Rider Aids:
None (ABS was not a standard or common option on this model)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 4,000 km (2,500 miles) or 6 months
Oil Filter Change Interval:
Every oil change (Suzuki Part No. 16510-07200 or equivalent)
Spark Plug Replacement:
Every 10,000 km (6,000 miles) (e.g., NGK CR9E or similar)
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after washing/rain
Valve Clearance Check:
Every 12,000 km (7,500 miles)
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4
Coolant Type:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water
Fork Oil Type:
Suzuki Fork Oil SS-02 or SAE 5W (approx. 470cc per fork leg)
Known Issues
Carburetor Synchronization:
Can drift over time, requiring periodic synchronization for smooth running.
Cam Chain Tensioner:
Automatic tensioner can weaken, leading to rattling noises; manual replacement or modification may be needed.
Electrical Connections:
Corrosion in connectors, especially on older models, can cause intermittent electrical faults.
📚 Vehicle History
Brand Heritage
Manufacturer:
Suzuki Motor Corporation
Brand Reputation:
Known for reliable, performance-oriented motorcycles, particularly inline-fours.
Model Evolution
Predecessor:
GSF400 Bandit (GK75A, first generation, introduced 1989)
Generation Change Gk75A:
The 1994 model is part of the GK75A chassis generation, which saw updates to styling, suspension, and potentially engine tuning over its production run (approx. 1991-1995).
Production
Production Period:
The GK75A generation was produced from approximately 1991 to 1995.
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Motorcycle Awards:
N/A (No specific widespread awards documented for this particular model year, but generally well-regarded in its class).
Ratings
Owner Satisfaction:
Generally positive among enthusiasts for its performance and character.
Certifications
Emissions Certification:
Meets Japanese domestic market emissions standards for its era.