23/01/2021
The Suzuki Bandit 600, a true staple on British roads, has earned its reputation as a reliable, versatile, and undeniably fun motorcycle. For many riders across the UK, it was a first big bike, a dependable commuter, or a weekend warrior. Its affordability, coupled with a forgiving nature and ample power for everyday riding, ensured its popularity for well over a decade. While Suzuki ceased production of the 600 in 2005, replacing it with the 650, countless Bandits still grace our highways and byways, a testament to their inherent robustness.
However, like any machine of its age, the Bandit 600 isn't entirely without its quirks. Owners, both new and old, often encounter a few common issues, particularly concerning the exhaust system. Understanding these challenges and knowing how to address them is key to keeping your beloved Bandit on the road and passing its annual MOT.
The Enduring Appeal of the Suzuki Bandit 600
First introduced in the mid-90s, the Bandit 600 quickly became a bestseller. It offered a compelling blend of performance and practicality. Available in both unfaired (GSF600N) and faired (GSF600S) versions, it catered to different tastes, providing wind protection for longer rides or a classic naked look for urban commutes. Over its production run, Suzuki implemented several updates to refine the model:
- 2000: A significant update brought a new frame, a longer wheelbase for improved stability, revised bodywork, and a lower seat height, making it more accessible to a wider range of riders.
- 2002: Practicality was enhanced with the addition of a fuel gauge as standard, a small but welcome improvement for daily use.
- 2004: In response to evolving emissions standards, a catalytic converter was added, demonstrating Suzuki's commitment to cleaner motoring.
- 2005: Production of the Bandit 600 ceased, making way for its larger sibling, the Bandit 650.
Despite being out of production for nearly two decades, the market for used Bandit 600s remains active, with a steady supply of bikes available. This continued demand speaks volumes about their enduring quality and the fond memories they evoke for many riders.
The Notorious Exhaust System: A Common Bandit 600 Ailment
While the Bandit 600 engine is largely bulletproof, a frequent point of concern for owners is the exhaust system, particularly the collector box and the join between the silencer and the downpipes. This area is notoriously prone to rust, often leading to a crack or perforation that results in an exhaust gas leak. This isn't merely an aesthetic issue; a significant exhaust leak is a definite MOT failure, meaning your bike won't be road legal until it's rectified.
The root cause of this widespread issue lies in the materials used. While much of the exhaust system, including the downpipes and muffler, might be stainless steel, Suzuki, in their wisdom, often used mild steel collars or sections, especially at the collector box where the four downpipes merge before connecting to the silencer. Mild steel, exposed to the elements, road salt, and the heat cycles of an exhaust, will inevitably rust. Over time, this rust can lead to a crack forming, often 2/3rds of the way around the join, allowing exhaust gases to escape.
Symptoms and Diagnosis
The most obvious symptom of an exhaust leak is a noticeable change in the bike's exhaust note – it might sound louder or 'farty'. You might also feel a small amount of gas blowing from the join when the engine is running. A visual inspection will usually reveal the rust and the crack, particularly around the collector box or where the silencer meets the link pipe.
Repairing the Exhaust: Options and Considerations
When faced with a rusty, cracked exhaust, Bandit owners have several avenues for repair, each with its own pros and cons regarding cost, longevity, and effort.
1. Welding the Existing Collector
For minor cracks, welding can seem like an attractive, cheaper option. A local welder might charge around £80-£100 to repair the crack. However, there are significant caveats:
- Material Mismatch: If the crack is in mild steel, welding it might only be a temporary fix, as the surrounding mild steel will continue to rust. For a lasting repair, a stainless steel patch should be welded into the collector, effectively replacing the rusted mild steel section. This requires a skilled welder and a specific piece of stainless pipe (e.g., 63mm OD, 60mm ID, 65mm long, slotted for clamping).
- Seized Bolts: A major hurdle in any exhaust work on an older Bandit is the high likelihood of seized exhaust manifold bolts. Mechanics often need to heat these bolts extensively to prevent them from snapping, which can lead to a much larger, more expensive problem involving drilling out broken studs. Be prepared for this possibility if taking it to a garage.
2. Replacing Downpipes or the Full System
This is often the most recommended long-term solution, especially if the rust is extensive or the collector box is severely compromised.
- New Downpipes: You can often find aftermarket stainless steel downpipes that are direct replacements for the original. Prices typically range from £170 to £200. These are generally identical in fit and performance to the original Suzuki parts but offer superior rust resistance.
- Full Aftermarket Exhaust System: For a more comprehensive upgrade, a full stainless steel exhaust system (downpipes, collector, and silencer) can be purchased. These might cost around £400, a significant saving compared to a new factory Suzuki system, which could set you back close to £800. Brands like Motad and Predator are often recommended for their quality and fit for Bandits.
Table: Exhaust Repair Options Comparison
| Option | Pros | Cons | Estimated Cost (GBP) |
|---|---|---|---|
| Weld Existing Mild Steel | Cheapest initial fix | Temporary, rust likely to return, may not hold well | £80 - £100 (for welding) |
| Weld In Stainless Patch | More durable, prevents future rust in that section | Requires skilled welder, difficult if bolts seized | £100 - £150 (parts + labour) |
| New Aftermarket SS Downpipes | Excellent durability, good fit, long-term solution | Higher initial cost, fitting can be challenging (seized bolts) | £170 - £200 (parts only) |
| New Aftermarket Full SS System | Complete overhaul, best longevity, potential performance gains | Highest initial cost (still cheaper than OEM) | £350 - £450 (parts only) |
| New OEM Full System | Guaranteed fit, original specification | Extremely expensive | £600 - £800+ (parts only) |
| Wire Mesh Gasket (Temporary) | Very cheap, quick 'bodge' for minor leaks | Not a permanent fix, may not pass MOT, can still leak | <£10 (for gasket) |
3. The Wire Mesh Gasket "Bodge"
One ingenious, albeit temporary, solution that some Bandit owners have successfully employed involves using a flexible wire mesh gasket. If the original collector has rusted to the point where a standard gasket won't fit snugly, this flexible gasket can be "shoved" into the remaining space, and the exhaust pipe squeezed into it. Some riders have reported passing MOTs and getting thousands of miles out of this method. While it's a testament to ingenuity, it's ultimately a bodge and not a permanent, guaranteed repair.
DIY vs. Professional Installation
If you're mechanically inclined, replacing Bandit downpipes or even a full system can be a rewarding DIY project. However, be prepared for seized bolts. Essential items for a successful DIY job include:
- New Pipes/Gaskets: Ensure you have the correct parts.
- Penetrating Oil: Liberally applied to exhaust manifold nuts days in advance.
- Heat: A blowtorch can be invaluable for freeing stubborn nuts.
- New Nuts (preferably brass): These are less likely to seize in the future.
- Copper Grease: Apply to all threads upon reassembly to prevent future seizing.
If you're not confident, or if bolts snap, taking it to a reputable garage is advisable. Be aware that garages may charge extra for dealing with seized or broken bolts, as it significantly increases the labour time.
Other Considerations for Bandit 600 Owners
While the exhaust is a prominent issue, general maintenance is crucial for a bike of this vintage. Regular oil changes, chain lubrication, and brake checks will ensure many more years of enjoyable riding. The Bandit 600's simplicity makes it a relatively easy bike to work on, which contributes to its long-term appeal and lower running costs.
Frequently Asked Questions (FAQs)
Q: Is the Suzuki Bandit 600 still a good bike to buy in the UK?
A: Absolutely! The Suzuki Bandit 600 remains an excellent choice for a first big bike, a reliable commuter, or a fun weekend ride. Its robust engine, comfortable ergonomics, and affordability make it a fantastic value for money. Just be mindful of common age-related issues, particularly the exhaust system, when purchasing.
Q: What are the main issues with the Bandit 600?
A: The most common and significant issue is rust on the exhaust collector box, which can lead to leaks and MOT failures. Other general wear-and-tear items for a bike of its age include suspension components, brakes, and carburettor tuning (though the text doesn't explicitly mention this).
Q: Can I ride my Bandit 600 with a leaking exhaust?
A: While technically possible, it's not advisable. An exhaust leak will cause your bike to fail its MOT, meaning it's not road legal. It can also affect engine performance, increase fuel consumption, and is generally unpleasant due to the noise and fumes.
Q: How much does it cost to fix a Bandit 600 exhaust?
A: The cost varies significantly depending on the chosen repair method. Welding a crack might cost £80-£150. Replacing the downpipes with new aftermarket stainless steel ones could be £170-£200 for parts. A full aftermarket stainless steel system might cost £350-£450. Labour costs for fitting would be additional, especially if seized bolts are encountered.
Q: Why does the Bandit 600 exhaust rust so easily?
A: The primary reason is that certain sections of the original exhaust system, particularly the collector box and connection collars, were made from mild steel rather than stainless steel. Mild steel is highly susceptible to rust when exposed to moisture, road salt, and the high temperatures and corrosive gases within an exhaust system. Over time, this leads to corrosion and eventual cracking.
Conclusion
The Suzuki Bandit 600 is a cherished machine on UK roads, and its continued presence is a testament to its fundamental quality. While the dreaded rusty exhaust collector is a common hurdle, it's a well-understood problem with several viable solutions. By being aware of this potential issue and choosing the appropriate repair method, you can ensure your Bandit 600 continues to deliver dependable and enjoyable riding for many years to come. Don't let a bit of rust deter you from owning or maintaining one of Britain's most beloved motorcycles!
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