Suzuki DR650SE Shop Manual Download Page 265 | Manualshive

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CONTENTS

SPECIFICATIONS.............................................................................. 11- 2
SERVICE DATA .................................................................................. 11- 3

11

DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) 11-1

DR650SEK2/K3/K4/K5 /K6/K7 (’02/’03/’04/’05/’06/’07 /’08-MODELS)

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Summary of Contents for DR650SE

Page 1: ...hey 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 sh...

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Page 3: ...SUPPLEMENTS DR650SEV W X Y 97 98 99 00 MODELS DR650SEK1 01 MODEL 9 10 11 DR650SEK2 K3 K4 K5 K6 K7 02 03 04 05 06 07 08 MODELS DR650SEK9 09 MODEL 12...

Page 4: ...first page of the section easily 4 On the first page of each section its contents are listed Find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit...

Page 5: ...ified torque 99000 32030 1lr Apply oil Use engine oil unless Use fork oil otherwise specified 99000 99044 10G Apply SUZUKI SUPER GREASE a Apply or use brake fluid IIA I 99000 25030 Apply SUZUKI SILICO...

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Page 8: ...u must use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more ex perienced mechanic for advice GENERAL PRECAUTIONS A...

Page 9: ...cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter from inside to outside diagonally to the specified tightening torque Whenever you remove oil seal...

Page 10: ...ded gasoline containing MTBE Methyl Tertiary Butyl Ether is permitted 4 Use of blended gasoline alcohol fuel is permitted provided that the fuel contains not more than 10 ethanol Gasoline alcohol fuel...

Page 11: ...d petroleum based fluid for refilling the system otherwise serious damage will result Do not use any brake fluid taken from old or used or unsealed containers Never re use brake fluid left over from a...

Page 12: ...Manufacturer plate For European markets Right knuckle cover Safety label For E 28 LH VIEW Engine starting label Warning safety label Brake approval label For E 02 21 22 34 53 Regulation approval label...

Page 13: ...Seat Fuel tank LH VIEW Vacuum hose I _ _ routing diagram label For E 33 Rear fender LH VIEW GENERAL INFORMATION 1 6 Fuel tank 1 0 label RH VIEW Tire air pressure label Swingarm pivot Swingarm...

Page 14: ...roke air cooled with SACS OHC Valve clearance IN 0 08 0 13 mm 0 003 0 005 in EX 0 17 0 22 mm 0 007 0 009 in Number of cylinders 1 Bore 100 mm 3 937 in Stroke 82 mm 3 228 in Piston displacement 644 cm3...

Page 15: ...ming 100 B T D C at 1 500 rpm Spark plug NGK CR 1OE or NIPPONDENSO U31 ESR N Battery 12V 28 8 kC 8 Ah 10 HR Generator Three phase A C generator Fuse 30 10 1 OA Headlight 12V 60 55W Parking or city lig...

Page 16: ...02 U K E 03 U S A E 04 France E 15 Finland E 16 Norway E 17 Sweden E 18 Switzerland E 21 Belgium E 22 Germany E 24 Australia E 25 Netherlands E 28 Canada E 33 California U S A E 34 Italy E 37 Brazil E...

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Page 18: ...ERVAL km 1 000 6000 12 000 18000 24000 THIS INTERVAL SHOULD BE JUDGED miles 600 4000 7 500 11 000 15000 BY ODOMETER READING OR MONTHS WHICHEVER COMES FIRST months 2 12 24 36 48 Valve clearance I I I S...

Page 19: ...r and clutch cable Side stand pivot and spring hook I Throttle cablp i Drive chain Brake pedal pivot NOTE Lubricate exposed parts which are subject to rust with a rust preventative spray whenever the...

Page 20: ...he piston is at Top Dead Center TDC on the compression stroke Remove the frame covers seat and fuel tank Remove the spark plug and valve inspection caps intake and exhaust Remove the valve timing insp...

Page 21: ...e the plug gap with a thickness gauge if it is correct If not adjust it to the following gap Standard Spark plug gap 0 7 0 8 mm 0 028 0 031 in a 09900 20803 Thickness gauge ELECTRODE S CONDITION Check...

Page 22: ...d squeeze the oil out of the element leaving it slightly wet with oil NOTE Do not twist or wring the element because it will tear or the individual cells of the element will be damaged A CAUTION Inspe...

Page 23: ...adjust the cable play in the fol lowing way Turn the handlebar all the way to the left Loosen the lock nuts Turn the adjuster j or move the adjuster to obtain the cable play of 0 5 1 0 mm 0 02 0 04 i...

Page 24: ...ly at 1 000 km 600 miles 2 months and Every 6 000 km 4 000 miles 12 months thereafter Loosen the lock nut CD and turn the clutch cable adjuster o fully in Loosen the lock nut and turn the clutch cable...

Page 25: ...lter cap and tighten the bolts securely NOTE Before installing the oil filter and oil filter cap check to be sure that the spring and new O rings r and j are in stalled correctly and apply engine oil...

Page 26: ...the axle cotter pin Canada and U S A Loosen the axle nut CD Tense the drive chain fully by turning both chain adjusters 0 Count out 21 pins 20 pitches on the chain and meas ure the distance between th...

Page 27: ...00 miles 12 months thereafter BRAKE HOSE AND BRAKE FLUID Inspect Every 6000 km 4 000 miles 12 months Replace hoses Every 4 years Replace fluid Every 2 years BRAKE FLUID LEVEL Keep the motorcycle uprig...

Page 28: ...r trapped in the 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 cali...

Page 29: ...m Make sure that there is always some fluid visible in the reservoir Close the bleeder valve and disconnect the pipe Fill the reservoir with brake fluid to the UPPER end of the in spection window I A...

Page 30: ...s exhaust resistance will be increased with a resultant decrease in pow er output Remove the drain plugs Start the engine and rev it to blowout the accumulated carbon particles Turn off the engine and...

Page 31: ...Inspect the rear shock absorber for oil leakage and check that there is no play in the swingarm assembly EXHAUST PIPE AND MUFFLER BOLTS Tighten Initially at 1 000 km 600 miles 2 months and Every 12 0...

Page 32: ...der mounting bolt 10 1 0 7 0 Front brake caliper mounting bolt 26 2 6 19 0 Front brake caliper pad mounting bolt 18 1 8 13 0 Brake hose union bolt Front Rear 23 2 3 16 5 Air bleeder valve Front Rear 8...

Page 33: ...PERIODIC MAINTENANCE 2 16...

Page 34: ...valves Ruptured or otherwise defective cylinder head gasket COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head bolts are tightened to t...

Page 35: ...way Damaged O ring Defective oil pump Combination of above items HIGH OIL PRESSURE Used a engine oil which is too high viscosity Clogged oil passage way Combination of above items OIL PRESSURE TEST P...

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Page 38: ...3 11 and 53 Starter motor 3 11 and 52 Cam drive chain 3 14 and 48 ENGINE LEFT SIDE ENGINE RIGHT SIDE Refer to page Refer to page Engine sprocket 3 5 and 7 Clutch cover 3 13 and 50 Generator cover 3 9...

Page 39: ...he following steps Remove the oil drain plug CD to drain out engine oil Remove the frame covers Refer to page 5 1 Remove the seat Refer to page 5 1 Remove the battery holder plate Disconnect the batte...

Page 40: ...ts Remove the exhaust pipe by loosening the connection bolt Disconnect the pick up coil power source coil lead wire coupler CD Disconnect the generator coil and neutral position indi cator switch lead...

Page 41: ...e Remove the carburetor by loosening the mounting clamp screws Disconnect the clutch cable by removing the cable lever Disconnect the starter motor lead wire CD and crankcase breather hose Remove the...

Page 42: ...OTE If it is difficult to remove the engine sprocket loosen the rear axle nut and then adjust the chain adjusters to provide additional chain slack Remove the engine ground wire and lead wire clamp Re...

Page 43: ...wing illustration NOTE The engine mounting nuts are self locking Once the nut has been removed it is no longer ofany use Be sure to use new nuts and tighten them to the specified torque hl CD e I LENG...

Page 44: ...CAUTION I Replace the O rings CD with new one to prevent oil leakage Tighten the oil cooler hose securing bolts to the speci fied torque Oil cooler hose bolt 10 N m 1 0 kg m 7 0 Ib ft Tighten the fro...

Page 45: ...Imp qt of engine oil SAE 10W 40 graded SE SF or SG into the engine after overhauling engine Start up the engine and allow it run for several minutes at idle speed About five minutes after stopping eng...

Page 46: ...ive chain tensioner by removing the bolts Remove the two spark plugs Remove the generator cover by removing the bolts NOTE When removing the cylinder head cover the piston must be at top dead center o...

Page 47: ...haft auto decompression assembly NOTE The cam chain tensioner bolt CD is to be removed only when disassembling the engine I A CAUTION I Do not drop camshaft drive chain pin C ring or sprock et into th...

Page 48: ...the piston pin circlips with a long nose pliers Remove the piston by removing the piston pin Remove the clutch cable holder and starter motor Remove the starter torque limiter CD and starter idle gear...

Page 49: ...he starter gear Remove the thrust washer Remove the ring nut with the special tools then remove the spacer S 09917 23711 Ring nut socket wrench 09910 20116 Conrod holder Remove the crankcase oil separ...

Page 50: ...iven gear do not lose gearshift pawl pin and spring Remove the clutch cover by removing the bolts Remove the clutch pressure plate by removing the bolts diagonally Remove the clutch drive and driven p...

Page 51: ...I A CAUTION I I This nut has left hand thread nut Remove the cam drive chain and key Remove the idle gear and oil pump driven gear by remov ing the circlips a 09900 06107 Snap ring pliers Remove the o...

Page 52: ...s parallel with the end face of the crankcase I A CAUTION I The crankshaft and transmission components must re main in the right crankcase half This is necessary be cause the gearshift cam stopper is...

Page 53: ...ear Remove the balancershaft assembly Remove the crankshaft from the crankcase by using a crankshaft remover a 09920 13120 Crankshaft remover Crankcase separating tool Remove the oil sump filter cover...

Page 54: ...to identify each removed part as to its loca tion and lay the parts out in groups designated as Ex haust Inlet so that each will be restored to the original location during assembly Remove the intake...

Page 55: ...4 mm O 4714 0 4718 in _ 09900 20205 Micrometer O 25 mm ROCKER ARM I D When checking the rocker arm the inside diameter of the rocker arm and wear of the camshaft contacting surface should be checked S...

Page 56: ...al with a long nose pliers Remove the spring seat NOTE Removal of the valves completes ordinary disassembling work If valve guides have to be removed for replacement after inspecting related parts car...

Page 57: ...100 mm 09900 21304 V block 100 mm VALVE HEAD RADIAL RUNOUT Place the dial gauge at right angles to the valve head and measure the valve head radial runout If it measures more than limit replace the va...

Page 58: ...subassemblies Only oversized valve guides are available as replacement part Part No 11115 32E70 Re finish the valve guide holes in cylinder head with the reamer CD and handle gOlf 09916 34580 Valve g...

Page 59: ...les The seat contact surface is cut 45 INTAKE EXHAUST 45 N 615 N 615 15 N 615 N 121 For U S A Valve seat cutter N 615 Valve seat cutter N 121 Solid pilot N 140 7 0 For the Others S 09916 24900 Valve s...

Page 60: ...and not a highly polished or shiny finish This will provide a soft surface for the final seating of the valve which will occur during the first few seconds of engine operation Clean and assemble the h...

Page 61: ...oming from the valve mechanism Check the springs for proper strength by measuring their free length and also by the force required to compress them If the spring length is less than the service limit...

Page 62: ...to bottom as shown in the il lustration Put on the valve spring retainer and using the valve lifter press down the springs fit the cotter halves to the stem end and release the lifter to allow the cot...

Page 63: ...eplace the camshaft if found it worn down to the limit fcFob 09900 20202 Micrometer 25 50 mm Cam height 6 Intake cam 33 410 mm 1 3154 in Service Limit Exhaust cam 33 400 mm 1 3150 in CAMSHAFT JOURNAL...

Page 64: ...1304 V block CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge taking a clearance read ing at several places as indicated If the lar...

Page 65: ...049 in 2nd 1 21 1 23 mm 0 047 0 048 in Oil 2 81 2 83 mm 0 110 0 111 in Piston ring thickness Standard 1st 1 170 1 190 mm 0 0461 0 469 in 2nd 1 150 1 170 mm 0 0453 0 0461 in NOTE Using a soft metal scr...

Page 66: ...imit 22 980 mm 0 9047 in CONROD SMALL END I D Using a caliper gauge measure the conrod small end inside diameter molt 09900 20605 Dial calipers Service Limit 23 040 mm 0 9071 in If the conrod small en...

Page 67: ...e limit by replacing the worn parts conrod big end bearing and crank pin etc CRANKSHAFT RUNOUT Support the crankshaft with V blocks as shown with the two end journals resting on the blocks Position th...

Page 68: ...laneershaft Key Inner raee Spring 6 pes Pin 3 pes Driven gear Washer Washer Circiip DISASSEMBLY Remove the circlip G and washers Remove the balancer driven gear Remove the 6 springs and 3 pins Inspect...

Page 69: ...6 springs CD and 3 pins set the pins to the triangle position as shown in photo CLUTCH DRIVE PLATE Measure the thickness of each drive plate with vernier calipers Replace drive plates found to have wo...

Page 70: ...0 20102 Vernier calipers Service Limit 33 0 mm 1 30 in CLUTCH RELEASE BEARING Inspect the release bearing for any abnormality particular ly cracks to decide whether it can be reused or should be repla...

Page 71: ...clutch Bearing Starter idle gear Idle gear shaft Starter torque limiter N m kg m 25 2 5 DISASSEMBLY Ib ft 18 0 Remove the starter clutch gear Remove the 3 bolts with a 6 mm hexagon wrench and 36 mm o...

Page 72: ...the rotor never turns in the opposite direction of the arrow mark STARTER TORQUE LIMITER A CAUTION Do not attempt to disassemble the starter toque limiter It is not serviceable Check the slip torque...

Page 73: ...ven gear 3rd driven gear 4th driven gear 2nd driven gear Driveshaft j Countershaft Low drive gear Top drive gear 3rd drive gear 4th drive gear 2nd drive gear 2ND DRIVE GEAR DISASSEMBLY Remove the 2nd...

Page 74: ...g action Shift fork Groove clearance Standard 0 10 0 30 mm 0 004 0 012 in Service Limit 0 50 mm 0 020 in If the clearance checked is noted to exceed the limit speci fied replace the fork or its gear o...

Page 75: ...xpand the end gap larger than required to slip the circlip over the shaft After installing a circlip always insure that it is com pletely seated in its groove and securely fitted 2ND DRIVE GEAR Press...

Page 76: ...assembling the transmission attention must be given to the locations and positions of washers and eirclips The cross sectional view given here will serve as a reference for correctly mounting the gear...

Page 77: ...03 to the bolt and tighten to the specified torque a 99000 32030 THREAD LOCK SUPER 1303 Bolt 10 N m 1 0 kg m 7 0 Ib ft CRANKCASE BEARINGS Inspect the play of the crankcase bearings by hand while they...

Page 78: ...oil filter 0 _ Install the new oil filter NOTE Before installing the oil filter and oil filter cap check to be sure that the spring and new a rings and are in stalled correctly_ GENERATOR Remove the...

Page 79: ...precautionary measures NOTE Apply engine oil to each running and sliding part before reas sembling OIL SEALS Fit the respective oil seals to the crankcase clutch cover and gearshift cover Apply SUZUKI...

Page 80: ...the crankcase em 09910 32812 Crankshaft installer 09910 32830 Attachment 09910 32860 Attachment I A CAUTION I ITEM CD Crankshaft R Conrod Crank pin Crankshaft L Crankshaft bearing nut Balancer drive g...

Page 81: ...ar and driven gear GEARSHIFT MECHANISM CD CD Gearshift arm stopper Gearshift shaft Gearshift lever Cam stopper plate Cam stopper Cam stopper bolt o Gearshift cam Gearshift fork No 1 Gearshift fork No...

Page 82: ...CD and are used They resemble each other very closely in externalappearance and configuration Carefully examine the illustration for correct installing posi tions and directions Position the gearshift...

Page 83: ...to conrod big end of the crankshaft and all parts of the transmission gears After the crankcase bolts have been tightened check if driveshaft and countershaft rotate smoothly Crankcase bolt 11 N m 1...

Page 84: ...SUPER 1303 Fit the dowel pins and new gasket Fit the gearshift cover and tighten the bolts diagonally NOTE After the gearshift cover and gearshift lever have been fit ted confirm that gear change is n...

Page 85: ...NOTE After installing the oil pump driven gear rotate the pump gear by hand to see if it turns smoothly Fix the idle gear with the circlip CAM DRIVE CHAIN AND PRIMARY DRIVE GEAR Engage the cam drive c...

Page 86: ...tch gear ass y Primary driven NOTE that concave k to be sure hecoperly installed_ d washer j IS pr washer CD ear assembly Insta r with prim II the thrust ary driven 9 Install the space gear ap driven...

Page 87: ...the clutch pressure plate Tighten the clutch spring mounting bolts diagonally to the specified torque with the special tool lib 09910 2011 6 Conrod holder Clutch spring mounting bolt 10 N m 1 0 kg m 7...

Page 88: ...et wrench 09910 2011 6 Conrod holder Ring nut 80 N m 8_0 kg m 58 0 Ib ft Install the starter gear and thrust washer Degrease the tapered portion of the generator rotor and also the crankshaft Fil the...

Page 89: ...e starter motor Fit the dowel pin and install the new gasket Install the generator cover OIL RING Install the spacer G into the oil ring groove first Then in stall both side rails one on each side of...

Page 90: ...er base to prevent the piston pin circlips from dropping into the crankcase Rub a small quantity of SUZUKI MOLY PASTE onto the piston pin 99000 25140 SUZUKI MOLY PASTE When fitting the piston turn arr...

Page 91: ...orarily tighten the cylinder base nuts Fit the dowel pins to the cylinder and attach a new gasket I A CAUTION I Use a new cylinder head gasket to prevent oil leakage Do not use the old gasket Place th...

Page 92: ...chain will be caught between crankcase and cam chain drive sprocket Install the C ring into the ring groove of the cylinder head NOTE Apply grease on the cam sprocket locating pin and install the pin...

Page 93: ...Y PASTE Thoroughly wipe off oil from the fitting surfaces of cylinder head and cover Fit the dowel pins CD and camshaft end cap to the cylinder head side Apply SUZUKI BOND NO 1207B uniformly to the ma...

Page 94: ...g bolt CD 10 N m 1 0 kg m 7 0 Ib ft Turn back and pull out the screwdriver from the chain ten sioner adjuster As the cylinder turns the tensioner rod is advanced under spring force and pushes the tens...

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Page 96: ...diaphragm of fuel valve through passage way provided in the carburetor main bore and vacuum hose and diaphragm builds up a negative pressure which is higher than the spring pressure Valve in the fuel...

Page 97: ...position FUEL VALVE FUEL FILTER REMOVAL Remove the frame cover and seat Refer to pages 5 1 and 2 Remove the fuel tank Refer to page 4 3 Remove the fuel valve by removing the mounting bolts AWARNING Ga...

Page 98: ...the fuel filter with compressed air FUEL TANK FUEL TANK REMOVAL Remove the frame cover and seat Refer to pages 5 1 and 2 Turn the fuel valve to ON position Remove the fuel tank mounting bolts CD Slid...

Page 99: ...LUBRICATION 4 4 CD Top cap Spring Spring seat E ring Washer Jet needle j a ring Diaphragm Piston valve Needle jet Main jet Pilot jet Main air jet Starter plunger Pilot screw a ring a ring Float Thr ot...

Page 100: ...E 02 U K E 03 U S A E 04 France E 1 7 Sweden E 1 8 Switzerland E 22 Germany E 02 04 34 MIKUNI BST40SS 40 mm 32EO 1 500 100 r min 14 7 1 0 mm 0 58 0 04 in M J 140 J N 6F19 3rd N J Y 5 Th V 95 P J 42 5...

Page 101: ...J Y 5M Throttle valve Th V 95 Pilot jet P J 425 Starter jet G S 40 Pilot screw P S PRE SET Throttle cable play 0 5 1 0 mm pulling cable O 02 0 04 in Starter cable play 0 5 1 0 mm 0 02 0 04 in 1 0 NO L...

Page 102: ...y pilot jet where it mixes with air coming in through pilot air jet This mixture rich with fuel then goes up through pilot passage to pilot screw A part of the mixture is discharged into the main bore...

Page 103: ...e dle jet in which it mixes with the air admitted through main air jet to form an emulsion The emulsified fuel then passes through the clearance between needle jet and jet needle J and is discharged i...

Page 104: ...the mixture is sprayed out through starter outlet port j into the main bore Air Q O 1 Fuel Air mixture _ Fuel FLOAT SYSTEM Floats G and needle valve 0 are associated with the same mechanism so that as...

Page 105: ...won t get lost Remove the carburetor top cap CD IA CAUTION I Do not blow the carburetor body with compressed air before removing the diaphragm It may cause a damage to the diaphragm Remove the piston...

Page 106: ...pilot screw in clockwise and count the number of turns until the screw is lightly seated Make a note ofhow many turns were made so the screw can be reset correctly after removing Remove the main air...

Page 107: ...ng for E 03 18 33 models PILOT SCREW REMOVAL FOR E 03 18 AND 33 MODELS Because harsh cleaning solvents can damage the O ring seals in the pilot system the pilot system components should be removed bef...

Page 108: ...ration replace it together with a valve seat Clean the fuel passage of the mixing chamber with compressed air FLOAT HEIGHT ADJUSTMENT To check the float height invert the carburetor body with the floa...

Page 109: ...arburetor the following adjust ments are necessary Engine idle r min Page 2 6 Throttle cable play Page 2 6 LUBRICATION SYSTEM AND COOLING SYSTEM OIL PRESSURE Refer to page 2 18 OIL FILTER Refer to pag...

Page 110: ...CAM FACE CYLINDER i HEAD COOLING H I HH CYLINDER i PISTON l WALL I I H CYLINDER HEAD I 4tH l t CONROD SMALL I I I CONROD BIG STARTER I I CYLINDER I END NOZZLE END BEARING CLUTCH i J6 n H H H H HH HH I...

Page 111: ...FUEL AND LUBRICATION 4 16...

Page 112: ...VAL Drain engine oil Refer to page 3 1 Remove the oil cooler hose mounting bolts Remove the oil cooler holder with cooler by removing its mounting bolts CD Oil cooler O ring Oil cooler hose To cylinde...

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Page 114: ...CHASSIS FRAME COVER AND SEAT REMOVAL AND REMOUNTING Remove the right and left frame covers by removing the mounting screws Remove the seat by removing the mounting bolts Remount the seat and frame cov...

Page 115: ...n a jack under the chassis tubes and raise until the front wheel is slightly off the ground Remove the front wheel by removing the front axle NOTE Do not operate the brake lever while dismounting the...

Page 116: ...wedge bar in the slit of the adapter Drive out the bearing by knocking the wedge bar A CAUTION The removed bearing should be replaced with new ones FRONT AXLE Check the front axle runout with a dial...

Page 117: ...nd remount the front wheel in the reverse order of removal and disassembly and also carry out the follow ing steps WHEEL BEARING Apply grease to the bearings 99000 25030 SUZUKI SUPER GREASE A Install...

Page 118: ...16 5 Ib ft Align the drive lugs CD to the recesses of the wheel hub Before tightening the front axle position the stopper of speedometer gearbox against stopper Tighten the front axle to the specifie...

Page 119: ...led containers Never reuse brake fluid left over from the last servicing or stored for long periods When storing the brake fluid seal the container completely and keep away from children When replenis...

Page 120: ...ver few times to operate the brake correctly and then check the brake fluid level BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the han dlebars straight Remove the master cy...

Page 121: ...d if it leaks will interfere with safe running and descolor painted surfaces Check the brake hose and hose joints for cracks and oil leakage Remove the brake pad Refer to page 5 7 Remove the caliper h...

Page 122: ...he dust seal grooves and piston seal grooves Specification and classification DOT 4 I A CAUTION I Wash the caliper components with fresh brake fluid before reassembly Do not wipe the brake fluid off a...

Page 123: ...TION Remove the front and rear wheels Refer to pages 5 2 and 5 27 Visually check the brake disc for damage or cracks Measure the thickness with a micrometer Replace the disc if the thickness is less t...

Page 124: ...n the master cylinder to catch any spilled drops of brake fluid Remove the union bolt and disconnect the brake hose master cylinder joint I A CAUTION I Immediately and completely wipe off any brake fl...

Page 125: ...09900 06108 Snap ring pliers Remove the piston secondary cup primary cup and spring MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or other damage Inspect the piston su...

Page 126: ...ponents with a rag Apply brake fluid to the cylinder bore and all the com ponent to be inserted into the bore Specification and classification DOT 4 When remounting the master cylinder on the handleba...

Page 127: ...r tube metal Oil lock piece Outer tube Front axle holder n I i 1 1 r r1C REMOVAL AND DISASSEMBLY Remove the front wheel Refer to page 5 2 Remove the front brake caliper Refer to page 5 8 Remove the fr...

Page 128: ...sening the lower clamp bolts Remove the front fork cap bolt CD spacer washer and spring Invert the fork and stroke it several times to drain fork oil Hold the fork inverted for a few minutes to drain...

Page 129: ...inner tube from the outer tube both anti friction metals may be damaged and must be replaced with new ones INSPECTION FORK SPRING Measure the fork spring free length If it is shorter than serv ice lim...

Page 130: ...rface of the Anti friction metal when mount ing it OUTER TUBE METAL OIL SEAL AND DUST SEAL Clean the metal groove of outer tube and metal outer surface Apply grease to the lip of new oil seal 99000 25...

Page 131: ...fork oil be sure to use a front fork oil whose vis cosity rating meets specifications below Fork oil type Fork oil 10 Fork oil capacity 565 ml 19 1 19 9 US Imp oz Hold the front fork vertical and adj...

Page 132: ...CD of the inner tube to the top sur face of the steering stem upper bracket Tighten each bolt to the specified torque Front fork cap bolt 23 N m 2 3 kg m 16 5 Ib ftl Upper clamp bolt 29 N m 2 9 kg m...

Page 133: ...nut Bearing Upper Bearing Lower Steering stem lower bracket ff REMOVAL AND DISASSEMBLY Remove the front wheel Refer to page 5 2 Remove the front fork Refer to page 5 14 Remove the speedometer cable c...

Page 134: ...ving the three screws Remove the lead wire cover CD Disconnect each lead wire coupler Remove the headlight bracket with headlight by remov ing the four bolts Remove the front brake master cylinder wit...

Page 135: ...light Remove the headlight bracket holders Remove the speedometer cable CD Remove the speedometer by removing the nuts Remove the throttle grip case screws Disconnect the throttle cables Remove the le...

Page 136: ...Remove the indicator light panel Remove the ignition switch mounting bolts with the spe cial tools Qu 09930 11920 Torx bit JT40H 09930 11940 Bit holder Remove the handlebars by removing the four moun...

Page 137: ...g stem lower bracket NOTE Hold the steering stem lower bracket by hand to prevent it from falling Remove the upper bearing Remove the steering stem lower bearing with a chisel Iii CAUTION I The remove...

Page 138: ...the steering stem in the reverse order of removal and disassembly Pay attention to the fol lowing points BEARING RACES Press in the upper and lower bearing races with the spe cial tool lim 09941 3451...

Page 139: ...t NOTE Before tighten the handlebar holder nuts install the handle bars temporarily HANDLEBARS Set the handlebars to match its punched mark to the mat ing face of the holder Secure the each handlebar...

Page 140: ...l Spacer Rear axle Cotter pin For Canada and U S A REMOVAL Remove the cotter pin For Canada and U S A Loosen the axle nut Support the motorcycle with a jack Remove the axle nut and axle c ITEM N m kg...

Page 141: ...pedal while dismounting the rear wheel Remove the rear sprocket mounting drum from the wheel Remove the cushions Remove the spacer CD Remove the rear sprocket by removing the mounting nuts and bolts...

Page 142: ...he inner ring by hand to inspect any abnormal noise occurs or rotating smoothly Replace the bearing if there is anything unusual Remove the both bearing with the special tool in the follow ing procedu...

Page 143: ...xceeds the limit replace the rear axle I ib 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set Service Limit 0 25 mm 0 010 in REAR SPROCKET Inspect the sprocket teeth f...

Page 144: ...0 25030 SUZUKI SUPER GREASE A Install the wheel bearings with the special tools MOl 09924 84510 Bearing installer 09924 84521 Bearing installer NOTE First install the bearing for right side Seal side...

Page 145: ...2 3 kg m 16 5 Ib ftl SPROCKET Tighten the sprocket nuts to the specified torque Sprocket nut 27 N m 2 7 kg m 19 5 Ib ftl NOTE Face the stamped mark on the sprocket to outside REAR AXLE NUT Adjust the...

Page 146: ...from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for long periods When storing the brake fluid seal the container completely and keep away from...

Page 147: ...pads correclty Tighten the pad mounting pin CD to the specified torque Pad mounting pin 18 N m 1 8 kg m 13 0 Ib ft NOTE After replacing the brake pads pump with brake pedal few times to operate the b...

Page 148: ...for long periods AWARNING Brake fluid if it leaks will interfere with safe running and discolor painted surfaces Check the brake hose and hose joints for cracks and fluid leakage Remove the caliper wi...

Page 149: ...ion to the following points IA CAUTION I Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the caliper bore...

Page 150: ...isconnect the brake rod by rotating brake rod Disconnect the brake hose Remove the reservoir tank by removing the mounting bolt Remove the connector by removing the circlip rooh 09900 06108 Snap ring...

Page 151: ...esh brake fluid before reassembly Never use cleaning sol vent or gasoline to wash them Apply brake fluid to the cylinder bore and all the in ternals to be inserted into the bore III Specification and...

Page 152: ...5 39 CHASSIS USPENSION AND S REAR SWINGARM CD Shock absorber Cushion rod Cushion lever Swingar Chain gUide Chain buffer o Rear axle Chain cover...

Page 153: ...Loosen the carburetor clamp screw CD Disconnect the crankcase breather hose Remove the air cleaner by removing the mounting bolts Disconnect the brake hose from the hose guides Remove the drive chain...

Page 154: ...m pivot nut after removing the caps Remove the rear swingarm by removing the pivot shaft Remove the rear shock absorber Remove the cushion rods with cushion lever Remove the drive chain buffer Remove...

Page 155: ...ct the spacer for any flaws or other damage Insert the spacer into the bearing and check the play to move the spacer up and down If an excessive play is noted replace the bearing with a new one Draw o...

Page 156: ...ool sm 09923 73210 Bearing remover 09930 30102 Sliding shaft I A CAUTION I The removed bearing should be replaced with new ones SHOCK ABSORBER Inspect the shock absorber for oil leakage or other damag...

Page 157: ...stall the new bearing with the special tool Bm 09941 34513 Bearing installer NOTE When installing the bearing punch marked side of bearing faces outside CUSHION LEVER BEARING Install the new bearing w...

Page 158: ...5 45 CHASSIS REASSEMBLING INFORMATION If j r Ii r IF ITEM N m kg m Ib ft 55 5 5 40 0 55 5 5 40 0 100 10 0 72 5 80 8 0 58 0 100 10 0 72 5 77 7 7 55 5 Left Right III DhT rr 1 l I p J i1SJ...

Page 159: ...from for increase or decrease the spring pre load after loosening the adjuster lock ring The standard set length is 247 5 mm After adjusting the pre load tighten the spring adjuster lock ring securely...

Page 160: ...006 Plug 1 42300 32810 62184 32EOO Plate 1 For the others 68380 32EOO Label set 1 NOTE Side stand length is defferent from in the above chart SPECIAL TOOLS This special tool is used for loosening and...

Page 161: ...NT FORK r c 71 II j J j U Standard spacer CD position d Pacer CD Change s position CD Spacer Wa her Spring Damper Spring Gasket eter gearbox o Speedom Front wheel spacte rake caliper Fron CHASSIS 5 48...

Page 162: ...brake caliper mounting bolts Remove the front brake hose clamp bolt and speedom eter cable guide bolt Slightly loosen the front fork cap bolt after loosening the front fork upper clamp bolt j to faci...

Page 163: ...everse order of removal and disassembly Pay atten tion to the following points Install the removed spacer and spring to the damp er rod as shown in the photo Insert the damper rod assembly to the inne...

Page 164: ...ach leg 563 ml 19 0 19 8 US Imp oz Hold the front fork vertical and adjust the fork oil level with the special tool gob 09943 74111 Fork oil level gauge Oil level 150 mm 5 9 in NOTE When adjusting the...

Page 165: ...Tighten the front brake caliper mounting bolts to the speci fied torque Brake caliper mounting bolt 26 N m 2 6 kg m 19 0 Ib ft Align the drive lugs CD with the recesses of the wheel hub Before tighte...

Page 166: ...ABSORBER Standard spring seat and mounting position G Rear shock absorber Plate Optional part Plug Optional part Spring seat LL JA fl l Changed spring seat and mounting position ITEM N m kg m Ib ft 5...

Page 167: ...rame covers Remove the seat by removing mounting bolts Loosen the carburetor clamp screw CD Disconnect the crankcase breather hose Remove the air cleaner by removing mounting bolts Remove the rear sho...

Page 168: ...sorber and air cleaner in the reverse order of removal and disassembly Pay attention to the following points When installing the spring seat CD to the shock absorber invert it from standard position P...

Page 169: ...t Install the shock absorber lower plate optional part as shown in the illustration Install the rear shock absorber and tighten it to the speci fied torque Mounting bolt 55 N m 5 5 kg m 40 0 Ib ft Upp...

Page 170: ...as shown in the illustration Tighten the side stand mounting bolt and nut to the speci fied torque Bolt 50 N m 5 0 kg m 36 0 Ib ft Nut 55 N m 5 5 kg m 40 0 Ib ft A WARNING A new shorter silver colored...

Page 171: ......

Page 172: ...lamp the wire harness at such positions as indicated in WIRE HARNESS ROUTING Refer to pages 7 12 and 13 Bend the clamp properly so that the wire harness is clamped securely In clamping the wire harnes...

Page 173: ...t If the terminal is found corroded remove the battery pour warm water over it and clean with a wire brush Upon completion of connection apply grease lightly Put a cover over the positive terminal WIR...

Page 174: ...EM LOCATION OF ELECTRICAL COMPONENTS CD Battery Fuse Starter relay Generator Ignition coil Starter motor o Horn COl unit Diode Turn signal relay Regulator rectifier Side stand ignition interlock relay...

Page 175: ...in the figure which is composed of an AC generator regulator rectifier unit and battery_ The AC current generated from AC generator is converted by rectifier and is turned into DC current then it char...

Page 176: ...rect 1 Faulty battery Abnormal driving condition Inspect continuity generator 1 No continuity l Faulty generator coils or discon coils Refer to page 6 7 nected lead wires I Correct Inspect generator n...

Page 177: ...oved one by one CHARGING OUTPUT INSPECTION Remove the frame covers and seat Remove the battery holder plate Start the engine and keep it running at 5000 r min with lighting switch turned ON and dimmer...

Page 178: ...ester Tester knob indication X Hl range GENERATOR NO LOAD PERFORMANCE INSPECTION Remove the frame covers and seat Disconnect the generator lead wire coupler CD Start the engine and keep it running at...

Page 179: ...place the regulator rectifier roOl 09900 25002 Pocket tester Tester knob indication X 1kQ range Unit kG Probe of tester to 0 8 Y1 Y2 Y3 Qj 00 00 00 00 J Q 8 1 20 1 10 1 10 1 10 0 Q Y1 1 10 00 00 00 0...

Page 180: ...tart the engine Starter relay Side stand Clutch lever Starter Engine stop relay position switch switch 0 1 0 c Diode Neutral switch Ignition switch SIDE STAND IGNITION INTERLOCK SYSTEM DESCRIPTION Thi...

Page 181: ...and the ignition coil lives even the side stand is kept down This is or warming up the engine Ignition switch To CDI and ignition coil Engine Starter Clutch lever stop switch position switch S d d I...

Page 182: ...ge amount of current flows I I Run Not run 1 Faulty starter motor Faulty starter relay Loosen or disconnected starter motor lead wire Not voltage J Faulty ignition switch Faulty engine stop switch Fau...

Page 183: ...to page 3 11 Disassemble the starter motor as shown in the illustration 5 STARTER MOTOR INSPECTION CARBON BRUSH Inspect the brushed for abnormal wear crack or smooth ness in the brush holder If the br...

Page 184: ...etween each segment and the arma ture shaft If there is no continuity between the segments or there is continuity between the segments and shaft replace the ar mature with a new one OIL SEAL INSPECTIO...

Page 185: ...relay Apply 12 volts to CD and terminals inspect the continui ty between the terminals positive and negative If the starter relay is in sound condition continuity is found roOl 09900 25002 Pocket tes...

Page 186: ...roperly check each component If any abnormality is found replace the com ponent with a new one u 09900 25002 Pocket tester DIODE The diode is located under the seat The diode can pass current only in...

Page 187: ...own position SIDE STAND IGNITION INTERLOCK RELAY The side stand ignition interlock relay is located under the seat Remove the frame covers and seat First check the insulation between CD and terminals...

Page 188: ...voltage current is induced in the secondary windings of the ignition coil resulting in strong spark between the spark plug gap BW Regulator rectifier R Ignition switch Neutral indicator light Engine s...

Page 189: ...ransmission is in neutral position and the engine stop switch is in the RUN position Inspect that the fuse is not blown before the diagnosis Looseness l Poor contact of coupler Incorrect Faulty igniti...

Page 190: ...oil gb 09900 28107 Electro tester Spark performance Over 8 mm 0 3 in AWARNING Do not touch the wire clips to prevent an electric shock when testing IGNITION COIL Checking with Pocket Tester A SUZUKI p...

Page 191: ...ket tester Tester knob indication X 1 kQ range r l Probe of tester 1 2 3 4 5 6 7 1 0 6 26 12 50 2 4 10 2 6 12 0 2 0 5 5 24 12 50 2 4 10 2 6 12 0 3 5 5 24 5 5 24 20 90 8 35 8 35 5 5 24 4 15 70 15 70 26...

Page 192: ...r burnt replace the plug Also replace the plug if it has a broken insulator damaged thread etc Heat Range NGK CR1 OE or NIPPONDENSO U31 ESR N should be used as the standard However the heat range of t...

Page 193: ...as follows INSPECTION Using the pocket tester check the continuity between lead wires in the diagram on next page If the continuity measured is incorrect replace the respec tive parts mob 09900 25002...

Page 194: ...ILLUMI Gr B W HIGH BEAM B R B W NEUTRAL B O BIBI TURN L B B Lg TURN R B Lg B B W HIGH BEAM 8 BIR HIGH BEAM BIO NEUTRAL BIBI NEUTRAL 8 BILg TURN R B Black Gr Gray BIBI Black with Blue tracer BIO Black...

Page 195: ...21 Disconnect the socket CD and remove the rubber cap Remove the bulb by unlocking the bulb holder spring Reassemble the bulb in the reverse order of removal I A CAUTION I When replacing the headlight...

Page 196: ...ENSE PLATE LIGHT Tail Brake light bulb 12V 5 21W Turn signal light bulb 12V 21 W License plate light bulb 12V 5W BULB REPLACEMENT Remove each light lens Push in on the bulb turn it to the left and pul...

Page 197: ...OIY B W Gr Br Position OFF STARTER BUTTON O W Y G Position ON 0 0 0 0 0 LOCK PUSH 0 P 0 HORN BUTTON LIGHTING SWITCH 0 Gr Y W Position r B BI B W Position OFF PUSH 0 0 FRONT BRAKE SWITCH ON 0 DIMMER SW...

Page 198: ...not remove or pierce the sealed areas of the elec trolyte container Insert the nozzles of the electrolyte container into the bat tery s electrolyte filler holes holding the container firmly so that it...

Page 199: ...SUZUKI pocket tester measure the battery voltage The tester should indicate more than 12 5 12 6V DC as shown in the Fig If the battery voltage is lower than the specification charge the battery with a...

Page 200: ...reful not to permit the charging current to exceed 4A at any time After recharging wait for more than 30 minutes and check the battery voltage with a pocket tester If the battery voltage is less than...

Page 201: ......

Page 202: ...adjustment valve clearance Noisy engine Excessive valve chatter 1 Too large valve clearance 2 Weakened or broken valve springs 3 Worn down rocker arm or rocker arm shaft 4 Worn and burnt camshaft jou...

Page 203: ...Distorted pressure plate or clutch plates Replace Transmission will 1 Broken gearshift cam Replace not shift 2 Distorted gearshift forks Replace 3 Worn gearshift pawl Replace Transmission will 1 Broke...

Page 204: ...linder wall Replace 5 Worn valves stems Replace 6 Defective stem seal Replace 7 Worn oil ring side rails Replace Engine lacks power 1 Loss of valve clearance Adjust 2 Weakened valve springs Replace 3...

Page 205: ...erflow and fuel 1 Worn or damaged needle valve Replace level fluctuations 2 Broken spring in needle valve Replace 3 Not working properly float Check and adjust 4 Foreign matter has adhered to needle v...

Page 206: ...t Symptom and possible causes Remedy Insufficient brake 1 Leakage of brake fluid from hydraulic system Repair or replace power 2 Worn pads Replace 3 Oil adhesion of engaging surface of pads Clean disc...

Page 207: ...or charge connections retighten 2 Shorted grounded or open generator coils Replace 3 Shorted or panctured regulator rectifier Replace Generator does 1 Lead wires tend to get shorted or open circuited...

Page 208: ...specified charging operation 2 Cell plates have lost much of their active Replace the battery material as a result of overcharging and correct the charg ing system 3 A short circuit condition exists...

Page 209: ...wncn F MAIN FUSE M STARTER MOTOR 53 E tn I I HORN I O DY BW _ _ L EI n_ 0 B En 3 mg 3 FUSE aox _ D HEADLIGHT IHII 9 2 HEADLIGHT L0 a w R a w I J 1 53 fI Id 1 1 1I 1I i d REAR TURN SIGNAL LIGHT IRI I B...

Page 210: ...itH 11 1111 I U L9 th B Q B W IJ I B W TAILIBRAKE LIGHT Gr 131 Gr B W B W W Bi I W B Br h Br B W lJ l B W LICENSE LIGHT B w lts W REAR TURN SIGNAL LIGHT ILl WIRE COLOR B Black BI Blue Br G Gr Lbl Lg...

Page 211: ...PUSH LOCK ci 0 t I I III r llt 1111 m lllllHUffily o f F cO I OJ d I M G Gr Lbl Lg o R W Y B BI B Lg BID B R B W BIIB BIIW GIBI OIW DIY RIB WIB WIBI YIB YIG Y W Brown Green Gray Light blue Light gree...

Page 212: ...RECTIFIER FUSE BOX NEUTRAL CD HEADLIGHT IHII F MAIN FUSE SWITCH 0 HEADLIGHT ILO M STARTER MOTOR TAILIBRAKE LIGHT Gr cl l Gr B W c3l B w W B c3l w B Br fh B B W y B W LICENSE LIGHT B w GtsfW REAR TURN...

Page 213: ...ght Clamp Blue tape Clutch lever position switch Throttle cable Starter cable Clamp Wiring harness Throttle position switch Except for E 03 18 28 and 33 Blue tape Wiring harness Clamp Battery 8 Fuse b...

Page 214: ...witch Wiring harness Rear brake switch Side stand switch Generator Rear brake __ switch coupler White tape Clamp Grenerator lead wire Clamp Tail Brake light Rear turn signal light Wiring harness Gener...

Page 215: ...ward Starter motor Starter motor lead wire Crankcase R I Breather cover l z _W t 4 Neutral switch Ignition coil 1r High tension cord 11M short cord High tension cord long cord SERVICING INFORMATION 7...

Page 216: ...LE ROUTING Fix the clutch cable with a clamp Clutch cable Brake hosE H Clutch cable Throttle cabIe f f Brake hose Clutch cable Throttle cables Starter cable Clutch cable holder Clutch cable Clamp Star...

Page 217: ...Ignition switch lead wire Cable guide Speedometer cable Cable guide i SERVICING INFORMATION 7 16...

Page 218: ...inside of the clutch cable Pass through the crankcase breather hose inside of the carburetor air hose Carburetor air hose Clutch cable Carburetor air hose Air vent hose Crankcase breather hose Rear b...

Page 219: ...Austria and Switzerland Pass through the PAIR control valve vacuum hose and air supply hose between the engine mounting plates SERVICING INFORMATION 7 18 Air supply hose PAlR control valve If k vacuum...

Page 220: ...ke hose Hose guide Throttle cable Starter cable kil Brake hose Master cylinder C lJ Hose guide l Jll rl Ciamp Brake hose I Clamp J After touching the brake hose union to the stopper tighten the union...

Page 221: ...4ci H Reservoir tank hose After touching the brake hose union to the stopper tighten the union bolt to the specified torque_ Brake hose guide Bmk hO VIEW B SERVICING INFORMATION 7 20 Ai J Reservoir ta...

Page 222: ...7 21 SERVICING INFORMATION HEAT SHIELD ADHERING Right frame cover SIDE STAND SPRING SET UP Side stand Inner spring Outer spring Heat shield...

Page 223: ...09913 60910 Bearing gear puller 09900 20204 Micrometer 75 100 mm 09900 20701 Magnetic stand 09900 28106 Electro tester 09910 33210 Attachment 09913 75810 Bearing installer SERVICING INFORMATION 7 22...

Page 224: ...925 18010 09924 84521 Steering bearing Bearing installer set installer 09930 33720 09930 73110 Generator rotor Starter torque remover limiter holder 09940 34520 09940 34592 T handle Attachment G 09916...

Page 225: ...09941 50111 Wheel bearing remover 09941 54911 Bearing outer race remover 09941 74910 Steering bearing remover 09943 74111 Front fork oil level gauge SERVICING INFORMATION 7 24...

Page 226: ...ket bolt Engine mounting bolt 8 mm Diam Engine mounting bolt 10 mm Diam Engine mounting bracket bolt Upper and Front Rear Exhaust pipe bolt Muffler mounting bolt Crankshaft bearing ring nut Engine oil...

Page 227: ...olt Front Rear 23 2 3 16 5 Brake pad mounting pin Front Rear 18 1 8 13 0 Front brake pad mounting pin plug 2 5 0 25 1 8 Brake air bleeder valve Front Rear 8 0 8 6 0 Brake disc mounting bolt Front Rear...

Page 228: ...d bolt 7 marked bolt mm N m kg m Ib ft N m kg m Ib ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 45 4 5 32 5...

Page 229: ...IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX INNER OUTER INNER OUTER SERVICING INFORMATION 7 28 Unit mm in STANDARD LIMIT 33 1 3 28 1 1 0 08 0 13 0 003 0 005 0 17 0 22 0 0067 0 0...

Page 230: ...IN EX 12 000 12 018 0 4724 0 4731 Rocker arm shaft 0 0 IN EX 11 973 11 984 0 4714 0 4718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 CYLINDER PISTON PISTON RING Unit...

Page 231: ...ston pin 0 0 22 996 23 000 22 980 0 9054 0 9055 0 9047 CONRaD CRANKSHAFT Unit mm in ITEM STANDARD LIMIT Conrod small end 1 0 23 006 23 014 23 040 0 9057 0 9061 0 9071 Conrod deflection 3 0 0 12 Conrod...

Page 232: ...tio ITEM STANDARD LIMIT Primary reduction ratio 2 178 61 28 Final reduction E 03 28 33 2 800 42115 ratio The others 2 733 41 15 Gear ratios Low 2 416 29112 2nd 1 625 26116 3rd 1 238 26 21 4th 1 000 21...

Page 233: ...1 0 turn back back Throttle cable play 0 5 1 0 mm pulling cable 0 02 0 04 in Starter cable play 0 5 1 0 mm 0 02 0 04 in CARBURETOR ITEM SPECIFICATION E 02 04 34 E 37 E 17 22 24 U type E 22 Carburetor...

Page 234: ...in Regulated voltage 13 0 16 0 V at 5 000 r min Starter relay resistance 3 5Q Battery Type designation YTX9 BS Capacity 12V 28 8 kC 8Ah 1 0 HR Standard 1 320 at 20 C 68 F electrolyte S G Fuse size Mai...

Page 235: ...02 1 1921 Brake caliper piston diam Front 26 90 26 95 1 0591 1 0610 Rear 30 16 30 18 1 1874 1 1882 Wheel rim runout Axial 2 0 0 08 Radial 2 0 0 08 Wheel axle runout Front 0 25 0 010 Rear 0 25 0 010 Ti...

Page 236: ...thanol or less than 5 methanol with appropriate cosolvents and corrosion inhibitor is permissible Use only unleaded gasoline of at least 87 pump octane R M method or 91 octane E 28 or higher rated by...

Page 237: ......

Page 238: ...needle is also of special manufacture Only one clip position is provided on the jet needle If replacement becomes necessary the jet needle may only be replaced with an equivalent perform ing replaceme...

Page 239: ...EMISSION CONTROL INFORMATION 8 2 EVAPORATIVE EMISSION CONTROL SYSTEM California model only Fuel tank Fuel filler pipe Carburetor Purge port II He VAPOR FUEL 4 FRESH AIR 11 Canister...

Page 240: ...Surge hose Red stripe Fuel tank Clamp Purge air hose IfJ Purge air hose 0 0 Q 2 h_ 000 I t 2 m Q JJ 3J 00 c oo m OJJ 2 0 c t 2 G CCI W m s en en CI 2 n C 2 4 CI 2 TI CI s z 4 is 2...

Page 241: ...DR650SEV W X Y 97 98 99 00 MODELS CONTENTS SPECIFICATIONS 9 1 SERVICE DATA 9 3 WIRING DIAGRAM 9 11 9...

Page 242: ...cooled with SACS OHC Valve clearance IN 0 08 0 13 mm 0 003 0 005 in EX 0 17 0 22 mm 0 007 0 009 in Number of cylinders 1 Bore 100 mm 3 937 in Stroke 82 mm 3 228 in Piston displacement 644 cm3 39 3 cu...

Page 243: ...C at 1 500 rpm Spark plug NGK CR10E or DENSO U31ESR N Battery 12V 28 8 kC 8 Ah 10 HR Generator Three phase A C generator Fuse 30 10 10A Headlight 12V 60 55W Parking or city light 12V 4W except E 03 24...

Page 244: ...g tension IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX IN EX INNER OUTER INNER OUTER Unit mm in STANDARD LIMIT 33 1 3 28 1 1 0 08 0 13 0 003 0 005 0 17 0 22 0 0067 0 0087 0 010 0...

Page 245: ...12 018 0 4724 0 4731 Rocker arm shaft 0 0 IN EX 11 973 11 984 0 4714 0 4718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 CYLINDER PISTON PISTON RING Unit mm in ITEM S...

Page 246: ...D 22 996 23 000 22 980 0 9054 0 9055 0 9047 CONROD CRANKSHAFT Unit mm in ITEM STANDARD LIMIT Conrod small end I D 23 006 23 014 23 040 0 9057 0 9061 0 9071 Conrod deflection 3 0 0 12 Conrod big end s...

Page 247: ...ANDARD LIMIT Primary reduction ratio 2 178 61 28 Final reduction E 03 28 33 2 800 42 15 ratio The others 2 733 41115 Gear ratios Low 2 416 29 12 2nd 1 625 26116 3rd 1 238 26121 4th 1 000 21 21 Top 0 8...

Page 248: ...play 0 5 1 0 mm pulling cable 0 02 0 04 in Starter cable play 0 5 1 0 mm 0 02 0 04 in CARBURETOR ITEM SPECIFICATION E 02 04 34 P 37 E 17 22 24 U type E 22 Carburetor type MIKUNI BST40SS Bore size 40...

Page 249: ...oltage 13 0 16 0 V at 5 000 r min Starter relay resistance 3 5 n Battery Type designation YTX9 BS Capacity 12V 28 8 kC 8Ah 1 0 HR Standard 1 320 at 20 C 68 F electrolyte S G Fuse size Main 30 A Headli...

Page 250: ...e caliper piston diam Front 26 90 26 95 1 0591 1 0610 Rear 30 16 30 18 1 1874 1 1882 Wheel rim runout Axial 2 0 0 08 Radial 2 0 0 08 Wheel axle runout Front 0 25 0 010 Rear 0 25 0 010 Tire rim size Fr...

Page 251: ...l with appropriate cosolvents and corrosion inhibitor is permissible Use only unleaded gasoline of at least 87 pump octane R M method or 91 octane or E 28 higher rated by the Research Method Gasoline...

Page 252: ...NAL LIGHT SWITCH II WIRE COLOR B Black BI Blue t f 1 Tf g g nn 0 Lbl lighl blue Lg lighl green j 0 Orange iii nr lli1 u 0 1 HEADLIGHT IHI BIBI Black wilh Blue Iracer I W Y V G VI To I 2 HEADLIGHT ILO...

Page 253: ...DR650SEK1 01 MODEL CONTENTS SPECIFICATIONS 10 1 SERVICE DATA 10 2 LIQUID GASKET 10 10 10...

Page 254: ...ID 525 V8 110 links CHASSIS Front suspension Telescopic coil spring oil damped Rear suspension Link type coil spring oil damped spring preload fully adjustable compression damping force adjustable Fro...

Page 255: ...0 014 Valve guide I D IN EX 5 500 5 512 0 2165 0 2170 Valve stem O D IN 5 475 5 490 0 2156 0 2161 EX 5 455 5 470 0 2148 0 2154 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 V...

Page 256: ...EX 12 000 12 018 0 4724 0 4731 Rocker arm shaft O D IN EX 11 973 11 984 0 4714 0 4718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 CYLINDER PISTON PISTON RING Unit mm...

Page 257: ...iston pin O D 22 996 23 000 22 980 0 9054 0 9055 0 9047 CONROD CRANKSHAFT Unit mm in ITEM STANDARD LIMIT Conrod small end I D 23 006 23 014 23 040 0 9057 0 9061 0 9071 Conrod deflection 3 0 0 12 Conro...

Page 258: ...io ITEM STANDARD LIMIT Primary reduction ratio 2 178 61 28 Final reduction E 03 28 33 2 800 42 15 ratio The others 2 733 41 15 Gear ratios Low 2 416 29 12 2nd 1 625 26 16 3rd 1 238 26 21 4th 1 000 21...

Page 259: ...cable play 0 5 1 0 mm pulling cable 0 02 0 04 in Starter cable play 0 5 1 0 mm 0 02 0 04 in CARBURETOR ITEM SPECIFICATION E 04 34 54 E 17 22 24 U type E 22 Carburetor type MIKUNI BST40SS Bore size 40...

Page 260: ...lated voltage 13 0 16 0 V at 5 000 r min Starter relay resistance 3 5 Battery Type designation YTX9 BS Capacity 12V 28 8 kC 8Ah 10 HR Standard electrolyte S G 1 320 at 20 C 68 F Fuse size Main 30 A He...

Page 261: ...2 1 1921 Brake caliper piston diam Front 26 90 26 95 1 0591 1 0610 Rear 30 16 30 18 1 1874 1 1882 Wheel rim runout Axial 2 0 0 08 Radial 2 0 0 08 Wheel axle runout Front 0 25 0 010 Rear 0 25 0 010 Tir...

Page 262: ...g 3 2 2 6 US Imp gal E 33 reserve 13 L 3 4 2 9 US Imp gal Other markets Only 3 0 L reserve 0 8 0 7 US Imp gal Engine oil type SAE 10W 40 API SF or SG Engine oil capacity Oil 2 300 ml change 2 4 2 0 US...

Page 263: ...DR650SEK1 01 MODEL 10 10 LIQUID GASKET CYLINDER HEAD COVER CYLINDER HEAD NOTE SUZUKI BOND NO 1215 or NO 1207B has to be applied to the cylinder head cover and cylinder head...

Page 264: ......

Page 265: ...CONTENTS SPECIFICATIONS 11 2 SERVICE DATA 11 3 11 DR650SEK2 K3 K4 K5 K6 K7 02 03 04 05 06 07 08 MODELS 11 1 DR650SEK2 K3 K4 K5 K6 K7 02 03 04 05 06 07 08 MODELS...

Page 266: ...scopic coil spring oil damped Rear suspension Link type coil spring oil damped Front fork stroke 260 mm 10 2 in 220 mm 8 7 in Low seat Rear wheel travel 260 mm 10 2 in 220 mm 8 7 in Low seat Steering...

Page 267: ...2165 0 2170 Valve stem O D IN 5 475 5 490 0 2156 0 2161 EX 5 455 5 470 0 2148 0 2154 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem end length IN EX 2 7 0 11 Valve...

Page 268: ...m shaft O D IN EX 11 973 11 984 0 4714 0 4718 Cylinder head distortion 0 05 0 002 Cylinder head cover distortion 0 05 0 002 CYLINDER PISTON PISTON RING Unit mm in ITEM STANDARD LIMIT Piston to cylinde...

Page 269: ...0 9055 0 9047 CONROD CRANKSHAFT Unit mm in ITEM STANDARD LIMIT Conrod small end I D 23 006 23 014 23 040 0 9057 0 9061 0 9071 Conrod deflection 3 0 0 12 Conrod big end side clearance 0 10 0 65 1 00 0...

Page 270: ...2 178 61 28 Final reduction E 03 28 33 2 800 42 15 ratio The others 2 733 41 15 Gear ratios Low 2 416 29 12 2nd 1 625 26 16 3rd 1 238 26 21 4th 1 000 21 21 Top 0 826 19 23 Shift fork to groove clearan...

Page 271: ...RE SET PRE SET 1 0 turn back Throttle cable play 2 0 4 0 mm 0 08 0 16 in CARBURETOR ITEM SPECIFICATION E 04 34 E 17 24 Carburetor type MIKUNI BST40SS Bore size 40 mm I D No 32E0 32E3 Idle r min 1 500...

Page 272: ...stance 3 5 Battery Type designation YTX9 BS Capacity 12V 28 8 kC 8Ah 10 HR Standard electrolyte S G 1 320 at 20 C 68 F Fuse size Main 30 A Headlight H 10 A Headlight L 10 A WATTAGE Unit W ITEM SPECIFI...

Page 273: ...0 26 95 1 0591 1 0610 Rear 30 16 30 18 1 1874 1 1882 Wheel rim runout Axial 2 0 0 08 Radial 2 0 0 08 Wheel axle runout Front 0 25 0 010 Rear 0 25 0 010 Tire rim size Front 21 1 85 Rear 17M C MT2 50 Ti...

Page 274: ...9 US Imp gal Others Only 3 0 L reserve 0 8 0 7 US Imp gal Engine oil type SAE 10W 40 API SF or SG Engine oil capacity Oil 2 300 ml change 2 4 2 0 US lmp qt Oil and 2 400 ml filter change 2 5 2 1 US l...

Page 275: ...E SPECIFICATIONS 12 2 NOTE Difference between K9 MODEL and K8 MODEL specification is indicated as an asterisk mark The service data is the same as the K8 MODEL 11 DR650SEK9 09 MODELS 12 1 DR650SE K9 0...

Page 276: ...26 16 3rd 1 238 26 21 4th 1 000 21 21 Top 0 826 19 23 Final reduction ratio 2 800 42 15 E 03 28 33 2 733 41 15 E 24 Drive chain DID 525V9 110 links CHASSIS Front suspension Telescopic coil spring oil...

Page 277: ...L 3 2 2 6 US Imp gal E 33 13 0 L 3 4 2 9 US Imp gal Others reserve 3 0 L 0 8 0 7 US Imp gal Engine oil change 2 300 ml 2 4 2 0 US Imp qt with filter change 2 400 ml 2 5 2 1 US Imp qt overhaul 2 600 m...

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