🏷️ Basic Information

Make:

Suzuki

Model:

GSF650 Bandit

Model Variant:

GSF650S (S-model/half-faired)

Year:

2005

Product Type:

Service Repair Workshop Manual

Product Name:

2005 Suzuki GSF650 GSF650S Service Repair Workshop Manual

Chassis Code:

A3

Engine Code:

WVC2

👋 Introduction

Segment:

Middleweight naked/sport-touring motorcycle.

Suzuki Brand Positioning:

Known for reliable and affordable motorcycles with a focus on performance and practicality.

Direct Competitors:

Yamaha FZ6, Honda CB600F Hornet, Kawasaki Z750.

Key Selling Points:

Versatile performance, comfortable riding position (especially the S-model), robust engine, accessible maintenance.

Engine Configuration:

Inline-four cylinder, DOHC.

Cooling Method:

Liquid-cooled.

Body Style:

Naked (GSF650) and Half-faired (GSF650S).

📋 Manual Details

Primary Coverage:

Comprehensive service, repair, and maintenance for 2005 Suzuki GSF650 and GSF650S models.

Engine Coverage:

Engine overhaul, tuning, fuel system, ignition system, lubrication, cooling system.

Transmission Coverage:

Clutch operation, gearbox disassembly and reassembly, shift mechanism.

Chassis Coverage:

Frame, suspension (front forks, rear shock absorber), steering, wheels, tires, brakes (front and rear).

Electrical Coverage:

Wiring diagrams, ignition system, lighting, starter system, charging system, instrumentation, ECU diagnostics.

Bodywork Coverage:

Fairings, body panels, seat, fuel tank, handlebars, fenders.

Troubleshooting Coverage:

Diagnostic procedures, common fault finding, solutions.

Estimated Pages:

Approx. 400-600 pages (typical for comprehensive service manuals).

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

Digital (likely PDF)

📖 Manual Coverage

Engine:

Yes, detailed internal components, assembly, disassembly, tuning.

Fuel System:

Yes, fuel injection system, injectors, throttle body, fuel pump, pressure regulator.

Ignition System:

Yes, spark plugs, ignition coils, ECU control, timing.

Cooling System:

Yes, radiator, coolant, fan, thermostat, water pump.

Exhaust System:

Yes, manifold, catalytic converter, muffler.

Transmission:

Yes, gearbox, clutch, shift drum, maintenance, repair.

Clutch:

Yes, wet multi-plate clutch, operation, maintenance, replacement.

Suspension Front:

Yes, telescopic forks, oil change, seal replacement, adjustment.

Suspension Rear:

Yes, monoshock absorber, linkage, preload adjustment, maintenance.

Brakes Front:

Yes, dual disc brakes, calipers, master cylinder, fluid replacement, pad replacement, bleeding.

Brakes Rear:

Yes, single disc brake, caliper, master cylinder, fluid replacement, pad replacement, bleeding.

Steering:

Yes, handlebars, steering head bearings, adjustment, replacement.

Wheels Tires:

Yes, wheel bearing maintenance, tire pressure, size specifications.

Electrical System:

Yes, comprehensive wiring diagrams, component testing.

Lighting System:

Yes, headlamp, taillight, turn signals, indicator bulbs.

Charging System:

Yes, stator, regulator/rectifier, battery testing.

Starter System:

Yes, starter motor, solenoid, battery checks.

Instrumentation:

Yes, speedometer, tachometer, indicators, warning lights.

Frame Chassis:

Yes, frame inspection, disassembly, reassembly.

Body Panels:

Yes, removal, installation, fairing repair.

Routine Maintenance:

Yes, oil changes, filter replacement, chain adjustment, lubrication.

Periodic Maintenance:

Yes, valve clearance adjustment, spark plug replacement, brake fluid flush.

Engine Rebuild:

Yes, detailed steps for complete engine overhaul.

Transmission Overhaul:

Yes, gearbox disassembly, inspection, and reassembly.

Suspension Fork Rebuild:

Yes, oil and seal replacement procedures.

Brake System Repair:

Yes, caliper rebuild, master cylinder service, bleeding.

Electrical Troubleshooting:

Yes, using wiring diagrams and diagnostic tests.

Fuel Injection Tuning:

Yes, ECU diagnostics and basic adjustments (if applicable).

Wiring Diagram Interpretation:

Yes, comprehensive and detailed diagrams.

Torque Specifications:

Yes, for all critical fasteners.

Special Tools:

Yes, identifies required special tools for specific procedures.

Depth:

In-depth, suitable for professional technicians and experienced DIY mechanics.

Diagnostic Level:

Advanced diagnostic procedures for engine, electrical, and fuel systems.

Rebuild Level:

Complete engine and gearbox rebuild instructions.

📊 Manual Specifications

Type:

PDF

Searchability:

Likely text-searchable for quick information retrieval.

Printability:

Printable pages for workshop use.

Image Resolution:

High-resolution diagrams and illustrations for clarity.

Type:

N/A (Digital Format)

Type:

N/A (Digital Format)

⚙️ Engine Specifications

Type:

Inline-4 Cylinder, 4-Stroke, DOHC, 16 Valves

Displacement:

656 cc

Bore X Stroke:

72 mm x 40 mm

Compression Ratio:

11.0:1

Horsepower:

83.8 HP @ 9500 rpm (approx.)

Torque:

62.3 Nm @ 7600 rpm (approx.)

System:

Fuel Injection (Digital Fuel Injection - DFIS)

Fuel Type:

Unleaded gasoline, minimum Octane Rating 91

Oil Type:

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

Coolant Type:

Ethylene glycol-based antifreeze coolant, 50% mixture with distilled water

Type:

NGK CR9E or DENSO U27FER-9

🔧 Transmission

Type:

6-Speed Constant Mesh

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain

Transmission Oil:

SAE 80 API GL-4 or GL-5 gear oil (though many recommend motorcycle-specific transmission oil for wet clutches)

📐 Dimensions

Length:

2130 mm (GSF650) / 2135 mm (GSF650S)

Width:

795 mm (GSF650) / 760 mm (GSF650S)

Height:

1070 mm (GSF650) / 1245 mm (GSF650S)

Wheelbase:

1450 mm

Dry Weight:

199 kg (GSF650) / 204 kg (GSF650S)

Curb Weight:

215 kg (GSF650) / 220 kg (GSF650S) (approx.)

Fuel Tank Capacity:

20 Liters

🛡️ Safety Features

Safety Equipment:

Standard motorcycle safety features: independent front and rear braking systems.

Braking System:

Dual front disc brakes with 4-piston calipers, Single rear disc brake with 2-piston caliper. ABS was an optional feature on some models/markets.

Suspension Stability:

Adjustable front forks and rear monoshock contribute to stable handling.

Lighting:

Halogen headlamp for good visibility.

💡 Technology Features

System:

N/A (Analog instrumentation with basic LCD display for odometer, trip meters, and clock).

Features:

ABS was an optional factory fitment in some markets for this model year.

🔧 Maintenance

Oil Change Interval:

Every 6,000 km or 6 months, whichever comes first.

Oil Filter Change Interval:

Every 6,000 km or 6 months (recommended with oil change).

Air Filter Check:

Inspect every 6,000 km, clean or replace as needed.

Spark Plug Replacement:

Every 12,000 km or 12 months.

Valve Clearance Check:

Every 12,000 km or 12 months.

Brake Fluid Replacement:

Every 24,000 km or 24 months.

Coolant Replacement:

Every 24,000 km or 24 months.

Chain Lubrication:

Lubricate every 1,000 km and after washing or riding in rain.

Chain Tension Adjustment:

Check every 1,000 km, adjust as needed to 20-30 mm free play.

Engine Oil Capacity:

3.4 Liters without filter change, 3.8 Liters with filter change.

Coolant Capacity:

2.0 Liters

Brake Fluid:

DOT 4

Common Complaints:

Occasional intermittent electrical connection issues, potential for weak clutch springs in high-mileage units, carburetors (on earlier 600cc models, not this fuel-injected 650) could be prone to sync issues. The 650 FI model is generally robust.

Recommended Checks:

Regular inspection of the fuel injection system, checking for any warning lights or performance anomalies. Ensure proper chain maintenance to prevent premature wear on sprockets and swingarm.

📚 Vehicle History

Suzuki Motorcycle History:

Suzuki has a long-standing reputation for producing a wide range of reliable and performance-oriented motorcycles, from smaller commuters to powerful sportbikes and cruisers.

Gsf Series Origin:

The GSF series, often known as 'Bandit', originated in the late 1980s, evolving from air-cooled to oil-cooled and eventually liquid-cooled engines. The 650cc variant replaced earlier 600cc models, offering increased displacement and performance.

Gsf650 Generation:

The 2005 model represents the first generation of the 650cc Bandit, building upon the success of the GSF600, featuring a new engine with higher displacement and fuel injection.

Manufacturing Location:

Primarily Japan and/or Spain (depending on specific market variants).

Production Years For Model:

The 650cc Bandit was produced from 2005 to 2006 in this initial configuration, before undergoing further updates.

🏆 Awards & Recognition

Industry Awards:

While specific awards for the 2005 GSF650 might not be widely publicized, the Bandit series has consistently been praised by motorcycle publications for its value, versatility, and all-around performance in the middleweight class.