suzuki_dl650k4_service_manual.pdf

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I

SERVICE MANUAL

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FOREWORD

This manual contains an introductory description on

the SUZUKI DL650 and procedures for its inspec-

tion/service and overhaul of its main components.

Other information considered as generally known is

not included.

Read the GENERAL INFORMATION section to

familiarize yourself with the motorcycle and its main-

tenance. Use this section as well as other sections

to use as a guide for proper inspection and service.

This manual will help you know the motorcycle bet-

ter so that you can assure your customers of fast

and reliable service.

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FI SYSTEM DIAGNOSIS

This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modificationshave been made since

then, differences may exist between the con-

tent of this manual and the actual motorcycle.

illustrations in this manual are used to show

the basic principles of operation and work

procedures. They may not represent the

actual motorcycle exactly in detail.

This manual is written for persons who have

enough knowledge, skills and tools, including

special tools, for servicing SUZUKI motorcy-

cles. If you do not have the proper knowledge

and tools, ask your authorized SUZUKI

motorcycle dealer to help you.

FUEL SYSTEM AND THROTTLE

BODY

COOLING AND LUBRICATION

SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the

services described in this manual.

Improper repair may result in injury to the

mechanic and may render the motorcycle

unsafe for the rider and passenger.

EMISSION CONTROL

INFORMATION

WIRING DIAGRAM

SUZUKl MOTOR CORPORATION

O COPYRIGHT SUZUKl MOTOR CORPORATION2003

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HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX.

3. Holding the manual as shown at the right will allow you to find

the first page of the section easily.

4. The contents are listed on the first page of each section to

help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit, is its exploded view. Work instructions and other service information

such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front wheel

@ 1 Brake disc

O I ~ust

I

seal

@ I Bearing

I

@ ( Center spacer

@ I Front wheel

@

@

Tire valve

Front axle

@ I Brake disc bolt

I

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SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servic-

-

ing. The meaning of each symbol is also included in the table.

SYMBOL

DEFINITION

SYMBOL

DEFINITION

Torque control required.

Data beside it indicates specified

torque.

PI

Apply THREAD LOCK SUPER "1360".

99000-32130

Apply oil. Use engine oil unless other-

wise specified.

Use engine coolant.

Apply molybdenum oil solution.

(Mixture of engine oil and SUZUKl

MOLY PASTE in a ratio of 1:1)

Use fork oil.

99000-99001-SS8

Apply SUZUKl SUPER GREASE "A.

99000-25030 (USA)

99000-25010 (Others)

Apply or use brake fluid.

Apply SUZUKl MOLY PASTE.

99000-25140

Measure in voltage range.

Apply SUZUKl SILICONE GREASE.

99000-25100

Measure in current range.

Apply SUZUKl BOND "121 5"

99000-31110 (Except USA)

Measure in resistance range.

Apply SUZUKl BOND "12078".

99104-31140 (USA)

99000-31140 (Others)

Measure in diode test range.

Apply THREAD LOCK SUPER "1303".

99000-32030

Measure in continuity test range.

Apply THREAD LOCK SUPER "1 322.

99000-32110 (Except USA)

Use special tool.

Apply THREAD LOCK "1342"

99000-32050

Indication of service data.

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ABBREVIATIONS USED IN THIS

MANUAL

E

ECM

: Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ABDC : After Bottom Dead Center

AC : Alternating Current

ACL : Air Cleaner, Air Cleaner Box

API : American Petroleum Institute

ATDC : After Top Dead Center

ATM Pressure: Atmospheric Pressure

Atmospheric Pressure Sensor

(APS)

: Air Fuel Mixture

-

ECT Sensor : Engine Coolant Temperature

Sensor (ECTS), Water Temp.

Sensor (WTS)

EVAP : Evaporative Emission

EVAP Canister: Evaporative Emission

Canister (Canister)

F

B

BBDC

BTDC

B+

FI

FP

FPR

FP Relay

: Fuel Injection, Fuel Injector

: Fuel Pump

: Fuel Pressure Regulator

: Fuel Pump Relay

: Before Bottom Dead Center

: Before Top Dead Center

: Battery Positive Voltage

C

CKP Sensor : Crankshaft Position Sensor

(CKPS)

CKT : Circuit

CLP Switch : Clutch Lever Position Switch

(Clutch Switch)

CMP Sensor : Camshaft Position Sensor

(CMPS)

G

GEN

GND

GP Switch

: Generator

: Ground

: Gear Position Switch

H

HC

: Hydrocarbons

: Carbon Monoxide

CO

I

CPU

: Central Processing Unit

IAP Sens

IAT Sensor

: Intake Air Pressure Senso r (IAPS)

: Intake Air Temperature Sensor

(IATS)

: Ignition

D

DC

DMC

DOHC

DRL

: Direct Current

: Dealer Mode Coupler

: Double Over Head Camshaft

: Daytime Running Light

L

LCD

LED

: Liquid Crystal Display

: Light Emitting Diode

(Malfunction Indicator Lamp)

: Left Hand

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