Suzuki DL650AK8 Referenzhandbuch

MOTORCYCLE

DATE:

Jul. 27, 2007

PAGE:

SUBJECT:

NOTICE OF SET-UP MANUAL

APPLICABLE MODEL:

DL650AK8

EFFECTIVE ENGINE OR FRAME NO.:

REFERENCE:

This bulletin is to inform you of set-up procedures of DL650AK8.

Please inform your dealers of this notice.

DL650AK8 Set-Up Manual will not be issued because the set-up procedures for this model remain

unchanged from DL650K4 except the differences described below.

To set-up DL650AK8, please use the DL650K4 Set-Up Manual and this Service Bulletin.

DIFFERENCE BETWEEN DL650K4 AND DL650AK8

DL650K4 Set-Up Manual: 99505-01124-011

1. LOCATION OF PARTS [Page: 2, 3, 4]

Item Part Name Q’ty Remarks

Windscreen 1

Screw 4 5 × 20 mm

Collared spacer 4 OD:14.0 ID:5.5 T:5.0

Rubber cushion (with nut) 4 5 mm L:17.0

BWindscreen cover 2

Tapping screw 2 5 × 16 mm

Handlebars assembly 1

Clamp 2

Allen bolt 4 8 × 30 mm

Burring washer 4 OD:13.0 ID:8.5

Plastic cap 4

OD11.0

For handlebar clamp

bolt

Screw 15 × 25 mm

For left switch

Screw 1 5 × 40 mm

For left switch

Screw 15 × 30 mm

For throttle assembly

Strap 2L:140

Clutch lever cover 1

Item Part Name Q’ty Remarks

Handlebar balancer weight 1 Right

Screw 1 6 × 105 mm

Flange rubber cushion 1 L:34.0

Spacer 1 L:50.0

Spacer 1 OD:16.0 ID:6.5 T:4.0

Rubber cushion 1 L:15.0

Spacer nut 1 6 mm

E Rear view mirror 2 Right and Left

F Flange bolt 1 10 × 25 mm for

front brake caliper

G Front wheel assembly 1

H Helmet holder wire 2

I Washer 2 OD:13.0 ID:6.5

J Warning label set 7 For

E-19 CC selection

K Warning label set 4 For

E-19 CD selection

LBattery electrolyte

container 1

MOwner’smanualset 1

NHolder 1For front brake

master cylinder

Flange bolt 26 × 22 mm

OD : Outside diameter (mm)

ID : Inside diameter (mm)

L : Length (mm)

T : Thickness (mm)

OD ID

NOTE:

The parts shown as Item J and K in the above table are supplied for limited markets.

Use washers of Item I for mounting the license plate.

Please hand over the parts shown as Items H and M in the above table to your customer together with

motorcycle.

MOTORCYCLE

DATE:

Jul. 27, 2007

PAGE:

RIGHT LEFT

[Page: 5, 6 Paragraph: 1]

The photographs shown indicate the parts dismounted

from the motorcycle in addition to the items shown in

the preceding page.

A: Front brake master cylinder

B: Throttle assembly

C: Left switch

D: Clutch cable

E: Speedometer drive gearbox

F: ABS sensor assembly

2. ASSEMBLY

REMOVING THE BRACKET

[Page: 5, 6 Paragraph: 3]

Remove the bolt to take off the front brake master cyl-

inder from the bracket.



A: Front brake master cylinder

B: Bolt

C: Bracket

THROTTLE [Page: 9, 10 Paragraph: 2]

Insert the boss of the throttle housing into the hole on

the handlebars.

Tighten the throttle assembly with two screws.



A: Boss

B: Hole

C: 5 × 30 mm screw

Keep the position of the front brake master cyl-

inder with its cap facing upwards until it is

installed.

NOTE:

The bolt is no longer needed and this may be

discarded.

Check to ensure that the throttle operates

freely and closes automatically.

MOTORCYCLE

DATE:

Jul. 27, 2007

PAGE:

FRONT BRAKE MASTER CYLINDER

[Page: 11, 12 Paragraph: 1]

Install the front brake master cylinder onto the handle-

bars.

Align the dot mark on the handlebars with the master

cylinder-to-holder fitting surface.

Tighten the front brake master cylinder mounting bolts

to the specified torque.

Front brake master cylinder mounting bolt:

10 N·m (1.0 kgf-m)

A: Holder

B: Front brake master cylinder

C: 6 × 22 mm flange bolt

D: 6 × 22 mm flange bolt

E: Dot mark

LEFT SWITCH [Page: 11, 12 Paragraph: 4]

Insert the boss of the left switch holder into the hole on

the handlebars.

Tighten the left switch assembly with the two screws.



A: Boss

B: Hole

C: 5 × 25 mm screw

D: 5 × 40 mm screw

RIGHT LEFT

CLAMP [Page: 13, 14 Paragraph: 4]

Clamp the wiring harness of handlebar right and left

switch with straps.

A: Strap L:140 mm

B: Handlebars

C: Right switch wiring harness

D: Left switch wiring harness

NOTE:

To install the holder correctly, first tighten the

bolt Cof the upper side with specified torque

and then tighten the bolt Dof the lower side.

Be careful not to pinch the wiring harness

between the housing and holder.

NOTE:

Cut off the excess strap as shown in the photo-

graph.

OUTSIDE OUTSIDE

MOTORCYCLE

DATE:

Jul. 27, 2007

PAGE:

FRONT WHEEL

[Page: 17, 18 Paragraph: 3 through

Page: 21, 22 Paragraph: 1]

When installing the front wheel onto the axle, special

attention must be paid to the arrow of the rotational

direction on the tire sidewall.

When the tire is properly installed, the arrow must indi-

cate forward rotation of the wheel.

Mount the front wheel assembly properly.

A: Right fork leg

B: Left fork leg

C: ABS sensor bracket

D: Speedometer drive gearbox

E: Front axle

RIGHT LEFT

Temporarily remove the front brake caliper.



A: Brake caliper

B: Flange bolt (Caliper mounting bolt)

C: Supporter

D: Pad

Insert tabs of the speedometer drive gearbox into front

wheel hub grooves.



A: Speedometer drive gearbox

B: Grooves

C: Tabs

D: Oil seal (Lip)

FRONT

Put a suitable pad on the front fender to pre-

vent the front fender and front wheel from

being damaged.

Do not remove the supporter inserted between

the brake pads until the brake caliper is

installed.

When install the speedometer drive gearbox,

be careful not to damage the oil seal lip.

MOTORCYCLE

DATE:

Jul. 27, 2007

PAGE:

Install the ABS sensor bracket to the front wheel hub.



A: ABS sensor bracket

B: Oil seal (Lip)

Align the ABS sensor bracket stopper with stopper on

the right fork leg.

A: ABS sensor bracket

B: Stopper (ABS sensor bracket)

C: Stopper (Right fork leg)

Insert the front axle from the right side of fork leg and

fix the front wheel assembly to the front fork.



A: Front axle



A: Stopper (Speedometer drive gearbox)

B: Stopper (Left fork leg)

When install the ABS sensor bracket, be careful

not to damage the oil seal lip.

FRONT

Never use force to install the front axle.

If it cannot be installed by hand, it is not cor-

rectly aligned.

Before tightening the front axle, turn the speed-

ometer drive gearbox until the stopper on the

speedometer gearbox and the stopper on the

left fork leg come in contact as shown.

FRONT

MOTORCYCLE

DATE:

Jul. 27, 2007

PAGE:

RIGHT LEFT

[Page: 23, 24 Paragraph: The next of 2]



A: ABS sensor lead wire

B: Speed sensor lead wire

C: Boss (Fork leg)

WARNING LABEL

[Page: 27, 28 Paragraph: 2]

Stick the label selected for your country.

A: For E-19 CC selection

B: For E-19 CD selection

C: Warning label (General warning)

D: Warning label (Windscreen)

E: Fuel tank

F: Meter panel

3. SERVICING

FRONT BRAKE LEVER

[Page: 37, 38 Paragraph: 2]

Make sure the front brake lever position is correct.

The standard setting for this motorcycle is as indicated

in the table below.

A: Adjuster

Pass the speed sensor lead wire and ABS sen-

sor lead wire to inside of the boss of front fork.

NOTE:

When sticking the new label, remove the origi-

nal label.

Standard setting 3

MOTORCYCLE

DATE:

Jul. 27, 2007

PAGE:

THROTTLE CABLE

[Page: 37, 38 Paragraph: 3, 4]

This motorcycle has a twin throttle cable system.

Cable Ais for pulling cable and cable Bis for return-

ing.

Check the throttle cable play at the throttle grip.

Throttle cable play: 2.0–4.0 mm

If adjustment is necessary, carry out the procedure

below:

1. Loosen the lock nut Cof the throttle returning cable

and fully turn in the adjuster D.

2. Loosen the lock nut Eof the throttle pulling cable.

3. Turn the adjuster Fin or out until the correct play is

obtained.

4. Tighten the lock nut Ewhile holding the adjuster F.

5. While holding the throttle grip at the fully closed

position, slowly turn out the adjuster Dof the throt-

tle returning cable to feel resistance.

6. Tighten the lock nut Cwhile holding the adjuster D.



2.0–4.0 mm

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.

MOTORCYCLE

DATE:

Jul. 27, 2007

PAGE:

REAR SUSPENSION

[Page: 43, 44 Paragraph: 3]

Rebound Damping Force Adjustment

(For Canada)

Adjust the setting of the rebound damping force to the

standard position.

Standard setting: 1 turn back

To adjust, turn the adjuster Bclockwise until it stops

and then turn it counterclockwise until approximately 1

turn and the two punch marks align.



ENGINE COOLANT

[Page: 45, 46 Paragraph: 2 through 4]

The engine coolant level should be kept between the

“FULL” and “LOW” level lines as shown in the photo-

graph.

Inspect the level with the motorcycle held upright on

level ground.

A: Engine coolant reservoir

If the level is lower than the “LOW” level line, add the

properly mixed engine coolant as follows.

1. Remove the seat using the key.

Remove the bolt to take off the frame covers.

A: Frame cover

B: Stepped Allen bolt

C: Boss

Do not force the adjuster Bpast the stopped

position or you may damage the adjuster.

NOTE:

The engine coolant reservoir is located under

the fuel tank.

FULL

LOW

MOTORCYCLE

DATE:

Jul. 27, 2007

PAGE:

2. Remove the fastener to take off the fuel tank front

cover.

A: Fuel tank front cover

B: Fastener

C: Boss

3. Remove the bolt.

A: Allen bolt

B: Meter panel

C: Side cowling

4. Unset the meter panel and side cowling from the

boss.

A: Meter panel

B: Side cowling

C: Boss

D: Hole

NOTE:

To remove the fastener, push in the center pin

and pull out the fastener.

MOTORCYCLE

DATE:

Jul. 27, 2007

PAGE:

5. Remove the bolt to take off the prop stay.

Lift the fuel tank and prop it up.

A: Prop stay

B: Bolt

C: Fuel tank

D: Boss

E: Hook

6. Remove the reservoir tank cap and add 50 : 50 mix-

ture of engine coolant and distilled water to the

“FULL” level line from the engine coolant filler hole.

7. Reinstall the reservoir tank cap.

8. Reinstall the fuel tank with prop stay.

9. Reinstall the side cowling and meter panel.

10.Reinstall the fuel tank front cover.

11.Reinstall the frame covers.

A: Reservoir tank cap

ENGINE OIL [Page: 47, 48 Paragraph: 2]

Engine oil

Oil quality is a major contributor to your engine’s per-

formance and life.

Always select good quality engine oil.

Use oil with an API (American Petroleum Institute)

classification of SF/SG or SH/SJ, or with a JASO clas-

sification of MA.

SAE Engine Oil Viscosity

Suzuki recommends the use of SAE 10W-40 engine

oil.

If SAE 10W-40 engine oil is not available, select an

alternative according to the left chart.

SAE API JASO

10W-40 SF or SG –

10W-40 SH or SJ MA

API: American Petroleum Institute

JASO: Japanese Automobile Standards Organization

-30 -20 -10 0 10 20 30 40

-22 -4 14 32 50 68 86 104

10W - 30

20W - 50

10W - 40 10W - 50

15W - 40 15W - 50

˚C

˚F

ENGINE OIL VISCOSITY RATING SELECTION CHART

ENGINE OIL

TEMP.

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