Suzuki bandit 600s manual

Page 84 Be sure to check and adjust the valve clearance. Replace the O-rings A and B with new ones to prevent oil leakage. Organize the parts in their respective groups i. Remove the camshaft journal holders and measure the width of the compressed plastigauge using the envelope scale. Inspect the teeth of each camshaft sprocket for wear or damage. NOTE: To remove the rocker arm shaft, screw a 8-mm bolt into the rocker arm shaft end and then pull out the shaft.

Check the gasket surface of the cylinder head for distortion. Use a straightedge and thickness gauge. Replace any valve with an abnormally worn face. The thickness of the valve face de- creases as the face wears. Measure the valve face T. If it is out of specification replace the valve with a new one.

Part No. Install the valve and attach a valve lapper onto it. Tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact.

Rotate the cutter one or two turns. Fill the intake and exhaust ports with gasoline to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. Page 99 Coat the entire stem making sure that there are no gaps. When inserting each valve, take care not to damage the lip of the oil seal. Take clearance readings at several places. If any reading exceeds the service limit, replace the cylinder block.

If the piston-to-cylinder clearance exceeds the service limit, rebore the cylinder and use an oversize piston or replace both the cylin- der and the piston. Piston-to-cylinder clearance Service Limit: 0. They bear the following identification numbers. The following two types of oversize oil rings are available as op- tional parts. The spacer and side rails do not have a designated top and bottom. Measure the thickness of the clutch drive plates using vernier calipers.

If a clutch drive plate thickness is thinner than the service limit, replace the clutch plates as a set. If any spring is shorter than the service limit, replace all of the springs.

Page Gearshift Linkage Inspection " Pinion bearing installer The removed oil seal must be replaced with a new one. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed. Measure the conrod small end inside diameter using the small bore gauge. If the conrod small end inside diameter exceeds the service limit, replace the conrod. If there is any damage, replace them with the specified set of bearings. Bearing selection table Crank pin O.

The oil pump service requires engine removal and disassembly. Refer to the engine removal and the engine disassembly sec- tions for oil pump removal. If the piston does not operate, replace the oil pressure regulator with a new one. NOTE: Refer to the following pages for the details of each step. If any de- fects are found, replace the oil cooler hose -s with a new one. When there is negative pressure vacuum in the combustion chamber, the fuel is able to flow from the fuel tank, through the fuel valve and then to the carburetor assembly.

Extreme care must be taken. Replace the fuel filter. Float height Page I. The piston valve moves according to the negative pressure present on the downstream side of the venturi A. Negative pressure is admitted into the diaphragm chamber 2 through an orifice 3 provided in the piston valve 1. The fuel from the float chamber 2 is metered by the pilot jet 3 where it mixes with air coming in through the pilot air jet 4.

This causes the piston valve 2 to move upward. The fuel in the float chamber 3 is metered by the main jet 4. The metered fuel enters the needle jet 5, mixes with the air admitted through the main air jet 6 and forms an emulsion.

The starter jet 2 meters this fuel. The fuel then flows into the fuel pipe 3 and mixes with the air coming from the float chamber 1. Study the service manual carburetor diagram and familiarize yourself with component locations and the different fuel circuits and their routing through the carburetor.

Do not use compressed air on the carburetor body, be- fore removing the diaphragm; this may damage the dia- phragm. Use a new O-ring to prevent fuel leakage.

Pay attention to the following points. Adjust the engine speed by turning the throttle stop screw. Observe the tachometer reading. Face the arrow mark A on the tire to the direction of wheel rotation, when remounting the wheel. NOTE: Be careful not to damage the inner tube. If it is worn or damaged, replace it with a new one. Make sure that the oil seal stopper ring is fitted securely.

E, 28, 33 ml NOTE: Place the rag on the fuel tank to prevent the fuel tank scratches. Do not use high pressure air to prevent brake caliper piston damage. Measure the thickness using the micrometer. Replace the brake disc if the thickness is less than the service limit or if damage is found.

Remove the brake hose union bolt and disconnect the brake hose. NOTE: Slightly loosen the brake caliper housing bolts 4 to facilitate later disassembly before removing the brake caliper mounting bolts. Do not reuse the dust seals and piston seals to prevent fluid leakage. Replace the O-ring with a new one. For this reason, it is recommended to use a tire changer that can satisfy this sealing requirement and can make the operation efficient as well as functional.

Never use oil, grease or gasoline on the tire bead in place of tire lubricant. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced. Im- proper use can cause damage to the motorcycle and tester. All regulator com- ponents are enclosed into a solid mold, and this unit is attached to the brush holder frame. The regulator voltage setting cannot be adjusted. Check accessories which use Accessories Remove accessories excessive amounts of electricity. Current leaks Short circuit of the wire harness Loose or disconnected wires Faulty battery No current leaks Measure the charging voltage between NOTE: Before disconnecting the generator lead wire, disconnect the battery - lead wire.

NOTE: Straighten the stator coil lead wires using long-nose pliers, then remove the rectifier. Also, rotate the rotor bearings by hand and make sure that they rotate smoothly.

Page If any defects are found, replace the generator driven gear dampers as a set. If the mea- surement is less then the service limit, replace the carbon brushes with new ones. Page Generator Reassembly And Remounting Pay attention to the following points: " The removed oil seal should be replaced with a new one.

For USA. The ignition coils will send voltage to the spark plugs dependant on what gear the transmission is in and whether the side-stand is either up or down. The gear position and side-stand switches work together in this system. The ignition coils work only in two situations as follows.

The transmission is in neutral. Grasp the Check if the starter motor runs clutch lever. Clicks the battery terminal Do not use Apply 12 volts to terminals A and B and measure for continuity between the positive and negative terminals. Grasp the clutch lever.

Check that the main fuse is not blown and the battery is fully-charged before diagnosing. NOTE: Make sure that all of the spark plug caps and spark plugs are connected properly and the battery is fully-charged. If the speed sensor and coupler connections are OK, replace the com- bination meter with a new one. If any abnormality is found, replace the respective switch assemblies with new ones. If the voltage read- Stop charging ing is less than Worn cylinder.

Rebore or replace. Worn piston ring. Worn valve guide or improper valve seating. Repair or replace. Excessive valve chatter 1.

Excessive valve clearance. Weak or broken valve spring. Worn rocker arm or rocker arm shaft. Worn or burnt camshaft journal. Broken gearshift shaft return spring. Rubbing or stuck gearshift shaft.

Worn or distorted gearshift fork. Worn gear. Some vehicle parts are very simple to mount and do not require professional help. Suzuki Bandit GSF This Repair Manual Download collection covers all the manuals below:.

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