Suzuki Bandit 600 GSF600S / GSF600 Service Manual, 1999–2002 (P/N 99500-36102-01E)

Suzuki’s factory Bandit 600 GSF600S / GSF600 Service Manual, P/N 99500-36102-01E, covers the faired GSF600S and naked GSF600. The third edition, issued in December 2001, uses the GSF600SY (2000 model) as its base and includes model-specific chapters for the GSF600Y, K1, and K2. The publication page dates the first edition to December 1999.

Searchable Text, Chapter Bookmarks, and Wiring Diagrams

Text search and diagram detail: Search works across the service chapters and in the text of the wiring diagrams. Some illustrations have image-based labels. Embedded bookmarks open the group index and all ten chapters. Small wire-color codes and connector markings in the wiring diagrams are easier to read when zoomed in.

The download is one printable English PDF with 380 pages, including the covers, front matter, two notes pages, and the publication page.

Engine Overhaul, Chassis Service, and Electrical Tests

These selected workshop topics show the range of the manual. Other examples include throttle cable adjustment and cowling installation.

• Engine and transmission: Engine removal, disassembly, and reassembly, with inspection and service procedures for the camshafts, cylinder head, valves and seats, cylinders, pistons, connecting rods, and crankshaft. The chapter also covers the clutch, starter clutch, transmission, shift linkage, lubrication system, and PAIR air-supply system.
• Carburetors and fuel supply: KEIHIN CVR32SS carburetor removal, disassembly, cleaning, inspection, and reassembly, plus throttle-position sensor setup and synchronization. The fuel chapter also covers the fuel valve and filter.
• Scheduled maintenance: The maintenance chart and lubrication points accompany procedures for valve-clearance adjustment, drive-chain inspection and adjustment, and compression and oil-pressure checks.
• Chassis and brakes: Front and rear wheel service, front-fork disassembly and seal replacement, steering bearing service and tension adjustment, and swingarm and rear suspension service. Brake coverage includes caliper and master cylinder overhaul, bleeding, and disc inspection. The chassis chapter also covers tire service.
• Electrical diagnosis: Troubleshooting and component tests for the generator with IC regulator, starter and side-stand ignition interlock, digital ignitor, combination meter, relays, switches, lamps, and maintenance-free battery.
• Shop data and routing: Exploded views identify torque, lubricant, and threadlocker callouts. The manual also includes engine and chassis torque tables, factory standards and service limits, electrical test specifications, wiring diagrams, and cable, harness, and hose routing views.

Suzuki wrote this manual for people who already have motorcycle service knowledge, practical experience, and the required tools, including special tools.

GSF600Y, K1, and K2 Changes

GSF600Y: The naked model chapter covers the combination meter, headlight and beam adjustment, wiring, harness layout, and front brake hose routing. Its specification and service tables identify market and U-type differences where applicable.

K1 and K2: The 2001 chapter covers the GSF600SK1, GSF600SUK1, and GSF600K1. It gives separate service data for the GSF600 and GSF600S/GSF600SU and shows the gasket washer added at the lower crankcase. The 2002 chapter covers the GSF600K2 and GSF600SK2. It carries over the K1 specifications and service data and adds fuel-level sender removal and inspection, fuel gauge diagnosis, and wiring and harness-routing sheets. The GSF600S wiring sheets show the fuel-level sender circuit. The naked GSF600 sheet retains the GSF600Y and GSF600UY labels.

Use the model-specific chapters alongside the base procedures in Chapters 1–7. Check the applicable market and U-type entries when selecting carburetor, ignition, lighting, chassis, or fluid data.

Workshop References and Repair Cautions

The engine chapter identifies which components can be serviced with the engine still in the frame, so you can check whether a job requires engine removal. The lubrication and cylinder head cooling charts show the oil paths. In the electrical chapter, the charging and starter interlock diagrams accompany fault-finding for a battery that won’t charge or a starter that won’t crank.

Suzuki identifies tools by name and number, including carburetor balancer 09913-13121, compression gauge set 09915-64510, valve-seat cutter set 09916-21111, and front-fork oil-seal installer 09940-52861.

Suzuki flags the risk of damage from uneven camshaft journal holder tightening, compressed air reaching an installed carburetor diaphragm, and attempted removal of the press-fit main air jet. Fuel-system work, brake service, and engine removal require appropriate shop equipment and safe working practices.

Sample Compression and Oil Pressure Specifications

For the base GSF600SY engine, Suzuki gives a standard cylinder compression of 1,000–1,500 kPa with the engine warm, the throttle fully open, and the battery fully charged. The maximum difference between cylinders is 200 kPa.

The oil-pressure check specifies a reading above 300 kPa and below 600 kPa at 3,000 r/min with the oil at 60°C.