Maintenance Andtuneup Procedures

This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart.

VALVE CLEARANCE

Inspect initially at 1 000 km (600 miles, 1 month) and every 12 000 km (7 500 miles, 12 months).

• Remove all of the spark plugs.

• Remove the cylinder head cover and signal generator cover.

The valve clearance specification is different for both intake and exhaust valves.

Valve clearance adjustment must be checked and adjusted 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshafts are removed for servicing.

ESK) Valve clearance (when cold):

IN.: 0.10 - 0.15 mm (0.004 - 0.006 in) EX.: 0.18 - 0.23 mm (0.007 - 0.009 in)

NOTE:

• The camshafts must be at positions ® or in order to check or adjust the valve clearance. Clearance readings should not be taken with the camshafts in any other position than the ones shown.

• The valve clearance should only be checked when the engine is cold.

• Turn the crankshaft clockwise using a 19-mm wrench. Make sure that all of the spark plugs have been removed.

• Turn the crankshaft clockwise and align the "T mark on the signal generator rotor with the center of the pickup coil. Also, position the notches © on the right end of each camshaft as shown. Then, measure the following valve clearances ©:

Cylinder #1: intake and exhaust valve clearances Cylinder #2: exhaust valve clearance Cylinder #3: intake valve clearance

Dyno Curve Suzuki Bandit Gsf 250Valve Adjuster Bandit

• Insert a thickness gauge between the end of the valve stem and the adjusting screw on the rocker arm. If the clearance is out of specification, hold the locknut with a wrench and use the special tool to adjust the clearance.

ItSSlI 09900-20803: Thickness gauge 09917-14910: Valve adjuster driver a caution1

Both the right and left valve clearances should be as closely as possible.

• Turn the crankshaft clockwise 360° (one full rotation) and align the "T" mark on the signal generator rotor with the center of the pickup coil. Also, position the notches ® on the right end of each camshaft as shown.

• Measure the valve clearances of the remaining valves © and adjust them if necessary.

Camshaft position

Notch © position

Intake camshaft

Exhaust camshaft

©

©

G

©

G

©

Suzuki Bond 1207b Price

• When installing the cylinder head cover, apply the recommended bond to the cylinder head cover groove and camshaft end caps. (CT3-47)

<Hz! 99000-31140: SUZUKI BOND "1207B"

• Tighten the cylinder head cover bolts to the specified torque. H Cylinder head cover bolt: 14 N m (1.4 kgf-m, 10.0 Ib-ft)

• Install the signal generator cover. (C7*3-46)

SPARK PLUGS

Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months).

Remove all of the spark plugs.

NOTE:

If it is difficult to remove any of the spark plug caps, pry them up using a screwdriver.

iroSh 09930-10121: Spark plug wrench set 09900-20803: Thickness gauge

NGK

Standard CR9EK

Cold type CR10EK

Hot type CR8EK

DENSO

U27ETR

U31ETR

Check to see if there are carbon deposits on the spark plug. If carbon is deposited, remove it using a spark plug cleaner machine or carefully use a tool with a pointed end.

Spark Plug Cleaning Procedure

SPARK PLUG GAP

Measure the spark plug gap using a thickness gauge. If out of specification, regap the spark plug.

(toSl) 09900-20803: Thickness gauge

ELECTRODE S CONDITION

Check the condition of the electrode. If it is extremely worn or burnt, replace the spark plug. Replace the spark plug if it has a broken insulator, damaged threads, etc.

A caution

Check the thread size and reach when replacing the spark plug. If the reach is too short, carbon will be deposited on the screw portion of the spark plug hole and engine damage may result.

SPARK PLUG INSTALLATION

a caution

To avoid damaging the cylinder head threads, first finger tighten the spark plug and then tighten it to the proper torque using the spark plug wrench.

• Insert the spark plugs to the cylinder heads by finger tight, and then tighten them to the specified torque.

EXHAUST PIPE BOLTS AND MUFFLER BOLTS

Tighten initially at 1 000 km (600 miles, 1 month) and every 12 000 km (7 500 miles, 12 months) thereafter.

• Tighten the exhaust pipe bolts and muffler mounting bolts to the specified torque.

H Exhaust pipe bolt: 23 Nm (2.3 kgf-m, 16.5 Ib-ft) Muffler mounting bolt: 29 N m (2.9 kgf-m, 21.0 Ib-ft)

AIR CLEANER

Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months).

Remove the seat and fuel tank. (CUT4-3) Remove the fuel tank mounting bracket ©. Remove the air cleaner element cover <2).

• Remove the air cleaner element

Air Filter Yfm 225

• Carefully use compressed air to clean the air cleaner element.

a caution"

Always apply compressed air to the inside of the air cleaner element. If compressed air is applied to the outside, dirt will be forced into the pores of the air cleaner element, restricting air flow through the air cleaner element.

• Reinstall the cleaned or new air cleaner element in the reverse order of removal.

• When installing the air cleaner element into the air cleaner case, make sure that the $ mark ® points up.

a caution

If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine without the element or to use a torn element. Make sure that the air cleaner is in good condition at all times. Life of the engine depends largely on this component!

• Remove the drain plug from the air cleaner drain hose to allow any water to drain out.

Hero Honda Engine Oil Screw

ENGINE OIL AND OIL FILTER

Oil Pump Gsf Suzuki

(ENGINE OIL)

Replace initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter.

(OIL FILTER)

Replace initially at 1 000 km (600 miles, 1 month) and every 18 000 km (11 000 miles, 18 months) thereafter.

iiic un siiuuiu ub oi lanycu vviinc u ic eiiyine is Wdllll. v_/ll until replacement at the above intervals, should be done together with the engine oil change.

ENGINE OIL REPLACEMENT

• Keep the motorcycle upright.

• Place an oil pan below the engine, and drain the oil by removing the oil drain plug © and filler cap

• Tighten the oil drain plug (3) to the specified torque, and pour new oil through the oil filler. When performing an oil change (without oil filter replacement), the engine will hold about 3.3 L (3.5/2.9 US/Imp qt) of oil. Use SF or SG classified (API) engine oil with a viscosity rating of 10W/40 (SAE).

• Start up the engine and allow it to run for several minutes at idling speed.

• Turn off the engine and wait about three minutes, then check the oil level through the inspection window If the level is below the "L' mark, add oil to the "F" mark. If the level is above the "F" mark, drain the oil until the level reaches the "F" mark.

OIL FILTER REPLACEMENT

• Drain the engine oil as described in the engine oil replacement procedure.

• Remove the oil filter © using the special tool.

• Apply engine oil lightly to the O-ring of the new oil filter, before installation.

Tension Chain Tool Remove Oil Filter

Install the new oil filter. Turn it by hand until you feel that the oil filter O-ring has contacted the oil filter mounting surface. Then, tighten the oil filter two full turns using the special tool.

09915-40610: Oil filter wrench

NOTE:

To properly tighten the oil filter, use the special tool. Never tighten the oil filter by hand.

• Add new engine oil and check the oil level as described in the engine oil replacement procedure.

H NECESSARY AMOUNT OF ENGINE OIL Oil change: 3.3 L (3.5/2.9 US/Imp qt) Oil and filter change: 3.5 L (3.7/3.1 US/Imp qt) Engine overhaul: 4.6 L (4.9/4.0 US/Imp qt)

a caution

ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER.

Other manufacturer's oil filters may differ in thread specifications (thread diameter and pitch), filtering performance and durability which may lead to engine damage or oil leaks. Also, do not use a genuine Suzuki automobile oil filter on this motorcycle.

FUEL HOSE

Inspect every 6 000 km (4 000 miles, 6 months). Replace every four years.

Inspect the fuel hoses © for damage and fuel leakage. If any defects are found, the fuel hoses must be replaced.

How Release Fuel Hose Z750
After contacting the gasket, tighten 2 turns.

FUEL FILTER

Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months).

Check the fuel filter for evidence of dirt and contamination. If present, replace the fuel filter with a new one.

Bandit 600 Idle

ENGINE IDLE SPEED

Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter.

NOTE:

Make this adjustment when the engine is hot.

• Start the engine, turn the throttle stop screw and set the engine idle speed between 1 100 and 1 300 r/min.

RS5S Engine idle speed: 1 200 ±100 r/min

Suzuki Bandit 600 Engine Idle Speed

THROTTLE CABLE PLAY

Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter.

Adjust the throttle cable play ® as follows.

Oil Pan Gsf

1st step:

• Loosen the locknut © of the throttle returning cable @ and fully turn in the adjuster © fully into the threads.

Harley Throttle Return Cable

2nd step:

• Loosen the locknut © of the throttle pulling cable (2).

• Turn the adjuster (D in or out until the throttle cable play (at the throttle grip) ® is between 2 - 4 mm (0,08 - 0.16 in).

• Tighten the locknut (D while holding the adjuster (3).

3rd step:

• While holding the throttle grip at the fully closed position, slowly turn out the adjuster ® of the throttle returning cable © until resistance is felt.

• Tighten the locknut (D while holding the adjuster pffil Throttle cable play ®: 2 - 4 mm (0.08 - 0.16 in)

a warning

After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically.

NOTE:

Major adjustments can be made at the carburetor side adjuster.

CARBURETOR SYNCHRONIZATION

Inspect initially at 1 000 km (600 miles, 1 month) (E-33 only) and every 12 000 km (7 500 miles, 12 months).

EVAPORATIVE EMISSION CONTROL SYSTEM (E-33 ONLY)

Inspect every 12 000 km (7 500 miles, 12 months). Replace vapor hose every four years.

PAIR (AIR SUPPLY) SYSTEM

Inspect every 12 000 km (7 500 miles, 12 months).

CLUTCH CABLE PLAY

Inspect every 6 000 km (4 000 miles, 6 months).

• Loosen the locknut © and turn the adjuster d) all the way into the clutch lever assembly.

Clutch Lever Loose Yamaha

• Remove the clutch release cover.

• Loosen the locknut and turn out the adjusting screw (4) two or three rotations.

• Then, slowly turn in the adjusting screw (4) until resistance is felt.

• Then, turn out the adjusting screw @ of a turn, and tighten the locknut (3).

• Loosen the locknut (I), and turn the cable adjuster (D to obtain 10-15 mm (0.4 - 0.6 in) of free play ® at the clutch lever end.

DRIVE CHAIN

Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Lubricate every 1 000 km (600 miles).

With the transmission in neutral, support the motorcycle using the center-stand and turn the rear wheel slowly by hand. Visually check the drive chain for the possible defects listed below.

* Loose pins * Excessive wear

* Damaged rollers * Improper chain adjustment

* Kinked or binding links

If any defects are found, the drive chain must be replaced. NOTE:

When replacing the drive chain, replace the drive chain and sprockets as a set.

CHECKING

• Tense the drive chain fully by turning both chain adjuster bolts

• Count out 21 pins (20 pitches) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the chain must be replaced.

ESS! Drive chain 20-pitch length

1 2 3 1 9202 1

•3L

^pfo o*„ ojo ofo „*. „ÏO olo olo olo

r^ f .

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• Loosen or tighten both chain adjuster bolts © until there is 25 - 35 mm (0.98 - 1.38 in) of slack at the middle of the chain between the engine and rear sprockets as shown. The reference marks @ on both sides of the swingarm and the edge of each chain adjuster must be aligned to ensure that the front and rear wheels are correctly aligned.

• Place the motorcycle on its side-stand for accurate adjustment.

• After adjusting the drive chain, tighten the axle nut ® to the

• Tighten both chain adjuster bolts © securely.

CLEANING AND LUBRICATING

• Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened.

a caution

Do not use trichloroethylene, gasoline or any similar solvent.

These fluids have too great a dissolving power for this chain and they can damage the O-rings. Use only kerosine to clean the drive chain.

• After cleaning and drying the chain, oil it with a heavyweight motor oil.

a caution

* Do not use any oil sold commercially as "drive chain oil". Such oil can damage the O-rings.

* The standard drive chain is a RK50MFOZ1. SUZUKI recommends to use this standard drive chain as a replacement.

BRAKES

(BRAKE)

Inspect initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter.

(BRAKE HOSE AND BRAKE FLUID)

Inspect every 6 000 km (4 000 miles, 6 months).

Replace hoses every 4 years. Replace fluid every 2 years.

a warning

* The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as silicone-based and petroleum-based fluids. Do not use any brake fluid taken from old, used or unsealed containers. Never re-use brake fluid left over from the last servicing or stored for a long period of time.

* Brake fluid, if it leaks, will interfere with safe running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding.

BRAKE FLUID LEVEL

• Keep the motorcycle upright and place the handlebar straight.

• Check the brake fluid level by observing the lower limit line on the front and rear brake fluid reservoirs.

• When the brake fluid level is below the lower limit line, replenish with brake fluid that meets the following specification.

^ Specification and Classification: DOT 4

BRAKE PADS

The extent of brake pad wear can be checked by observing the grooved limit line © on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. (C7=5-42 and -52)

a caution"

Replace the brake pads as a set, otherwise braking performance will be adversely affected.

Brake Pad Bandit

BRAKE PEDAL HEIGHT

• Turn the push rod (2) until the brake pedal is 50 mm (2.0 in) ® below the top of the footrest.

Suzuki Bandit Push Rod

BRAKE LIGHT SWITCH

Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed.

Brake Fluid Circuit

air bleeding the brake fluid circuit

Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the brake caliper. The presence of air is indicated by "sponginess" of the brake lever and also by lack of braking force. Considering the danger to which such trapped air exposes the machine and rider, it is essential that, after remounting the brake and restoring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:

• Fill the master cylinder reservoir to the too of the inspection window. Replace the reservoir cap to prevent dirt from entering.

• Attach a hose to the air bleeder valve, and insert the free end of the hose into a receptacle.

• Front brake: Bleed air from the brake system.

• Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip. Then, close the air bleeder valve, pump and squeeze the lever, and open the valve. Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles.

NOTE:

While bleeding the brake system, replenish the brake fluid in the reservoir as necessary. Make sure that there is always some fluid visible in the reservoir.

• Close the air bleeder valve, and disconnect the hose. Fill the reservoir with brake fluid to the top of the inspection window.

H Air bleeder valve: 8 N m (0.8 kgf-m, 6.0 Ib-ft) A CAUTION

Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials, etc.

Rear brake: The only difference between bleeding the front and rear brakes is that the rear master cylinder is actuated by a pedal.

Tire Gauge Depth Motorcycle

TIRES

Inspect every 6 000 km (4 000 miles, 6 months).

TIRE TREAD CONDITION

Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specification.

iroSh 09900-20805: Tire depth gauge

IB Tire tread depth

Service limit: FRONT 1.6 mm (0.06 in) REAR 2.0 mm (0.08 in)

Measuring The Tire Depth With Procedure

TIRE PRESSURE

If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, maintain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows.

COLD INFLATION TIRE PRESSURE

SOLO RIDING

DUAL RIDING

kPa

kgf/cm2

psi

kPa

kgf/cm2

psi

FRONT

225

2.25

33

225

2.25

33

REAR

250

2.50

36

250

2.50

The standard tire fitted on this motorcycle is a 120/60 ZR17 (55 W) for the front (BRIDGESTONE BT56F F) and a 160/60 ZR17 (69 W) for the rear (BRIDGESTONE BT56R F).The use of tires other than those specified may cause instability. It is highly recommended to use the specified tires.

STEERING

Inspect initially at 1 000 km (600 miles, 1 month) and every 12 000 km (7 500 miles, 12 months) thereafter.

The steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. Support the motorcycle so that the front wheel is off the ground. With the wheel facing straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, readjust the steering. (C7"5-25)

Front Fork Tube Cap XjrFrontfork Bottom Pinch Bolt Herohonda

Inspect every 12 000 km (7 500 miles, 12 months).

FRONT FORKS

Inspect the front fork for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. (CUT* 5-15)

Rear Shock Absorder Xvs 650a

Inspect every 12 000 km (7 500 miles, 12 months).

REAR SUSPENSION

Inspect the rear shock absorbers for oil leakage and check that there is no play in the swingarm. (C7=5-37)

CHASSIS BOLTS AND NUTS

Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-23 for the locations of the following nuts and bolts.)

ITEM

N-m

kgf-m

Ib-ft

(D Steering stem head nut

65

6.5

47.0

d) Front fork upper pinch bolt

23

2.3

16.5

(I) Front fork lower pinch bolt

23

2.3

16.5

@ Front fork cap bolt

23

2.3

16.5

© Front axle

65

6.5

47.0

© Front axle pinch bolt

23

2.3

16.5

® Handlebar holder bolt

23

2.3

16.5

(D Front brake master cylinder clamp bolt

10

1.0

7.0

(D Front brake caliper mounting bolt

39

3.9

28.0

® Brake hose union bolt (front & rear)

23

2.3

16.5

@ Air bleeder valve (front & rear)

8

0.8

6.0

® Brake disc bolt (front & rear)

23

2.3

16.5

® Rear brake caliper mounting bolt

25

2.5

18.0

@ Rear brake caliper housing bolt

30

3.0

21.5

® Rear brake master cylinder mounting bolt

23

'S*1**" ^

16.5

© Rear brake master cylinder rod locknut

18

1.8

13.0

® Front footrest bolt

39

3.9

28.0

© Front footrest bracket bolt

23

2.3

16.5

® Swingarm pivot nut

100

10.0

72.5

© Rear shock absorber mounting nut (upper & lower)

50

5.0

36.0

@ Cushion lever mounting nut

78

7.8

56.5

@ Cushion lever rod mounting nut

78

7.8

56.5

® Rear axle nut

100

10.0

72.5

®> Rear sprocket nut

50

5.0

36.0

® Rear torque link nut (front & rear)

35

3.5

25.5

Tighten initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 12 months) thereafter.

Suzuki Part Number 09915 40610
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Responses

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