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2005 Suzuki GSF650/GSF650S Motorcycle Service & Repair Manual-PDF

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🏷️ Basic Information Identification Make: Suzuki Model: GSF650/GSF650S Bandit Year: 2005 Codes Engine Code: WVCB (typical for Bandit 650 series, actual code may vary slightly by region) 👋 Introduction Market...
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Type: Motorcycle
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Sku: 604285
2005 Suzuki GSF650/GSF650S Motorcycle Service & Repair Manual-PDF2005 Suzuki GSF650/GSF650S Motorcycle Service & Repair Manual-PDF2005 Suzuki GSF650/GSF650S Motorcycle Service & Repair Manual-PDF2005 Suzuki GSF650/GSF650S Motorcycle Service & Repair Manual-PDF
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
GSF650/GSF650S Bandit
Year:
2005
Codes
Engine Code:
WVCB (typical for Bandit 650 series, actual code may vary slightly by region)
👋 Introduction
Market Position
Category:
Middleweight Naked/Sportbike
Target Audience:
Riders seeking a versatile, reliable, and capable motorcycle for commuting, touring, and spirited riding.
Competitive Analysis
Competitors:
Honda CBF600, Yamaha FZ6, Kawasaki ER-6n/f
Key Features
Engine Type:
In-line four-cylinder, liquid-cooled, DOHC, 16-valve.
Fueling:
Electronic Fuel Injection (EFI) with Suzuki Dual Throttle Valve (SDTV) system.
Frame Type:
High-tensile steel pipe frame.
Braking System:
Dual front discs, single rear disc.
📋 Manual Details
Coverage Areas
Manual Type:
Service & Repair Manual
Language:
English
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine overhaul, cylinder head, pistons, connecting rods, crankshaft, timing system, lubrication system, cooling system (liquid-cooled).
Fuel System:
Fuel injection system (Suzuki Dual Throttle Valve - SDTV), fuel pump, injectors, throttle body, sensors (TPS, MAP, IAT), ECU diagnosis.
Ignition System:
Ignition control unit (ICU), ignition coils, spark plugs, wiring.
Transmission:
Clutch operation and adjustment, gearbox inspection, gear shift mechanism, transmission oil maintenance.
Chassis And Suspension:
Front fork (telescopic, cartridge type) overhaul, rear shock absorber (monoshock) inspection and adjustment, swingarm, bearings, suspension linkages.
Brakes:
Front and rear disc brake systems, brake calipers, master cylinders, brake lines, hydraulic system bleeding, pad replacement, rotor inspection.
Electrical System:
Battery, charging system (stator, regulator/rectifier), starter motor, lighting system (headlight, taillight, indicators), horn, fuses, relays, wiring diagrams.
Exhaust System:
Catalytic converter, muffler, exhaust pipes, gasket replacement.
Cooling System:
Radiator, fan, thermostat, water pump, coolant specifications, flush and refill procedures.
Bodywork And Trim:
Fairing removal and installation, seat, fuel tank, fenders, side covers.
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, lubrication, tire pressure checks, brake checks, coolant level checks.
Troubleshooting:
Diagnostic procedures for common symptoms, fault code interpretation (where applicable), electrical system diagnostics.
Repair Procedures:
Step-by-step instructions for disassembly, inspection, repair, and reassembly of all major components.
Component Rebuild:
Detailed instructions for rebuilding the engine, forks, and brake calipers.
Torque Specifications:
All critical fastener torque values for engine, chassis, and bodywork.
Electrical Troubleshooting:
Use of multimeters, continuity testing, voltage checks, detailed wiring diagrams for tracing faults.
Technical Depth
Depth Level:
Comprehensive: Covers basic maintenance to full engine and component rebuilds.
Diagnostic Capability:
Advanced: Includes guidance for diagnosing electronic fuel injection and ignition systems.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Fully searchable text for quick access to information.
Print Quality:
High-resolution scans, suitable for printing.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, DOHC, 4-valve per cylinder, inline-four
Displacement:
656 cc
Bore X Stroke:
72.0 mm x 40.2 mm
Compression Ratio:
12.4 : 1
Performance
Claimed Horsepower:
Approx. 83.0 HP (61.9 kW) @ 9,500 rpm (performance figures vary based on regional regulations and testing methods)
Claimed Torque:
Approx. 62.8 Nm (46.3 lb-ft) @ 7,600 rpm (performance figures vary based on regional regulations and testing methods)
Fuel System
Fuel Delivery:
Fuel Injection with SDTV (Suzuki Dual Throttle Valve)
Throttle Body Size:
36 mm
Fuel Tank Capacity:
20 Liters (5.3 US gal)
Lubrication
Oil Capacity W Filter:
3.0 Liters (3.2 US qt)
Oil Capacity Wo Filter:
2.7 Liters (2.9 US qt)
Cooling System
Coolant Type:
Antifreeze coolant (refer to manual for specific type and mixture ratio)
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Optional
ABS:
Optional (on some models/markets)
Features
Clutch Type:
Wet, multi-plate
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
2,130 mm (83.9 in)
Width:
775 mm (30.5 in)
Height:
1,050 mm (41.3 in) (GSF650) / 1,230 mm (48.4 in) (GSF650S - with screen)
Wheelbase:
1,440 mm (56.7 in)
Ground Clearance:
150 mm (5.9 in)
Weights
Dry Weight:
Approx. 180 kg (397 lbs) (GSF650) / 185 kg (408 lbs) (GSF650S)
Curb Weight:
Approx. 210 kg (463 lbs) (GSF650) / 215 kg (474 lbs) (GSF650S) (fully fueled, all fluids)
Tire Sizes
Front Tire:
120/70ZR17 M/C (58W)
Rear Tire:
180/55ZR17 M/C (73W)
Suspension Travel
Front Suspension Travel:
130 mm (5.1 in)
Rear Suspension Travel:
135 mm (5.3 in)
🛡️ Safety Features
Ratings
ABS Availability:
Available as an optional feature on some models.
Active Features
Braking System Design:
Dual 310 mm discs with 4-piston calipers (front), 240 mm disc with 2-piston caliper (rear).
Passive Features
Lighting:
Halogen headlight, LED taillight.
💡 Technology Features
Infotainment
Display:
Analog tachometer, digital speedometer, LCD multi-function display (odo, trip meters, clock, fuel gauge, coolant temp).
Driver Assistance
ABS:
Optional anti-lock braking system provides enhanced safety.
Connectivity
Electronics:
Advanced ECU for engine management, EFI, and ignition timing.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first (refer to manual for specific conditions).
First Service:
1,000 km (600 miles) or 1 month (includes oil and filter change, general inspection).
Valve Clearance Check:
Every 24,000 km (15,000 miles).
Fluid Specifications
Engine Oil Recommendation:
SAE 10W-40 API SG or higher (Synthetic or Mineral blend, refer to manual for specific grades).
Coolant Specifications:
Ethylene glycol-based coolant, 50% mixture with distilled water.
Brake Fluid Type:
DOT 4
Fork Oil Type:
SAE 10W (refer to manual for capacity and specific type).
Transmission Oil Type:
SAE 80W-90 API GL-5 Gear Oil (refer to manual for capacity).
Known Issues
Common Wear Items:
Clutch plates, chain and sprockets, brake pads, fork seals.
Common Issues
Potential Electrical:
Rarity, but stator or regulator/rectifier issues can occur with age/mileage, as with many motorcycles.
Fuel System Maintenance:
Regular cleaning of fuel injectors and throttle bodies recommended for optimal performance.
📚 Vehicle History
Brand Heritage
Brand Focus:
Suzuki has a long-standing reputation for producing reliable, performance-oriented motorcycles across various segments.
Model Evolution
Predecessor:
The GSF650 Bandit is an evolution of the popular GSF600 Bandit series, featuring an increased engine displacement and updated fuel injection system.
Production
Manufacturing Location:
Japan (primary manufacturing, with potential for assembly in other regions).
🏆 Awards & Recognition
Recognitions
General Reputation:
The Bandit series is widely recognized for its reliability, value for money, and versatility in the middleweight motorcycle market.
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