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2005 Suzuki GSF650 650S K5 Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: GSF650 Bandit / GSF650S Bandit Model Code: GSF650 K5 Year: 2005 Generation Generation Code: Gen 2 (Bandit 650) Codes Chassis Code: GV70A 👋...

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标签: 2005 GSF Bandit Series GSF650 GSF650S K5 Motorcycle Motorcycles Suzuki

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Description

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

GSF650 Bandit / GSF650S Bandit

Model Code:

GSF650 K5

Year:

2005

Generation

Generation Code:

Gen 2 (Bandit 650)

Codes

Chassis Code:

GV70A

👋 Introduction

Market Position

Category:

Middleweight Naked/Sportbike

Segment:

All-arounder, commuting, sport-touring, light sport riding.

Competitive Analysis

Competitors:

Yamaha FZ6, Kawasaki Z750, Honda CBF600, Triumph Street Triple.

Key Features

Engine Layout:

Inline-4 cylinder, liquid-cooled.

Fuel Delivery:

Electronic Fuel Injection (EFI).

Chassis Type:

Steel twin-spar frame.

Styling:

Naked (GSF650) and Half-Fairing (GSF650S) variants available.

Ergonomics:

Comfortable, upright riding position suitable for various riding styles.

📋 Manual Details

Coverage Areas

Engine Service:

Yes

Transmission Service:

Yes

Electrical System Service:

Yes

Chassis Service:

Yes

Bodywork And Fairings:

Yes

Fuel System:

Yes

Exhaust System:

Yes

Cooling System:

Yes

Suspension And Steering:

Yes

Braking System:

Yes

Wheel And Tire Service:

Yes

Troubleshooting Guide:

Yes

Maintenance Schedules:

Yes

Wiring Diagrams:

Yes

Page Count

Number Of Pages:

~400+

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul, cylinder head, pistons, crankshaft, connecting rods, valve train, oil pump, lubrication system, timing chain.

Engine Electrical:

Ignition system, starting system, charging system, CDI unit, sensors (TPS, MAP, Crankshaft Position), EFI components.

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel pressure regulator, fuel tank, fuel filter.

Transmission And Drivetrain:

Gearbox inspection and repair, clutch operation, gear shift mechanism, final drive (chain and sprockets).

Cooling System:

Radiator, cooling fan, coolant pump, thermostat, hoses, fluid capacities and specifications.

Exhaust System:

Muffler, exhaust pipes, catalytic converter (if applicable).

Suspension:

Front forks (telescopic, cartridge type), rear shock absorber (monoshock), linkage, adjustment procedures.

Steering:

Handlebar assembly, steering stem, headstock bearings, steering damper (if equipped).

Braking System:

Front and rear disc brakes, calipers, master cylinders, brake lines, fluid specifications, bleeding procedures, ABS (if equipped).

Wheels And Tires:

Wheel removal and installation, tire replacement, balancing, recommended tire pressures.

Electrical And Ignition:

Battery, lighting system (headlights, taillights, turn signals), instrumentation, horn, starter motor, charging system (alternator, regulator/rectifier).

Frame And Bodywork:

Frame inspection, fairing removal and installation, seat, fuel tank mounting, body panel repair and alignment.

Troubleshooting:

Diagnostic charts for common problems, symptom-based troubleshooting for engine, electrical, and chassis issues.

Procedures Included

Preventive Maintenance:

Oil changes, filter replacements, spark plug service, chain lubrication and adjustment, brake pad inspection, coolant flush, air filter cleaning/replacement.

Engine Repair:

Complete engine disassembly, reassembly, component inspection, piston ring replacement, cylinder head gasket replacement, timing chain replacement.

Fuel System Diagnosis:

Troubleshooting EFI system faults, injector testing, throttle body cleaning, fuel pump pressure testing.

Suspension Adjustment:

Front fork oil level and viscosity changes, rear shock preload and damping adjustments.

Brake System Maintenance:

Brake pad replacement, caliper service, master cylinder overhaul, brake fluid flush and bleeding.

Electrical Troubleshooting:

Wiring diagram interpretation, testing of electrical components, fault finding for starting, charging, and lighting issues.

Clutch Service:

Clutch lever adjustment, clutch plate inspection and replacement (if necessary).

Wheel Bearing Replacement:

Procedure for removing and replacing wheel bearings.

Carburetor Synchronization:

Not applicable for this fuel-injected model.

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and electrical system overhauls).

📊 Manual Specifications

File Format

Format Details:

High-resolution PDF, searchable text, printable pages.

Print Quality

Quality:

Clear, legible text and diagrams.

Binding Type

Binding:

N/A (Digital format)

Paper Type

Paper:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, liquid-cooled, DOHC, inline four.

Displacement:

656 cc

Bore X Stroke:

72.0 mm x 41.5 mm

Compression Ratio:

11.5:1

Valve Train:

DOHC, 4 valves per cylinder.

Ignition System:

Electronic Ignition (CDI).

Performance

Horsepower:

~85.1 HP @ 10000 rpm (approximate, depending on market/tuning)

Torque:

~62 Nm @ 7500 rpm (approximate, depending on market/tuning)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle valves.

Fuel Tank Capacity:

20 Liters (5.3 US gal)

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/2.

Lubrication

Oil Type:

API SG, SF, SH, SJ, SL or higher, JASO MA certified motorcycle oil.

Oil Capacity W Filter:

3.4 Liters (3.6 US qt)

Cooling System

Coolant Type:

Ethylene glycol based coolant (50% coolant, 50% distilled water).

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Features

Clutch Type:

Wet multi-plate

Final Drive:

Sealed chain

📐 Dimensions

Exterior

Overall Length Gsf650:

2130 mm (83.9 in)

Overall Length Gsf650S:

2130 mm (83.9 in)

Overall Width Gsf650:

775 mm (30.5 in)

Overall Width Gsf650S:

790 mm (31.1 in)

Overall Height Gsf650:

1080 mm (42.5 in)

Overall Height Gsf650S:

1215 mm (47.8 in)

Wheelbase:

1440 mm (56.7 in)

Ground Clearance:

155 mm (6.1 in)

Seat Height:

785 mm (30.9 in)

Weights

Dry Weight Gsf650:

~190 kg (419 lbs)

Dry Weight Gsf650S:

~195 kg (430 lbs)

Wet Weight:

~213 kg (470 lbs) (estimated)

🛡️ Safety Features

Ratings

Crash Safety:

N/A (Motorcycle, not subjected to automotive crash testing standards)

Active Features

Braking:

Dual front disc brakes, single rear disc brake. ABS optional on some market variants.

Lighting:

Halogen headlight, LED taillight.

Passive Features

Frame Construction:

High-tensile steel frame designed for rigidity and rider feedback.

Ride Posture:

Upright and neutral, promoting rider awareness and control.

💡 Technology Features

Infotainment

Display Type:

Analog tachometer and speedometer, LCD multi-function display (odometer, trip meters, fuel gauge, clock).

Driver Assistance

ABS:

Optional on certain market versions.

Connectivity

Port Type:

N/A (no built-in connectivity features like USB or Bluetooth)

Engine Management

System:

Electronic Fuel Injection (EFI) with dual throttle valve system for improved throttle response and power delivery.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Oil Filter Change Interval:

Every 12,000 km (7,500 miles) or 12 months, replace at every oil change for best practice.

Spark Plug Service Interval:

Every 12,000 km (7,500 miles).

Air Filter Service Interval:

Every 6,000 km (3,700 miles), clean or replace as needed.

Chain Lubrication Adjustment:

Every 1,000 km (600 miles) or after washing/riding in rain.

Coolant Flush Interval:

Every 24,000 km (15,000 miles) or 24 months.

Fluid Specifications

Engine Oil Grade And Spec:

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

Brake Fluid:

DOT 4

Coolant:

50% Ethylene Glycol and 50% Distilled Water

Fork Oil Type:

According to manual specification, typically SAE 10W

Known Issues

Common Complaints:

Stalling at low RPMs (often related to EFI mapping or vacuum leaks), occasional clutch judder, rear shock absorber wear over time.

Typical Repairs:

Throttle body synchronization, cleaning injectors, checking for vacuum leaks, fork seal replacement, rear shock replacement.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation, Japan.

Reputation:

Known for reliable, well-engineered motorcycles with a focus on performance and value.

Model Evolution

Predecessor:

Suzuki GSF600 Bandit series.

Generation Introduction:

The GSF650 Bandit series was introduced for the 2005 model year as an evolution of the popular GSF600, featuring a larger 656cc engine.

Variants:

Available as a naked bike (GSF650) and with a half-fairing (GSF650S) for improved wind protection.

Production

Production Period:

2005-2006 for the K5/K6 generation.

Manufacturing Location:

Japan (primarily)