Suzuki GSF600S 1995 Service Repair Workshop Manual

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Type: Motorcycle

Vendor:

Sku: 91534

Tags: 1995 GSF600S Misc Motorcycle Motorcycles Suzuki

Product variants

Description

The GSF600S Bandit, produced in 1995, represents a robust middleweight sportbike known for its versatility and engaging riding experience. Featuring an air/oil-cooled, 598 cc inline-four engine, this model utilizes a steel diamond frame and, in the 'S' variant, a half-fairing for enhanced aerodynamics and rider comfort. The heritage in producing reliable and performance-oriented motorcycles underpins the Bandit's reputation for delivering a balanced and enjoyable ride, making it a popular choice for both commuting and spirited riding. This comprehensive workshop manual provides detailed guidance for the maintenance and repair of your 1995 GSF600S Bandit. It covers a wide array of systems, including engine mechanicals, fuel, ignition, cooling, transmission, suspension, braking, and electrical systems, offering factory-level detail for professional mechanics and enthusiasts alike. The manual includes step-by-step procedures for routine maintenance, component removal and installation, rebuilding, troubleshooting, and essential technical specifications, ensuring you have the knowledge to keep your motorcycle in optimal condition.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GSF600S Bandit

Year:

Codes

Engine Code Family:

GSF600

Chassis Code Family:

GN77B

👋 Introduction

Market Position

Segment:

Middleweight Naked/Sportbike

Target Audience:

Riders seeking a reliable, versatile, and engaging motorcycle for commuting and sport riding.

Competitive Analysis

Key Competitors:

Yamaha FZR600R, Kawasaki ZZ-R600, Honda CBR600F.

Key Features

Engine Type:

Air/oil-cooled inline-four cylinder.

Frame Type:

Steel diamond frame.

Styling:

The 'S' model features a half-fairing for improved aerodynamics and rider comfort.

📋 Manual Details

Coverage Areas

Coverage Type:

Comprehensive Service and Repair

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, overhaul, and reassembly of all engine components.

Fuel System:

Carburetor tuning, cleaning, rebuilding, fuel pump inspection, fuel lines.

Ignition System:

Ignition timing, spark plug specifications, coil testing, CDI unit troubleshooting.

Cooling System:

Coolant types, radiator service, fan operation, thermostat testing.

Transmission And Drivetrain:

Gearbox disassembly, clutch inspection and replacement, final drive maintenance.

Suspension System:

Front fork service (oil change, seal replacement), rear shock absorber inspection, linkage maintenance.

Braking System:

Brake pad replacement, caliper service, hydraulic system bleeding, master cylinder inspection.

Electrical System:

Wiring diagrams, lighting systems, charging system (stator, regulator/rectifier), starting system (starter motor, battery).

Chassis And Frame:

Frame inspection, steering head bearing service, wheel bearing replacement.

Bodywork And Fairings:

Fairing removal and installation, seat maintenance, tank mounting.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, lubrication points.

Troubleshooting Guides:

Diagnostic procedures for common problems, symptom-based troubleshooting.

Component Removal And Installation:

Step-by-step instructions for replacing major and minor components.

Rebuilding Procedures:

Detailed instructions for overhauling carburetors, brake calipers, and engine components.

Torque Specifications:

Critical torque values for all fasteners and assemblies.

Technical Depth

Depth Of Coverage:

Factory-level detail suitable for professional mechanics and advanced DIY enthusiasts.

Diagnostic Capabilities:

In-depth diagnostic trees for electrical and mechanical issues.

Diagnostic Tools Required:

Specifies required tools and their usage for diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchable PDF

Print Quality

Image Resolution:

High-resolution scans for clear diagrams and text.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, DOHC, 4-valve per cylinder, Inline-4

Displacement:

598 cc

Bore X Stroke:

62.6 mm x 48.7 mm

Compression Ratio:

10.4:1

Cooling System:

Air/Oil Cooled

Performance

Claimed Horsepower:

78 hp @ 10,500 rpm (approx.)

Claimed Torque:

55 Nm @ 9,000 rpm (approx.)

Fuel System

Carburetors:

Mikuni BST34 x 4

Fuel Tank Capacity:

20 Liters (5.3 US gal)

Fuel Type:

Unleaded gasoline, minimum 91 octane.

🔧 Transmission

Standard

Type:

Constant mesh, 6-speed sequential

Optional

Options:

N/A (Single transmission option)

Features

Clutch Type:

Wet multi-plate

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Length:

2,170 mm (85.4 in)

Width:

770 mm (30.3 in)

Height:

1,225 mm (48.2 in)

Wheelbase:

1,485 mm (58.5 in)

Weights

Dry Weight:

190 kg (419 lbs)

Wet Weight:

211 kg (465 lbs) (approx.)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle safety is primarily performance and rider-controlled).

Active Features

Braking System Front:

Dual 290 mm discs, 4-piston calipers

Braking System Rear:

Single 240 mm disc, 2-piston caliper

Passive Features

Lighting:

Halogen headlamp, LED tail light (typical for era).

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic instrumentation: speedometer, tachometer, fuel gauge, indicator lights).

Driver Assistance

Rider Aids:

N/A (No electronic rider aids like ABS or traction control).

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 4,000 km (2,500 miles) or 6 months.

Valve Clearance Check:

Every 8,000 km (5,000 miles) or 12 months.

Chain Maintenance Interval:

Clean and lubricate every 1,000 km (600 miles) or after riding in wet conditions.

Fluid Specifications

Engine Oil Type:

SAE 10W-40 API SG or higher, JASO MA.

Engine Oil Capacity:

3.1 L (3.3 US qt) without filter change, 3.3 L (3.5 US qt) with filter change.

Coolant Type:

Ethylene glycol-based antifreeze coolant, mixed 50/50 with distilled water.

Brake Fluid Type:

DOT 4

Fork Oil Type:

SAE 10W (Specific Suzuki recommendation available in manual)

Known Issues

Common Wear Items:

Cam chain wear, clutch wear, carburetor float bowl leaks, fork seal leaks.

Potential Electrical Issues:

Regulator/rectifier failure, stator output degradation.

Filter Part Numbers

Oil Filter Part Number:

Suzuki: 16510-07300 or equivalent (e.g., Hiflofiltro HF138, K&N KN-138)

📚 Vehicle History

Brand Heritage

Manufacturer Heritage:

Suzuki has a long-standing history in motorcycle manufacturing, known for its performance-oriented and reliable machines across various classes.

Model Evolution

Generations:

The GSF600 Bandit was introduced in the early 1990s as a successor to older models, evolving into a popular 'naked' bike that also offered faired variants like the GSF600S.

Key Updates For 1995:

While the core design remained consistent, incremental updates typically occurred, focusing on refining carburetion, electrical components, and minor styling tweaks.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Model Awards:

While specific awards for the 1995 model are scarce, the Bandit series was widely praised for its value, performance, and versatility in motorcycle publications of its era.

Ratings

Review Sentiment:

Generally positive for its class, noted for a torquey engine and balanced handling.

Certifications

Certification:

N/A (Typically refers to road legality and emissions standards).