2000-2004 Suzuki GSF600 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 GREASE"~'. ~ 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.

GENERAL INFORMATION 1-3 IA CAUTION I * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. * Be sure to use special tools when instructed. * Make sure that all parts used in reassembly are clean. Lubricate them when specified. * Use the specified lubricant, bond, or sealant. * When removing the battery, disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal. * When performing service to electrical parts, if the service procedures not require use of battery power, disconnect the negative cable the battery. * When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first. Always tighten the bolts and nuts diagonally from the inside working out and to the specified tightening torque. * Whenever you remove oil seals, gaskets, packing, 0-rings, locking washers, self-locking nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. * Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. _ * Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. * After reassembling, check parts for tightness and proper operation. * To protect the environment, do not unlawfully dispose of used motor oil and other fluids: batteries, and tires. * To protect Earth's natural resources, properly dispose of used motorcycle and parts.

1·4 GENERAL INFORMATION SUZU Kl GSF600SY (2000-MODEL) LEFT RIGHT * Difference between photograph and actual motorcycle depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.l.N. (Vehicle Identification Number) CD is stamped on the right side of the steering head pipe. The engine serial number ~ is located on the right side of the crankcase. These num- bers are required especially for re gistering the machine and ordering spare parts. FUEL AND OIL RECOMMENDATION FUEL (For Canada) 1. Use only unleaded gasoline of at least 87 pump octane ( R~M) method or 91 octane or higher rated by the research method. 2. Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it. 5. If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. 6. Failure to follow these guideline cou ld possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above. FUEL (For the others) Gasoline used should be graded 91 octane (Research Method) or higher. An un leaded gasoline is recom - mended .

ENGINE OIL Use a premium quality 4-stroke motor oil to ensure longer service life of your motorcycle. Use only oils which are rated SF or SG under the API service classification. The recommended viscosity is SAE 1 OW-40. If an SAE 1 OW-40 motor oil is not available, select an alternative according to the right chart. BRAKE FLUID Specification and classification: DOT 4 A. WARNING MULTIGRADE TEMP. cc OF GENERAL INFORMATION 1-5 • ' ' . . • • • • l OW 30 -30 -20 -10 0 10 20 30 40 -22 -4 14 32 60 68 86 104 Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result. Do not use any brake fluid taken from old or used or unsealed containers. Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. FRONT FORK OIL Use fork oil #10 or equivalent fork oil. BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to "BREAK-IN" before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and re- straint exercised during its early life. The general rules are as follows. • Keep to these break-in engine speed limits: Initial 800 km (500 miles): Below 6 000 r/min. Up to 1 600 km (1 000 miles): Below 9 000 r/min. Over 1 600 km (1 000 miles): Below 12 000 r/min. • Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. However, do not exceed 12 000 r/min. at any time. CYLINDER IDENTIFICATION The four cylinders of this engine are identified as No.1, No.2, No.3 and No.4 cylinder, as counted from left to right (as viewed by the rider on the seat).

1-6 GENERAL INFORMATION INFORMATION LABELS CD @ @ @ @ @ -T 10 mm (0.4 in) 28mm -, L (1.1 in) 28mm (1.1 in) __,,..___._ (Except E-28)--@.._____=.· t~=I: ~... 1 o mm (0.4 in) Noise label (For E-03, 33) ({) Warning steering label Information label (For E-03, 28, 33) ® Tire pressure label Vacuum hose routing label (For E-33) ® Warning safety label Fuel caution label (For E-02, 24) ® ICES Canada label (For E-28) Manual notice label (For E-03, 33) ® ID plate (Except E-03, 28, 33) Warning screen label © Safety plate (For E-03, 28, 33)

SPECIFICATIONS DI MENSIONS AND DRY MASS Overall length ................ .. ..... .. ... .. ................................ . Overall width ..... .. ... ..... ......................... .. .. ... .. .... ........ ... . Overall height ............. ................... ........ ... . .. ... .... ... ... ... . Wheelbase .... .............. ..... ..... ......... ...... ... ... .................. . Ground clearance .... .. .... ..... ....... ....................... ......... ... Seat height ... ........ .... ..... ......... ..... .. .... . ... ... ..... ..... . .. ....... . Dry mass ..... ........... .. ... .... ... .. ...... .... ........ ...... .. ... ...... ..... . ENGINE 2 060 mm (81.1 in) 770 mm (30 .3 in) 1 220 mm (48 .0 in) 1 440 mm (56.7 in) 130 mm (5 .1 in) 790 mm (31.1 in) 208 kg (458 lbs) G ENERAL INFORMATION 1-7 Type .. .. .. ... .... .. .... ... .. .. ... ..... .. ... .. ... ........ . ... . ... ....... .. .... .. ... Four-stroke, air-cooled, with SACS, DOHC, TSCC Number of cylinders ........ ... .... .. ... ..... ... ... ...... .. .. .. .... .. .... 4 Bore . .. .. .. ...... ... . .... ..... .. .. .... ... ... .. .. .... ... .. ... .. .. ... . .. .. .. ........ 62.6 mm (2.465 in) Stroke ............ .. .. .. .. .. ........ ... ....... .. ...... .... ... ..... .. ...... .... .... 48.7 mm (1.917 in) Compression ratio ....... ......... ..... ... .... ........ . .. .. .... .. .. .. .. ... 11.3 : 1 Piston diplacement ... .... .... .. ........ .. .. .. ... .... .... .... .. ....... .... 600 cm 3 (36.6 cu.in) Carburetor .... ........ ...... ........ .... .. .. ....... ... ......... ... ... ... ... ... KEIHIN CVR32SS, four Air cleaner ............ .. ..... ........... .. ........ . .. ............ ............ .. Non-woven fabric element Starter system ....................... .. ... .. ................................ Electric starter Lubrication system ..... .. ... ...... ............. .. .............. .......... Wet sump TRANSMISSION Clutch .. ..... ... .. ........ ... ... .. .... ..... .. .. .. ................................. Wet multi-plate type Transmissio n. ... .... ... ..... .. . .. .. ........ ............ ....... .. ... .. ........ 6-speed constant mesh Gearshift pattern ..... . .. ... .. .... .. ........ .. . .. .. . .. ... . ... .... .. . ... .... 1-down, 5-up Primary reduction ratio ....... ... ...... ..... ..... ... .... ... .... ... .. .... 1.744 (75/43) Final reduction ratio ........... ........ .. ....... ...... .. .. .......... .... .. 3.133 (47/15) Gear ratios, Low...... ......... .. .... .......... .. .... ...... .. ... ........... 3.083 (37/12) 2nd ... .......... .. ... ....... ... ....... .. .. ........... ..... .. .. 2.062 (33/16) 3rd .. .. ..... ... .. ... ... ... ............... ........... ... ........ 1.647 (28/17) 4th ... ..... .... .. ... .······· ....... .. ... .. ... .. . .. .. .. .. .. ..... 1.400 (28/20) 5th .. ... ....... ...... .... .. .. ... .... ..... ... ................ ... 1.227 (27/22) Top .. ....... ....... .. .. ... .. .... ......... . .. ....... .... .. .. .... 1.095 (23/21) Drive chain .. ..... .. ................... .... . .. .. .. . ... .. ... ... . .. . .. .. .. ... .... RK50MFOZ1 , 112 links ' ~ : j ' • '

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2000-2004 Suzuki GSF600 Bandit 600 Service & Repair Manual

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