![Suzuki GSF 400 (1991-1993) [81/270] Engine reassembly](/img/pdf.png)
Suzuki GSF 400 (1991-1993) [81/270] Engine reassembly
![Suzuki GSF 400 (1991-1993) [81/270] Engine reassembly](/views2/1121318/page81/bg51.png)
Содержание
- Chassis 2
- Cooling system 2
- Electrical system 2
- Emission control information 2
- Foreword group index 2
- Fuel and lubrication 2
- General information 2
- Gsf400m c92 model 2
- Gsf400p c93 model 2
- Important 2
- Servicing information 2
- Suzuki motor corporation 2
- System 2
- View of suzuki gsf400 bamdit 3
- Contents 4
- General informa tion 4
- General information 4
- Fuel for canadian model 5
- Fuel for the other models 5
- Fuel for u s a model 5
- Fuel oil and coolant recommendation 5
- Serial number location 5
- Anti freeze coolant 6
- Brake fluid 6
- Coolant 6
- Engine oil for the other models 6
- Engine oil for u s a model 6
- Front fork oil 6
- Water for mixing 6
- Break in procedures 7
- Cylinder identification 7
- Liquid amount of water coolant 7
- For other models 8
- General information 14 8
- Special materials 8
- The materials listed below are needed for maintenance work on the gsf400 bandit and should be kept on hand for ready use they supplement such standard materials as cleaning fluids lubricants emery cloth and the like how to use them and where to use them are described in the text of this manual 8
- 5 general information 9
- General information 1 6 10
- Precautions and general instructions 11
- Replacement parts 11
- Asbestos information 12
- Dimensions and dry mass 13
- Engine 13
- Specifications 13
- Transmission 13
- Capacities 14
- Chassis 14
- Electrical 14
- Country or area 15
- Air cleaner side covers 16
- Exterior parts removal 16
- Frame covers 16
- Contents 17
- Periodic maintenance and 17
- Periodic maintenance tune up 17
- Tune up procedures 17
- Periodic maintenance chart 18
- Periodic maintenance schedule 18
- Lubrication points 19
- Note before lubricating each part dean off any rusty spots and wipe off any grease oil dirt or grime lubricate exposed parts which are subject to rust with oil or grease 19
- Periodic maintenance and tune up procedures 2 2 19
- Proper lubrication is important for smooth operation and long life of each working part of the motor cycle major lubrication points are indicated below 19
- Battery 20
- Cylinder head nuts and exhaust pipe bolts 20
- Maintenance and tune up procedures 20
- Air cleaner 21
- Valve clearance 22
- Spark plugs 24
- Engine oil and oil filter 25
- Fuel line 25
- Carburetors 26
- Cooling system 26
- Clutch 27
- Drive chain 28
- Brakes 30
- Steering 33
- Front forks 34
- Rear suspension 34
- Chassis bolts and nuts 35
- Contents 37
- Engine 37
- Compression pressure check 38
- Compression test procedure 38
- Oil pressure check 39
- Oil pressure test procedure 39
- Engine components removable with engine in place 40
- Engine removal 41
- Engine removal and reinstallation 41
- Engine reinstallation 45
- Engine disassembly 47
- Cylinder head 57
- Engine components inspection and service 57
- Cylinder head distortion 58
- Valve head radial runout 58
- Valve stem runout 58
- Valve face wear 59
- Valve guide servicing 59
- Valve stem deflection 59
- Valve stem wear 59
- Valve seat servicing 60
- Valve seat width 60
- Valve springs 62
- Valve stem end condition 62
- Reassembly 63
- Camshaft 64
- Cam wear 65
- Camshaft journal wear 65
- Cam chain 20 pitch length 67
- Cam chain guide 67
- Cam chain tensioner 67
- Cylinder bore 67
- Cylinder distortion 67
- Piston cylinder clearance 68
- Piston diameter 68
- Piston ring groove clearance 68
- Piston pin and pin bore 69
- Piston ring free end gap and piston ring end gap 69
- Conrod big end side clearance 70
- Conrod crank pin bearing selection 70
- Conrod small end i d 70
- Bearing assembly 72
- Crankcase crankshaft bearing selection 73
- Crankshaft thrust clearance 75
- Crankshaft runout 76
- Clutch 77
- 41 engine 78
- Caution do not attempt to disassemble the oil pump assembly the oil pump is available only as an assembly 78
- Disassembly disassemble the transmission gears as shown in the illustration 78
- Oil pump 78
- Transmission 78
- When removing the 2nd drive gear use an appropriate gear puller 78
- Gearshift fork groove clearance 80
- Engine reassembly 81
- Clutch 87
- Breather cover servicing 99
- Contents 100
- Fuel and lubrication system 100
- Fuel lubrication system 100
- Fuel system 101
- Fuel cock removal 102
- Fuel tank and fuel cock 102
- Fuel tank removal 102
- Inspection and clelaning 102
- 3 fuel amd lubrication system 103
- Carburetor 103
- Construction 103
- Specifications 104
- I d no location 105
- Diaphragm and piston operation 106
- Slow system 107
- Main system 108
- Float system 109
- Starter system 109
- Disassembly 110
- Float height adjustment 110
- Inspection and adjustment 110
- Needle valve inspection 110
- Reassembly and remounting 110
- Removal 110
- Balance of carburetors 111
- Lubrication system 113
- Oil filter 113
- Oil pressure 113
- Oil sump filter 113
- Lubrication system chart 114
- Contents 115
- Cooling system 115
- Cooling system 116
- Description 116
- Construction 117
- Cooling system 5 2 117
- 3 coollig system 118
- Cooling solution 119
- Cooling system removal and disassembly 120
- Radiator 120
- Cooling fan 121
- Water thermo switch and cooling fan thermo switch 121
- Thermostat 122
- Water pump 122
- Inspection 124
- Installation 124
- Radiator 124
- Removal 124
- Cooling fan 125
- Inspection 125
- Reassembly 125
- Removal 125
- Water thermo switch 125
- Cooling fan thermo switch 126
- Inspection 126
- Reassembly 126
- Removal 126
- Inspection 127
- Reassembly 127
- Removal 127
- Thermostat 127
- Inspection 128
- Reassembly 128
- Removal and disassembly 128
- Water pump 128
- Contents 130
- Electrical system 130
- Charging system 131
- Description 131
- Inspection 133
- Description 135
- Ignition system digital ignitor 135
- Inspection 136
- Description 140
- Removal and disassembly 140
- Starter system 140
- Inspection 141
- Reassembly 142
- Description 143
- Side stand ignition interlock system 143
- Starter relay inspection 143
- Electrical system 6 14 144
- Side stand up on 144
- The circuit consists of relay iamp diode and switches and decides to live the ignition coil depending on the position of the transmission and side stand with the neutral and side stand switches work ing mutually the ignition coil lives only in two situations as follows 1 transmission neutral on side stand down off 144
- The current flow a turns on the relay and the ignition coil lives even the side stand is kept down this is for warming up the engine 144
- The current flow turns on the relay and the ignition coil lives the engine can be easily start ed at any transmission position 144
- Inspection 145
- Combination meter 146
- Removal and disassembly 146
- 17 electrical system 147
- 25002 pocket tester 147
- Inspection 147
- Note when making this test it is not necessary to remove the com bination meter 147
- Tester knob indication x w range 147
- Using the pocket tester check the continuity between iead wires in the diagram as shown beiow if the continuity measured is incorrect replace the respective 147
- Oil pressure switch 149
- Switches 149
- Turn signal light 149
- Side stand relay 150
- Starter relay 150
- Turn signal relay 150
- Battery 151
- Initial charging 151
- Specifications 151
- Servicing 152
- Recharging operation 153
- Chassis 154
- Contents 154
- Front wheel 155
- Removal 155
- Inspection and disassembly 156
- Reassembly and remounting 157
- Brake pad replacement 160
- Front brake 160
- Caliper and disc inspection 161
- Caliper removal and disassembly 161
- Caliper reassembly and remounting 162
- Master cylinder removal and disassembly 162
- Master cylinder inspection 164
- Master cylinder reassembly and remounting 164
- Front fork 165
- Removal 165
- Disassembly 166
- Inspection 167
- Reassembly and remounting 168
- Steering 170
- Disassembly 171
- Removal 171
- Inspection 172
- Reassembly and remounting 172
- Steering tension adjustment 173
- Ignition switch 174
- Ance will be adversely affected 175
- Brake pad replacement 175
- Caution do not operate the brake pedal while removing the pads replace the brake pad as a set otherwise braking perform 175
- Chassis 175
- Rear brake 175
- Remove the dust sea cover remove the clips pins and springs remove the pads 175
- Caliper removal and disassembly 176
- Caliper and disc inspection 177
- Caliper reassembly and remounting 177
- Master cylinder removal and disassembly 178
- Master cylinder inspection 179
- Master cylinder reassembly and remounting 180
- 27 chassis 181
- Caliper along with the torque link 181
- Note do not operate the brake pedal while removing the rear wheel 181
- Rear wheel 181
- Removal 181
- Support the motorcycle with the center stand remove the rear brake caliper mounting bolts and lower the 181
- Inspection and disassembly 183
- Reassembly and remounting 184
- Tire and wheel 187
- Tire removal 187
- Inspection 189
- Rear suspension 192
- Swingarm 192
- Shock absorber and cushion lever 193
- Removal 194
- Inspection 195
- Disassembly 196
- Swingarm 196
- Cushion lever rod 197
- Apply suzuki super grease a 198
- Chassis 7 44 198
- Reassembly information 198
- Reassembly and remounting 199
- Final inspection and ajdustment 200
- Shock absorber spring pre load 200
- Contents 201
- Servicing informa tion 201
- Servicing information 201
- 1 servicing information 202
- Engine 202
- Troubleshooting 202
- Servicing information 8 2 203
- 3 servicing information 204
- Radiator 204
- Carburetor 205
- Servicing information 84 205
- 5 servicing information 206
- Electrical 206
- Battery 207
- Servicing information 8 6 207
- 7 servicing information 208
- Chassis 208
- Brakes 209
- Servicing information 8 8 209
- 9 servicing information 210
- 9 wiring schematic 210
- Servicing information 8 10 211
- 11 servicing information 212
- Servicing information 842 213
- Wire routing 214
- Wire routing 215
- 17 servicing information 218
- Fuel hose vacuum hose and air vent hose routing 219
- Serviclwg information 8 18 219
- 19 servicing information 220
- Air cleaner water drain hose and fuel tank water drain 220
- Fuel hose and vacuum hose routing 220
- Hose routing 220
- 21 servicing snformation 222
- Center stand spring and side stand spring 222
- Servicing information 8 22 223
- Special tools 223
- B 23 servicing iiformatioi 224
- Servicing information 8 24 225
- Engine 226
- Tightening torque 226
- Chassis 227
- 27 servicing information 228
- For other bolts and nuts not listed previously refer to this chart 228
- Tightening torque chart 228
- Service data 229
- Valve guide 229
- Camshaft cylinder head 230
- Cylinder piston piston ring 230
- Conrod crankshaft 231
- Clutch 232
- Oil pump 232
- Thermostat radiator faim 232
- Transmission drive chain 232
- Carburetor 233
- Electrical 234
- Wattage 234
- Brake wheel 235
- Fuel oil coolant 236
- Suspension 236
- Tire pressure 236
- Contents 238
- Emission control information 238
- Canister hose routing only for california model 241
- Appendix 1992 model 242
- Contents 242
- Gsf400n f 92 model 242
- 1 gsf400n 02 m0del 243
- Dimensions and dry mass 243
- Engine 243
- Specifications 243
- Transmission 243
- Capacities 244
- Chassis 244
- Electrical 244
- K 0 rr 244
- Service data 245
- Valve guide 245
- Camshaft cylinder head 246
- Cylinder piston piston ring 246
- 5 gsf4ßßä s2 0del 247
- Conrod crankshaft 247
- S or a crocus w ct 247
- Sco c 3 3 3 247
- Clutch 248
- Oil pump 248
- Thermostat raw7cr ax 248
- Transmission drive chain 248
- U2l123el s 6 248
- _______________i 2 __________________ 248
- Carburetor 249
- Electrical 250
- Wattage 250
- Rake wheel 251
- S gsf4ö08 sz odel 251
- Fuel oil coolant 252
- Suspension 252
- Tire pressure 252
- Appendix 1993 model 254
- Contents 254
- Foreword 254
- Gsf400p 93 model 254
- Dimensions and dry mass 255
- Engine 255
- Specifications 255
- Transmission 255
- Capacities 256
- Chassis 256
- Electrical 256
- Service data 257
- Valve guide 257
- Camshaft cylinder head 258
- Cylinder piston piston ring 258
- Conrod crankshaft 259
- Clutch 260
- Oil pump 260
- Thermostat radiator fan 260
- Transmission drive chain 260
- Carburetor 261
- Electrical 262
- Wattage 262
- Brake wheel 263
- Fuel oil coolant 264
- Suspension 264
- Tire pressure 264
- 93 model only the exhaust valve spring lower seat shim has been eliminated from 93 model 266
- Engine mounting 266
- Gsf4o0p cs3 m0deu 11 12 266
- Chassis 267
- Tightening torque 267
- Gsf400p c93 model 11 14 268
- 15 gsf400p г93 мооец 269
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ENGINE 3 Shift fork groove width Standard No 1 No 2 No 3 5 50 5 60 mm 0 217 0 220 in Shift fork thickness Standard No 1 No 2 No 3 5 30 5 40 mm 0 209 0 213 in Checking thickness ENGINE REASSEMBLY The engine is reassembled by carrying out the steps of disassembly in the reversed order but there are a number of steps which demand special descriptions or precautionary measures NOTE Apply engine oil to each running and sliding part before reassembling Install the gearshift cam related parts Gearshift cam Washer Pin Gearshift cam stopper plate Spacer NOTE When installing the cam stopper plate align the pin groove with the pin as shown in the Fig Install the gearshift forks to the crankcase in the correct positions and directions For 5th driven gear No 1 For 3rd 4th drive gear No 3 For Top driven gear No 2 Gearshift cam stopper
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