2006–2012 Suzuki Bandit GSF1250/S/A/SA Service Manual (P/N 99500-39300-01G)

This service manual covers the 2006–2012 Suzuki Bandit GSF1250, GSF1250S, GSF1250A, and GSF1250SA. It includes the GSF1250S/SAK9 specification supplement alongside the main repair sections.

• Engine repair: Engine removal and installation, top- and bottom-end disassembly, cylinder-head service, camshaft timing, and crankshaft bearing selection.

• FI diagnosis and adjustment: DTC troubleshooting, Secondary Throttle Valve Actuator (STVA) tests, throttle valve synchronization, and ISC valve preset and opening initialization.

• Lubrication and cooling: Oil-pressure checks, oil-pump and strainer service, radiator inspection, thermostat testing, water-pump repair, and coolant replacement.

• Transmission and clutch: Gear and shaft inspection, shift-mechanism service, clutch inspection, and hydraulic master and release cylinder repair.

• Chassis and driveline: Front-fork overhaul, rear-shock adjustment, steering-stem service, wheel-bearing replacement, and drive-chain and sprocket inspection.

• Brakes and ABS: Caliper and master-cylinder overhaul, fluid replacement and bleeding, wheel-speed sensor diagnosis, and ABS control unit/HU removal and installation.

• Electrical systems: Ignition, starting, and charging-system tests, plus lighting, combination meter, fuel meter, and horn checks supported by wiring diagrams.

Written for mechanics who already have the knowledge, skills, and tools—including special tools—needed to service Suzuki motorcycles.

Engine Overhaul and Scheduled Maintenance

Periodic maintenance charts cover lubrication, cooling, brakes, and drive-chain service. Valve-clearance work includes tappet shim selection charts, while the engine chapters add piston and cylinder inspection, valve and guide checks, and connecting-rod and crankshaft bearing selection tables.

The Camshaft and Sprocket Assembly Diagram, timing illustrations, and exploded component views support engine reassembly. Component-specific torque tables and wear limits accompany the inspection and assembly procedures.

Fuel Injection, STVA, and Emission Controls

The FI section pairs DTC tables with circuit diagrams, connector views, and electrical checks. Suzuki Diagnosis System (SDS) coverage includes data recorded when a fault occurs and comparisons with saved operating data, helping trace intermittent sensor and wiring problems.

Throttle-body service limits: C28/P1655 troubleshooting addresses STVA circuit and actuator faults. The STVA and integrated IAP/TP/IAT sensor are supplied with the throttle-body assembly; the manual prohibits removing them separately.

Cleaning the throttle body's main bore can strip the throttle-valve molybdenum coating. The fuel-delivery pipe instructions also warn that twisting its T-joint can damage the connection.

Emission-control coverage includes PAIR system inspection and hose-routing diagrams, along with California E-33 EVAP canister and purge-solenoid testing.

Cooling, Lubrication, and Drivetrain Service

The Cooling Circuit Diagram and Engine Lubrication System Chart Diagram show the fluid paths. Water-pump inspection extends to the mechanical seal, oil seal, impeller, and shaft.

Transmission coverage includes countershaft and driveshaft assembly, shift-fork and gearshift-cam inspection, and gear checks. Hydraulic clutch procedures cover bleeding, master-cylinder service, release-cylinder repair, and push-rod inspection.

Suspension, Steering, and ABS

Front-fork procedures extend to damper-rod and oil-seal service. Rear-suspension work covers spring preload, damping adjustment, and the cushion lever, cushion rod, and swingarm bearings; steering instructions include stem-bearing replacement and steering-tension adjustment.

ABS diagnosis includes fault-code checks, SDS active-control inspections, and wheel-speed sensor and rotor tests. The ABS Unit Diagram identifies control-unit connections, relays, and solenoids. The ABS control unit/HU is covered as a replaceable assembly and must not be disassembled.

Follow the manual's precautions for brake hydraulics, pressurized fuel, and supporting the motorcycle during engine removal.

Wiring and Instrument Checks

Full wiring sheets are labeled for GSF1250S and GSF1250SA, with E-03/E-24/E-28 and E-33 versions. Wire-color legends and harness-routing views accompany the circuit drawings.

Lighting and combination-meter sections cover headlight adjustment, indicator and gauge tests, speed-sensor checks, and meter disassembly.

Sample Fuel-Capacity and Cylinder-Head Specifications

These figures are a small selection of the service specifications included in the manual.

Fuel-tank capacity, including reserve, is 18.5 L for E-33 California models and 19.0 L for other markets.

Cylinder-head data specify 25 N·m initial and 42 N·m final for the L175 bolts, with a separate 10 N·m specification for the L65 bolts.

Text Search, Bookmarks, and PDF Contents

Search and diagram detail: The main service text is searchable, and embedded bookmarks provide chapter and section navigation. Text search in the K9 supplement is limited by faulty character encoding. Small wiring labels require zooming.

Supplied as one 695-page printable PDF in English: 689 pages of service-manual content and front matter, a three-page K9 specification supplement, one added cover page, and two blank pages. All are included in the total.