Suzuki Bandit GSF600 1995-2005 Service Workshop Manual

Workshop Service and Repair Manual for the Suzuki Bandit GSF600, an absolute gem for any Bandit owner. This full workshop manual covers every component, service and repair procedure in full Suzuki factory specification with clear step by step photographs and technical drawings for the GSF600 with torque setting values throughout each chapter, this is the most comprehensive service manual available for the GSF600 complete with supplements for servicing & Suzuki factory upgrades such as the introduction of a digital fuel gauge, new wiring circuits etc, as used by main and independent garages the world over.

Includes supplemental chapters for K0, K1, & K2 bikes.

Later Model Supplement GSF600 K0 (2000-Model)
Specifications
Combination Meter
Headlight
Headlight Beam Adjustment
Wiring Diagram
Wire Harness Routing
Front Brake Hose Routing
Service Data

Later Model Supplement GSF600 K1:
Specifications
Service Data (GSF600)
(GSF600S/GSF600SU)
Change

Later Model Supplement GSF600 K2:
Specifications
Service Data (GSF600S)
Service Data (GSF600)
Fuel Level Gauge
Fuel Level Meter
Wiring Diagram (GSF600S)
Wiring Diagram (GSF600)
Wire Harness Routing (GSF600S)
Wire Harness Routing (GSF600)

Chapters covered within this manual:

Maintenance:
Periodic Maintenance Schedule
Periodic Maintenance Chart
Lubrication 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
Carburettor Synchronization
Evaporative Emission Control System (E-33 Only)
Pair (Air Supply) System
Clutch Cable Play
Drive Chain
Brakes
Tyres
Steering
Front Forks
Rear Suspension
Chassis Bolts And Nuts
Compression Pressure Check
Oil Pressure Check

Engine:
Engine Removal And Reinstallation
Engine Disassembly And Reassembly
Engine Components Inspection And Service
Camshaft/Cylinder Head
Cam Chain Tensioner
Valve Guide, Seat & Spring
Cylinder
Piston
Piston Ring
Piston Pin
Clutch
Starter Clutch
Gearshift Linkage
Transmission
Conrod
Crankshaft
Engine Lubrication System
Pair (Air Supply) System

Fuel System:
Fuel Tank Removal, Inspection, Cleaning, Remounting
Fuel Valve Removal, Inspection, Cleaning, Remounting
Fuel Filter Removal. Inspection, Remounting
Carburettor Specifications
I.D. No. Location
Diaphragm And Piston Operation
Slow System
Main System
Starter (Enricher) System
Float System Removal & Reassembly
Carburettor Cleaning
Carburetor Heater Inspection
Thermo-switch Inspection
Carburetor Inspection,Reassembly & Remounting
Carburettor Synchronization

Chassis:
Exterior Parts Construction, Removal & Remounting
Front Fork Construction, Removal And Disassembly, Inspection, Reassembly And Remounting
Steering Removal, Disassembly, Inspection & Reassembly
Steering Tension Adjustment
Front & Rear Wheels Removal Inspection & Remounting
Rear Suspension Removal Inspection, Reassembly Remounting
Front & Rear Brake
Brake Disc Inspection
Brake Disc Removal And Remounting
Brake Pad Replacement
Brake Fluid Replacement
Brake Calipers Removal, Inspection & Reassembly
Master Cylinder Removal, Inspection & Reassembly
Tyres And Wheels
Tyre Removal & Installation

Electrical System:
Location Of Electrical Components
Charging System
Description (Generator With Ic Regulator)
Troubleshooting
Generator Removal – Disassembly – Inspection – Remounting
Starter System And Side-stand Ignition
Interlock System
Starter System Description
Side-stand/Ignition Interlock System Description & troubleshooting
Starter Motor Removal And Disassembly
Starter Motor Inspection
Starter Motor Reassembly And Remounting
Starter Relay Inspection
Side-stand/Ignition Interlock System Part – Inspection
Ignition System (Digital Ignitor) Description, Troubleshooting & 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
Servicing Information:
Troubleshooting
Engine
Carburettor
Chassis
Brakes
Electrical
Battery
Wiring Diagram
Wire Harness, Cable And Hose Routing
Wire Harness Routing
Cable Routing
Pair (Air Supply) 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 And Center Stand Springs
Cowling And Cowling Brace Set-up
Frame Cover And Side Frame Cover Set-up
Cowling Cushion And Tape
Front Mudguard Cushion
Seat Lock Cable Routing
Special Tools
Tightening Torque Chart
Service Data
Wiring Diagram