Suzuki GSF600 GSF600S Bandit (1995-2002) - Repair, Service and Maintenance Manual

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SUZUKI GSF600 & GSF600S BANDIT (1995-2002) - SERVICE MANUAL

- English Service Manual to Suzuki GSF600 GSF600S Bandit.


INDEX:


 
GSF 600S / GSF600 SERVICE MANUAL

- Foreword
- Group Index
- How to Use this manual
- Symbol

1 GENERAL INFORMATION

- Warning/caution/note
- General precautions
- Suzuki GSF600SY (2000 model)
- Serial number location
- Fuel and Oil recommendation
- Fuel
- Engine oil
- Brake fuild
- Front fork oil
- Break-in procedures
- Cylinder identification
- Information labels
- Specifications
- Country or area codes

2 PERIODIC MAINTENANCE

- Periodic maintenance schedule
- Periodic Maintenance chart
- Lubrications points
- Maintenance and tune-up procedures
- Valve clearance
- Spark plugs
- Exhaust pipe bolts and muffler bolts
- Air cleaner
- Engine oil and oil filter
- Fuel hose
- Fuel filter
- Engine idle speed
- Throttle cable play
- Carburetor synchronization
- Evoporative Emission control system
- Pair system
- Clutch cable play
- Drive Chain
- Brakes
- Tires
- Steering
- Front forks
- Rear Suspension
- Chassis bolts and nuts
- Compression pressure check
- Oil pressure check

3 ENGINE

- Engine components removable with engine in place
- Engine removal and instalation
- Engine removal
- Engine reinstallation
- Engine disassembly and reassembly
- Engine components inspection and service
- Camshaft / cylinder head
- Cam chain tensioner
- Valve
- Valve guide
- Valve seat
- Valve spring
- Cylinder
- Piston
- Piston ring
- Piston pin
- Clutch
- Starter clutch
- Gearshift linkage
- Transmission
- Conrod
- Crankshaft
- Engine lubrication system
- Pair system

4 FUEL SYSTEM

- Fuel System
- Fuel tank
- Removal
- Remounting
- Fuel Valve
- Removal
- Inspection and cleaning
- Remounting
- Fuel filter removal
- Inspection
- Fuel filter remounting
- Carburetor
- Construction
- Specifications
- I.D. no. locations
- Diaphragm and piston operation
- Slow System
- Main system
- Starter system
- Float system
- Removal
- Disassembly
- Carburetor cleaning
- Carburetor heater inspection
- Thermo-switch inspection
- Carburetor inspection
- Reassembly
- Remounting
- Carburetor synchronization

5 CHASSIS

- Exterrior parts
- Construction
- Removal
- Remounting
- Front wheel
- Construction
- Removal
- Inspection and disassembly
- Reassembly
- Remounting
- Front fork
- Construction
- Removal and disassembly
- Inspection
- Reassembly and remounting
- Steering
- Construction
- Removal and disassembly
- Inspection and disassembly
- Reassembly and remounting
- Steering tension adjustment
- Rear Wheel
- Construction
- Removal
- Inspection and disassembly
- Reassembly
- Remounting
- Rear suspension
- Construction
- Removal
- Inspection and disassembly
- Reassembly
- Rear shock absorber disposal
- Remounting
- Final inspection and adjustment
- Suspension setting
- Front brake
- Construction
- Brake pad replacement
- Brake fluid replacement
- Brake caliper removal and disassembly
- Brake caliper inspection
- Brake caliper reassembly and remounting
- Brake disc inspection
- Brake disc removal and remounting
- Master cylinder removal and disassembly
- Master cylinder inspection
- Master cylinder reassembly and remounting
- Rear brake
- Construction
- Brake pad replacement
- Brake fluid replacement
- Brake caliper removal and disassembly
- Brake Caliper reassembly and remounting
- Master cylinder removal and disassembly
- Master cylinder inspection
- Master cylinder reassembly and remounting
- Tires and Wheels
- Tire Removal
- Inspection
- Tire installation

6 ELECTRICAL SYSTEM

- Cautions in servicing
- Lokation of electrical components
- Charging system
- Description
- Troubleshooting
- Inspection
- Generator
- Removal and disassembly
- Inspection
- Reassembly and remounting
- Starter system and side-stand Ignition interlock system
- Starter system description
- Side-stand / ign. interlock system description
- Trouble shooting
- Starter motor removal and disassembly
- Starter motor inspection
- Starter motor reassembly and remounting
- Starter relay inspection
- Side-stand / ign. interlock system part inspection
- Ignition System
- Discription
- Trouble shooting
- Inspection
- Combination Meter
- Removal
- Disassembly
- Inspection
- Lamps
- Headlight
- Brake light / taillight and license plate light
- Turn signal lights
- Relays
- Starter relay
- Turn signal / side-stand relay
- Switches
- Battery
- Specifications
- Removal
- Remounting
- Initial charging
- Servicing
- Recharging operation

7 SERVICING INFORMATION

- Troubleshooting
- Engine
- Carburetor
- Brakes
- Electrical
- Battery
- Wiring Diagram
- Wire harness, cable and hose routing
- Wire harness routing
- Cable routing
- Pair system hose routing
- Front brake hose routing
- Rear brake hose routing
- Front footrest bracket set-up
- Fuel tank set-up
- High-tension cord routing
- Muffler mounting
- Side-stand springs
- Center-stand springs
- Cowling and cowling brace set-up
- Frame cover and side frame cover set-up
- Cowling cushion and tape
- Front fender cushion
- Seat lock cable routing
- Specials tools
- Tightening torque
- Engine
- Chassis
- Tighting torque chart
- Service data