2005-2008 Suzuki GSF650/S Bandit Service Manual (339 P.)

Technician-level documentation for GSF650 and GSF650S models covering engine overhaul, component inspection, and complete repair procedures. Includes transmission servicing and clutch assembly details.

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Document Details

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Document Number / Seller:
23893 / Sandra Sanchez
File Size:
22.35 MB
File Type:
PDF
Language:
English
Printable:
Yes
Category:
Motorbike
Last updated / verified
Jan 11, 2026

Models Covered & Key Technical Specifications

Suzuki GSF650/S Bandit — 2005–2008 Detailed Reference Manual | Bandit Series Module.

  • Maximum RPM Specs: 12,000 r/min is rated at the engine revolution limit Framework.
  • Authorized Weight Data: 201 kg for GSF650 and 204 kg for GSF650S establishes the dry mass Architecture.
  • Fundamental Resolution Data: 656 cm³ supports the engine displacement cylinder volume Norms.
  • Specific Twist Specifications: 10.5:1 provides the compression ratio combustion standards Protocol.
  • Critical Deviation Limits: 20.0 L fuel tank capacity achieves the total fuel storage Bounds.
  • Rated Throughput Data: 3,300 ml oil change volume reaches the engine lubrication capacity Topology.

Professional Workshop Service Manual & Technical Specifications

Verified Assembly Repair Manual: Motorcycle Suzuki GSF650/S Bandit Manual - Ultimate Service, Maintenance & Repair Reference (2005-2008) Technical-Briefing

Conceptual-Layout: Suzuki GSF650/S (2005) // Year-Coverage: Complete coverage for model years 2005-2008 Bandit engines, chassis, and electrical circuits // Conceptual-Layout: Document spans engine rebuilding, transmission service, fuel delivery, and brake system procedures.

Performance-Element Parameters Context
Engine Displacement 656 cm³, four-stroke DOHC, 4 cylinders Comprehensive specifications provided across all operating ranges
Drive Train 6-speed transmission, primary ratio 1.744 Complete gear ratio documentation for all positions
Suspension Travel Front 130 mm, Rear 126 mm Detailed setup instructions and damping settings documented
Brake Systems Dual front disc, single rear disc, DOT 4 fluid Complete hydraulic procedures with bleeding sequences detailed

Major sections focus on engine removal and installation, valve clearance procedures and camshaft timing, cylinder head servicing and compression testing, and crankshaft assembly with bearing selection protocols. The document contains fuel system circuit diagrams and carburetor operation principles, transmission gear inspection and reassembly protocols, rear suspension bearing replacement and bushing documentation, and brake caliper reassembly with master cylinder servicing.

Rigorously requiring proper tool selection, the manual includes detailed examination of spark plug conditions and electrode measurement. Verification procedures are included for signal generator operation and ignition coil resistance values. Repair information is provided for starter clutch engagement and drive chain connection using the chain cutting tool. The document includes coverage of oil circulation pathways through all main galleries and bearing surfaces. Brake system specifications are included for master cylinder bore dimensions and caliper piston fit tolerances.

The document includes reference data documenting torque specifications for the fuel system connections to ensure proper seal integrity. A wiring diagram schematic shows complete electrical circuit paths for ignition, charging, and lighting systems. Lubrication points are mapped with identification numbers throughout the frame, engine, and suspension assemblies. Component removal sequences are presented with photographic references to prevent parts damage during disassembly. Service data tables provide compression pressure limits, oil pressure thresholds, and battery voltage specifications for diagnostic troubleshooting.

FAQ

What **essential** compression pressure specifications apply to engine testing? keyboard_arrow_down

1 000 – 1 500 kPa (10 – 15 kgf/cm²) is the standard specification at service, with 800 kPa (8 kgf/cm²) as the absolute minimum limit before engine overhaul is required.

Check the **correct** valve clearance adjustment values for cold engine operations. keyboard_arrow_down

0.10 – 0.15 mm is required for intake valves and 0.18 – 0.23 mm for exhaust valves when the engine is cold, measured at camshaft positions A and B using a thickness gauge.

What does the **documented** engine oil capacity requirement specify for different service types? keyboard_arrow_down

3 300 ml during oil changes, 3 500 ml when changing the filter, and 4 600 ml for complete engine overhaul operations, using SAE 10W-40 API SF/SG or SH/SJ with JASO MA classification.

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Reviews (5)

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The step-by-step guidance made it easy to perform repairs. The download link arrived quickly after purchase. Excellent experience overall!
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Rated 5 out of 5 stars
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The periodic maintenance schedule is very useful. I appreciate the prompt email support I received when I needed clarification on a few points. Great service!
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I found the instructions easy to follow, and the download process was quick and hassle-free. Great support from the team when I had questions!
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This manual has been a lifesaver! The diagrams are super clear, and I was able to tackle my maintenance tasks with confidence. Highly recommend!