🏷️ Basic Information

Make:

Suzuki

Model:

GSF400 Bandit

Year:

1996

Product Name:

Suzuki GSF400 Bandit 1996 Factory Service Repair Manual

Generation Identifier:

GK75B

👋 Introduction

Market Segment:

Naked sportbike, lightweight performance motorcycle.

Competitors 1996:

Honda CB400 Four, Yamaha XJR400, Kawasaki Zephyr 400, Kawasaki ZRX400.

Bike Features:

Inline-four engine, classic Bandit styling, strong performance for its displacement, versatile for commuting and sport riding.

📋 Manual Details

Coverage Scope:

Comprehensive repair, maintenance, diagnostics, and adjustment procedures for the Suzuki GSF400 Bandit 1996 model.

Estimated Page Count:

300-400 pages (typical for a factory service manual of this era)

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (likely PDF)

📖 Manual Coverage

Engine:

Engine overhaul, disassembly, assembly, tuning, cooling system, lubrication system, ignition system, fuel system (carburetion).

Transmission:

Gearbox disassembly, assembly, clutch operation, inspection, and adjustment.

Chassis:

Frame, suspension (front forks, rear shock absorber), steering system, wheels, tires, brakes (front and rear), and associated components.

Electrical:

Wiring diagrams, battery, charging system (stator, regulator/rectifier), ignition system components, lighting, instrumentation, and starter motor.

Fuel System:

Carburetor identification, disassembly, cleaning, synchronization, jetting, and troubleshooting.

Exhaust System:

Inspection, removal, and installation of exhaust pipes and mufflers.

Bodywork:

Fairing, fuel tank, seat, fenders, side covers removal and installation.

Maintenance:

Regular servicing, oil changes, filter replacements, chain adjustment, spark plug replacement, brake fluid flush, coolant checks.

Diagnostics:

Troubleshooting guides for common symptoms, electrical system checks, engine performance issues, and component testing.

Repair:

Step-by-step instructions for component removal, repair, installation, and adjustments, including full engine rebuilds.

Assembly Disassembly:

Detailed breakdown of how to safely and correctly disassemble and reassemble various motorcycle components.

Wheel Tire Service:

Wheel bearing inspection and replacement, tire mounting and dismounting, wheel balancing.

Steering Head Bearing:

Inspection, adjustment, and replacement of steering head bearings.

Depth:

Factory-level technical information, suitable for professional mechanics and experienced DIY enthusiasts. Covers basic maintenance through complete engine and component overhauls.

Engine Rebuild:

Detailed procedures for engine disassembly, piston replacement, ring replacement, bearing checks, crankshaft inspection, and complete reassembly.

📊 Manual Specifications

Digital Format:

PDF

Print Quality:

High-resolution, clear text and diagrams suitable for printing.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

4-stroke, Liquid-cooled, DOHC, Inline-4

Displacement:

398 cc

Bore X Stroke:

56.0 mm x 40.4 mm

Compression Ratio:

11.5:1

Horsepower Ps:

57 PS @ 12,000 rpm (approximate, depending on market tuning)

Torque Nm:

39 Nm @ 10,000 rpm (approximate)

Carburetor Type:

4 x Mikuni CV carburetors (e.g., Mikuni BSF32)

Fuel Capacity Liters:

17 Liters

Oil Type:

API SG, SAE 10W-40 motorcycle oil (specific recommendations in manual)

Ignition System:

Digital CDI

Cooling Type:

Liquid-cooled

Radiator Fan:

Electric fan, automatic activation.

🔧 Transmission

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-plate

Gear Ratios:

Detailed in manual, specific to model variant.

Final Drive:

O-ring sealed chain

📐 Dimensions

Length Mm:

2,130 mm

Width Mm:

770 mm

Height Mm:

1,040 mm

Wheelbase Mm:

1,410 mm

Ground Clearance Mm:

135 mm

Dry Weight Kg:

187 kg

Wet Weight Kg:

204 kg (approximate with fluids)

Payload Capacity Kg:

Not specified for rider/cargo, focus on machine weight.

🛡️ Safety Features

Safety Standards:

Compliance with relevant national and international motorcycle safety standards for its production era.

Braking System:

Dual 290mm front discs with 4-piston calipers, Single 240mm rear disc with 2-piston caliper.

Lighting:

Halogen headlamp, LED taillight, incandescent turn signals.

💡 Technology Features

Infotainment Features:

Basic analog instrumentation: speedometer, tachometer, fuel gauge, neutral indicator, turn signal indicators, high beam indicator.

Driver Assistance Features:

None (standard for this era and class of motorcycle)

Connectivity Features:

None

🔧 Maintenance

Oil Change Interval Km:

Every 6,000 km or 6 months

Valve Clearance Check Km:

Every 12,000 km

Chain Maintenance Interval Km:

Every 1,000 km or as needed

Engine Oil Capacity Liters:

3.2 Liters (without filter change), 3.4 Liters (with filter change)

Coolant Type:

Mixture of ethylene glycol-based coolant and distilled water (50:50)

Brake Fluid Type:

DOT 4

Transmission Oil Type:

API GL-1 or GL-4, SAE 80W-90 gear oil (verify with specific Suzuki recommendations).

Fork Oil Type Ml:

Suzuki Suspension Oil SS-02 or equivalent SAE 10W fork oil, 450 ml per fork leg.

Common Wear Items:

Carburetor synchronization drift, aging fuel lines, worn clutch plates, starter motor reliability, suspension seal leaks.

Electrical Gremlins:

Corrosion in connectors, regulator/rectifier failure due to heat management, intermittent lighting issues.

📚 Vehicle History

Suzuki Heritage:

Suzuki has a long history in motorcycle manufacturing, known for innovations like the RG500 Gamma and GSX-R series. The Bandit line aimed to offer a more accessible, versatile, and stylish naked sportbike experience.

Bandit Evolution:

The GSF400 Bandit was part of Suzuki's popular Bandit series, which emphasized usable power, comfortable ergonomics, and a distinctive naked styling. It was a key player in the 400cc class, particularly popular in Japanese domestic markets.

Production Period:

The GSF400 Bandit (GK75B) was primarily produced in the mid to late 1990s, with variations and updates across its production run.

🏆 Awards & Recognition

Market Reception:

Generally well-regarded in its class for performance, handling, and value, especially within the Japanese domestic market where 400cc bikes were popular.