Suzuki Bandit GSF600S 2003 Service Manual (Silver Model)

Table of Contents

1. Introduction
2. General Specifications
3. Maintenance Schedule
4. Engine
   • Oil and Filter Change
   • Air Filter
5. Transmission
6. Brakes
   • Brake Fluid Change
7. Suspension
8. Electrical System
   • Battery
   • Fuses
9. Tires and Wheels
10. Final Drive
11. Fuel System
12. Cleaning and Storage
13. Troubleshooting

Introduction

Welcome to the service manual for the Suzuki Bandit GSF600S 2003 (Silver Model). This manual is designed to guide you through regular maintenance and basic troubleshooting procedures to keep your motorcycle running smoothly.

General Specifications

Maintenance Schedule

Engine

Oil and Filter Change

1. Preparation:

   • Start the engine and run for a few minutes to warm the oil (this will make it drain faster).
   • Place the bike on a level surface and use a center stand if available.
   • Use a pan to collect the old oil.

2. Procedure:

   • Remove the drain plug from the engine oil pan.
   • Allow the oil to drain completely.
   • Replace the drain plug and install a new oil filter.
   • Fill with recommended oil (10W-40 or equivalent, 2.9 liters).

3. Check Oil Level:

   • Start the engine and let it run for a few minutes, then turn it off.
   • Let the oil settle and check the oil level using the dipstick.

Air Filter

1. Removal:

   • Locate the air filter housing under the fuel tank.
   • Remove the screws securing the air filter cover and carefully take out the filter.

2. Cleaning/Replacement:

   • If the filter is reusable, clean it with compressed air (from the inside out) or wash it with mild detergent.
   • If the filter is too damaged or excessively dirty, replace it with a new one.

Transmission

1. Chain Adjustment:

   • Check the slack on the chain. It should have about 25-35mm of play.
   • Adjust the chain tension by loosening the rear axle nut and using the adjusters on either side of the swingarm.

2. Lubrication:

   • Clean the chain using a degreaser and brush.
   • Apply chain lube to the entire chain, focusing on the inner side.

Brakes

Brake Fluid Change

1. Preparation:

   • Place the bike securely on a stand.
   • Remove the brake fluid reservoir cap.

2. Procedure:

   • Use a brake fluid syringe to remove old fluid from the reservoir.
   • Refill with the recommended brake fluid (DOT 4).
   • Bleed the brakes by using a brake bleeder kit to remove air from the brake lines.

3. Check Brake Pads:

   • Inspect brake pads for wear. Replace if the thickness is below 1mm.

Suspension

1. Forks:

   • Check for any oil leakage from the forks.
   • If needed, replace the fork oil with the specified type and amount.

2. Rear Shock Absorber:

   • Ensure the rear shock is not leaking fluid.
   • Adjust preload, damping, and rebound as necessary based on riding preferences.

Electrical System

Battery

1. Checking Voltage:

   • Use a multimeter to check the battery voltage (should be around 12.6V when the bike is off).
   • If the voltage is low, recharge the battery or replace it if it’s no longer holding a charge.

2. Maintenance:

   • Ensure the terminals are clean and free of corrosion. Use a wire brush if necessary.

Fuses

1. Inspection:
   • Locate the fuse box, typically near the battery or under the seat.
   • Check for any blown fuses and replace with the appropriate rating.

Tires and Wheels

1. Tire Pressure:

   • Front: 2.25 bar (32 psi)
   • Rear: 2.50 bar (36 psi)

2. Tire Inspection:

   • Check for uneven wear, punctures, or damage to the tires.
   • Replace tires if tread depth is below 1.5mm.

Final Drive

1. Inspection:

   • Check the condition of the rear sprocket and chain for any signs of wear.
   • Lubricate the chain regularly and ensure proper tension.

2. Sprocket Teeth:

   • Inspect the sprocket teeth for signs of wear or damage. Replace if necessary.

Fuel System

1. Fuel Filter Replacement:
   • Remove the fuel tank.
   • Disconnect the fuel lines and remove the old fuel filter.
   • Replace with a new fuel filter and reconnect the lines.

Cleaning and Storage

1. Cleaning:

   • Wash the bike regularly using mild soap and water.
   • Clean the chain and lubricate it after every wash.

2. Storage:

   • If storing for a long period, fill the fuel tank to prevent rusting, and add a fuel stabilizer.
   • Remove the battery and store it in a cool, dry place.

Troubleshooting

This service manual provides the necessary steps for maintaining and servicing your Suzuki Bandit GSF600S 2003. Always follow the manufacturer's recommendations for the best results and consult a professional mechanic if you're unsure about any procedures.