Suzuki DR650SE Installationsanleitung

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FUEL AND LUBRICATION

SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

GROUP INDEX

FOREWORD

This manual contains an introductory description

on SUZUKI DR650SE and procedures for its in-

spection/service and overhaul of its main compo-

nents.

Other information considered as generally known

is not included.

Read GENERAL INFORMATION section to famil-

iarize yourself with outline of the vehicle and MAIN-

TENANCE and other sections to use as a guide

for proper inspection and service.

This manual will help you know the vehicle better

so that you can assure your customers of your

optimum and quick service.

* This manual has been prepared on the ba-

sis of the latest specification at the time of

publication.

If modification has been made since then,

differences may exist between the content

of this manual and the actual vehicle.

* Illustrations in this manual are used to show

the basic principles of operation and work

procedures.

They may not represent the actual vehicle

exactly in detail.

* This manual is intended for those who have

enough knowledge and skills for servicing

SUZUKI vehicles. Without such knowledge

and skills, you should not attempt servicing

by relying on this manual only.

Instead, please contact your nearby autho-

rized SUZUKI motorcycle dealer.

EMISSION CONTROL

INFORMATION

IMPORTANT

All street-legal Suzuki motorcycles with engine

displacement of 50cc or greater are subject to

Environmental Protection agency emission regula-

tions. These regulations set specific standards for

exhaust emission output levels as well as particular

servicing requirements. This manual includes spe-

cific information required to properly inspect and

service DR650SE in accordance with all EPA regu-

lations. It is strongly recommended that the chapter

on Emission Control, Periodic Servicing and Carbu-

retion be thoroughly reviewed before any type of

service work is performed.

Further information concerning the EPA emission

regulations and U.S. Suzuki’s emission control

program can be found in the U.S. SUZUKI EMIS-

SION CONTROL PROGRAM MANUAL/SERVICE

BULLETIN.

SUPPLEMENTS

DR650SEV/W/X/Y

(’97/’98/’99/’00-MODELS)

DR650SEK1 (’01-MODEL)

DR650SEK2/K3/K4/K5/K6/K7

(’02/’03/’04/’05/’06/’ 07/’08-MODELS)

DR650SEK9(’09-MODEL)

HOW

USE

THIS MANUAL

TO LOCATE

WHAT

YOU

ARE

LOOKING

FOR:

The

text

this

manual

divided

into

sections.

the

title

these

sections

are

listed

the

previ-

ous page as GROUP INDEX, select

the

section

where

what

you

are

looking

for

belong.

Holding

the

manual

shown

the

right

will

allow

you

find

the

first

page

the

section

easily.

the

first

page

each

section,

its

contents

are

listed.

Find

the

item

and page

you

need.

COMPONENT PARTS AND WORK TO

DONE

Under

the

name

each

system

unit,

its

exploded

view

provided

with

work

instruction

and

other

service

information

such

the

tightening

torque,

lubricating

points

and

locking

agent

points.

Example:

Front

wheel

O-ring

Housing

end (inside)

Washer

set

@ O-ring (2 pes)

Starter

motor

ease

Armature

(f)

Washer

set

® Brush

holder

® Brush

spring

Housing

end

(outside)

SYMBOL

Listed in

the

table

below

are

the

symbols

indicating

instructions

and

other

information

necessary

for

servicing

and meaning associated

with

them

respectively.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque

control

required. •

Apply

THREAD LOCK SUPER

Data beside

indicates

"1303"

specified

torque.

(99000-32030)

1lr

Apply

oil. Use engine oil unless

Use

fork

oil.

otherwise

specified.

(99000-99044-10G)

Apply

SUZUKI SUPER GREASE a

Apply

use brake

fluid.

IIA'I.

(99000-25030)

Apply

SUZUKI SILICONE GREASE.

Measure in

voltage

range.

(99000-25100)

Apply

SUZUKI

MOLY

PASTE.

Measure in resistance range.

(99000-25140)

"12078]

Apply

SUZUKI

BOND"

1207B".

Measure in

current

range.

(99104-31140)

•

Apply

THREAD

LOCK"

1342".

'{ooli

Use special

tool.

(99000-32050)

681

Apply

THREAD LOCK SUPER

"1360"

(99000-32130)

1·1

GENERAL

INFORMATION

WARNING/CAUTION/NOTE

Please read

this

manual and

its

instructions

carefully.

emphasize special

information,

the

symbol

and

the

words

WARNING,

CAUTION and NOTE have special meanings. Pay special

atten-

tion

the

messages

highlighted

these

signal

words.

A WARNING

Indicates

potential

hazard

that

could

result

death

injury.

I A CAUTION I

Indicates

potential

hazard

that

could

result

vehicle

damage.

NOTE:

Indicates special information to

make

maintenance easier or instructions clearer.

Please

note,

however,

that

the

warnings

and cautions contained in

this

manual

cannot

possibly

cover

all

potential

hazards relating

the

servicing,

lack

servicing,

the

motorcycle.

addition

the

WARNINGS

and

CAUTIONS

stated,

you

must

use

good

judgement

and basic mechanical

safety

principles.

you

are unsure

about

how

perform

particular

service

operation,

ask

ex-

perienced

mechanic

for

advice.

GENERAL PRECAUTIONS

A WARNING

• Proper service and repair

procedures

are

important

for

the

safety

the

service

mechanic

and

the

safety

and

reliability

the

vehicle.

•

When

persons

work

together,

pay

attention

the

safety

each

other.

•

When

is necessary

run

the

engine indoors, make sure

that

exhaust

gas is

forced

outdoors.

•

When

working

with

toxic

flammable

materials,

make

sure

that

the

area

you

work

well-

ventilated

and

that

you

all

the

material

manufacturer's

instructions.

•

Never

use gasoline as a cleaning

solvent.

•

avoid

getting

burned,

not

touch

the

engine, engine oil

exhaust

system

during

for

while

after

engine

operation.

•

After

servicing

fuel,

oil,

exhaust

brake

systems,

check

all lines and

fittings

the

system

for

leaks.

GENERAL

INFORMATION

1·2

CAUTION I

•

parts

replacement

necessary, replace

the

parts

with

Suzuki

Genuine Parts

their

equivalent.

•

When

removing

parts

that

are

be reused, keep

them

arranged in an

orderly

manner

that

they

may

be reinstalled in

the

proper

order

and

orientation.

•

sure

use special

tools

when

instructed.

•

Make

sure

that

all

parts

used in

reassembly

are clean, and also

lubricated

when

specified.

• When use

a certain

type

lubricant, bond,

sealant is specified, be sure

use

the

specified

type.

•

When

removing

the

battery,

disconnect

the

negative

cable

first

and

then

the

positive

cable.

When

reconnecting

the

battery,

connect

the

positive

cable

first

and

then

the

negative

cable,

and replace

the

terminal

cover

the

positive

terminal.

•

When

performing

service

electrical

parts,

the

service

procedures

not

require use

bat-

tery

power,

disconnect

the

negative

cable

the

battery.

•

Tighten

cylinder

head and case

bolts

and

nuts,

beginning

with

larger

diameter

and

ending

with

smaller

diameter,

from

inside

outside

diagonally,

the

specified

tightening

torque.

•

Whenever

you

remove

oil seals,

gaskets,

packing,

O-rings,

locking

washers,

cotter

pins,

cir-

clips, and

certain

other

parts

specified,

be sure

replace

them

with

new

ones.

Also,

be-

fore

installing

these

new

parts,

be sure

remove

any

left

over

material

from

the

mating

surfaces.

• Never reuse a

circlip.

When

installing

new

circlip,

take

care

not

expand

the

end gap larg-

than

required

slip

the

circlip

over

the

shaft.

After

installing

circlip,

always

ensure

that

completely

seated in

its

groove

and

securely

fitted.

• Do

not

use

self-locking

nuts

few

times

over.

• Use a

torque

wrench

tighten

fastners

the

torque

values

when

specified.

Wipe

off

grease

oil

thread

is smeared

with

them.

•

After

reassembly,

check

parts

for

tightness

and

operation.

•

protect

environment,

not

unlawfully

dispose

used

motor

oil and

other

fluids:

batter-

ies, and

tires.

•

protect

Earth's

natural

resouces,

properly

dispose

used

vehicles

and

parts.

1·3

GENERAL

INFORMATION

SUZUKI DR650SET ('96-MODEL)

RIGHT SIDE

LEFT

SIDE

*Difference

between

photographs

and

actual

motorcycles

depends

the

markets.

SERIAL NUMBER LOCATION

The

frame

serial

number

V.I.N.

(Vehicle

Identification

Number)

stamped

the

right

side

the

steering head pipe. The engine serial

number

@ is

located

the

left

side

the

crankcase.

These

numbers

are required especially

for

registering

the

machine

and ordering spare parts.

FUEL

AND

OIL

RECOMMENDATION

FUEL (For

U.S.A.

model)

1. Use

only

unleaded gasoline

least

pump

octane

(R;

method

octane

higher

rated

the

research

method.

2. Suzuki

recommends

that

customers

use alcohol free, unleaded gasoline

whenever

possible.

3. Use

blended gasoline

containing

MTBE

(Methyl

Tertiary

Butyl Ether) is

permitted.

4. Use

blended gasoline/alcohol fuel is

permitted,

provided

that

the

fuel

contains

not

than

10%

ethanol. Gasoline/alcohol fuel

may

contain

methanol

appropriate

cosolvents

and

corrosion

inhibitors

are

present

it.

5. If

the

performance

the

vehicle is

unsatisfactory

while

using blended gasoline/alcohol fuel,

you

should

switch

alcohol-free unleaded gasoline.

6. Failure

these

guideline could

possibiy

void

applicable

warranty

coverage.

Check

with

your

fuel supplier

make sure

that

the

fuel you intend

use meets

the

requirements listed above.

FUEL (For Canadian model)

Use

only

unleaded gasoline

least

pump

octane

method

octane

higher

rated

the

research

method.

FUEL (For the other models)

Gasoline used should be graded

85-95

octane

(Research

Method)

higher.

unleaded gasoline

type

recommended.

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