DL650K4_svc_man.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.
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.
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.
INFORMATION
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
seal
I
@ ( Center spacer
@ I Front wheel
@ I Brake disc bolt
Tire valve
Front axle
I
@ I Bearing
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
PI
Torque control required.
Data beside it indicates specified
torque.
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
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
E
ECM
: Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
-
ECT Sensor : Engine Coolant Temperature
Sensor (ECTS), Water Temp.
Sensor (WTS)
EVAP : Evaporative Emission
EVAP Canister: Evaporative Emission
Canister (Canister)
B
BBDC
BTDC
B+
F
: Before Bottom Dead Center
: Before Top Dead Center
: Battery Positive Voltage
FI
FP
FPR
FP Relay
: Fuel Injection, Fuel Injector
: Fuel Pump
: Fuel Pressure Regulator
: Fuel Pump Relay
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
CO
: Carbon Monoxide
I
CPU
: Central Processing Unit
D
DC
DMC
DOHC
DRL
IAP Sens
IAT Sensor
: Intake Air Pressure Senso r (IAPS)
: Intake Air Temperature Sensor
(IATS)
: Ignition
: 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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