1995-2003 Suzuki Bandit 600 Service & Repair Manual

FOREWORD This manual contains an introductory description on the SUZUKI GSF600S and procedures for its inspection/se1Vice and overhaul of its main com- ponents. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and se1Vice. This manual will help you know the motorcycle bet- ter so that you can assure your customers of fast and reliable selVice. * This manual has been prepared on the basis of the latest specifications at the time of pub- lication . If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle. * Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual motorcycle exactly in detail. * This manual is written for persons who have enough knowledge, skills and tools, includ- ing special tools, for se1Vicing SUZUKI mo- torcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you . .A WARNING Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider and passenger. SUZUKI MOTOR CORPORATION Motorcycle Service Department © COPYRIGHT SUZUKI MOTOR CORPORATION 1999 GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE FUEL SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION GSF600

HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on the first page of each section to help find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel ® ITEM N·m kgf·m ® 65 6.5 @ 23 2.3 lb-ft 47.0 16.5 CD Front axle Spacer @ Collar @ Brake disc (R) @ Bearing (R) @ Spacer ({) Bearing (L) @ Brake disc (L) ® Collar @ Front wheel @ Air valve @ Balancer ® Axle shaft ® Brake disc bolt

SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for seNic- ing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. • Apply THREAD LOCK SUPER Data beside it indicates specified "1360". torque. 99000-32130 l]l1 Apply oil. Use engine oil unless I Apply or use brake fluid. otherwise specified. m' Apply molybdenum oil solution (mixture of engine oil and SUZUKI MOLY Measure in voltage range. PASTE in a ratio of 1: 1 ). Apply SUZUKI SUPER Measure in resistance range. 99000-25010 Apply SUZUKI SILICONE GREASE. Measure in current range. 99000-25100 Apply SUZUKI MOLY PASTE. @J Measure in diode test range. 99000-25140 Apply THERMO-GREASE. Ut Measure in continuity test range. 99000-59029 •1201sJ Apply SUZUKI BOND "12078". lfooLI Use special tool. 99000-31140 • Apply THREAD LOCK SUPER Em Use fork oil. "1303". 99000-99044-1 OG 99000-32030 • Apply THREAD LOCK "1342". tm Indication of seNice data. 99000-32050

GENERAL INFORMATION 1·1 GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE............................................................. 1- 2 GENERAL PRECAUTIONS............................................................. 1- 2 SUZUKI GSF600SY (2000-MODEL) ................................................ 1- 4 SERIAL NUMBER LOCATION ........................................................ 1- 4 FUEL AND OIL RECOMMENDATION............................................. 1- 4 FUEL.............................................................................................. 1- 4 ENGINE OIL ................................................................................... 1- 5 BRAKE FLUID............................................................................... 1- 5 FRONT FORK OIL ............................................................... ... ..... .. 1- 5 BREAK-IN PROCEDURES.................................... .. ... ..................... 1- 5 CYLINDER IDENTIFICATION........................ .. ................................ 1- 5 INFORMATION LABELS.................. .................... ............................ 1- 6 SPECIFICATIONS ...................... .. .................................................... 1- 7 COUNTRY OR AREA CODES ......................................................... 1- 9

1 ·2 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. A WARNING Indicates a potential hazard that could result in death or injury. IA CAUTION I Indicates a potential hazard that could result in motorcycle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARN- INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice. GENERAL PRECAUTIONS A WARNING * Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle. * When 2 or more persons work together, pay attention to the safety of each other. * When it is necessary to run the engine indoors, make sure that exhaust gas is forced out- doors. * When working with toxic or flammable materials, make sure that the area you work in is well- ventilated and that you follow all of the material manufacturer's instructions. * Never use gasoline as a cleaning solvent. * To avoid getting burned, do not touch the engine, engine oil, oil cooler and exhaust system until they have cooled. * After servicing the fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for leaks.

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1995-2003 Suzuki Bandit 600 Service & Repair Manual

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