Suzuki dl650a Owner's Manual
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Suzuki dl650a Owner's Manual

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DL650A
OWNER'S MANUAL

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  • Page 1 DL650A OWNER’S MANUAL...
  • Page 2 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.
  • Page 3 Suzuki parts are  WARNING manufactured of high quality materi- als, and machined parts are finished Indicates a potential hazard that to close tolerances.
  • Page 4 Your autho- rized Suzuki dealer has experienced technicians that are trained to provide your machine with the best possible service with the right tools and equip- ment.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS CONSUMER INFORMATION CONTROLS FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS BREAK-IN (RUNNING-IN) AND INSPECTION BEFORE RIDING RIDING TIPS INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE PROCEDURE AND MOTORCYCLE CLEANING SPECIFICATIONS INDEX...

  • Page 7: Consumer Information

    CONSUMER INFORMATION ACCESSORY USE AND MOTORCYCLE LOADING ......... 1-2 SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS ....1-4 LABELS ....................... 1-5 SERIAL NUMBER LOCATION ................1-6 NOISE CONTROL SYSTEM (AUSTRALIA ONLY) ..........1-6...

  • Page 8: Accessory Use And Motorcycle Loading

    It is not possible for Suzuki to mounted. test each accessory on the market or • Inspect for proper ground clear- combinations of all the available ance and bank angle.

  • Page 9: Controls

    LOADING LIMIT LOADING GUIDELINES This motorcycle is primarily intended WARNING to carry small items when you are not riding with a passenger. Follow the guidelines below to carry a passenger Overloading or improper loading or cargo: can cause loss of motorcycle con- •...

  • Page 10: Safe Riding Recommendation For Motorcycle Riders

    One of the most vehicle operating condition and sub- serious injuries that can happen is a sequent accident. Suzuki will not be head injury. ALWAYS wear a properly responsible in any way for personal approved helmet. You should also injury or damage to the motorcycle wear suitable eye protection.

  • Page 11: Labels

    KNOW YOUR LIMITS LABELS Ride within the boundaries of your Read and follow all the labels on the own skill at all times. Knowing these motorcycle. Make sure you under- limits and staying within them will help stand all of the labels. Do not remove you to avoid accidents.

  • Page 12: Serial Number Location

    SERIAL NUMBER LOCATION NOISE CONTROL SYSTEM (AUSTRALIA ONLY) TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit: (a) The removal or rendering inopera- tive by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the pur- pose of noise control prior to its...

  • Page 13: Controls

    CONTROLS LOCATION OF PARTS ..................2-2 KEY ........................2-5 IGNITION SWITCH ....................2-7 INSTRUMENT PANEL ..................2-9 LEFT HANDLEBAR ................... 2-20 RIGHT HANDLEBAR ..................2-22 FUEL TANK CAP ....................2-24 GEARSHIFT LEVER ..................2-25 REAR BRAKE PEDAL ..................2-25 SEAT LOCK ....................... 2-26 HELMET HOLDER ....................

  • Page 14: Location Of Parts

    CONTROLS LOCATION OF PARTS 1 Clutch lever 2 Left handlebar switches 3 Instrument panel 4 Front brake fluid reservoir 5 Right handlebar switches 6 Throttle grip 7 Front brake lever 8 Ignition switch 9 Fuel tank cap...
  • Page 15 0 Air cleaner A Spark plugs B Battery and fuses C Helmet holders D Tools E Seat lock F Engine oil filter G Engine oil drain plug H Gearshift lever I Side stand...
  • Page 16 J Rear brake fluid reservoir K Engine oil filler cap L Rear brake pedal M Engine oil inspection window...

  • Page 17: Key

    Immobilizer identification code is programmed into the key. There- fore, a key made by an ordinary locksmith will not work. Ask Suzuki dealer if you need to make a spare key. • If you lose the key, ask your Suzuki dealer to have the lost one deactivated.

  • Page 18: Immobilizer Indicator

    IMMOBILIZER INDICATOR NOTE: (if equipped) • It is impossible to start the engine when the indicator remains blink- ing. • If the indicator remains blinking, it means immobilizer system com- munication error between key and ECM or use of wrong key. Turn off the ignition switch and then turn on to communicate immobilizer system properly.

  • Page 19: Ignition Switch

    IGNITION SWITCH “ON” POSITION The ignition circuit is completed and the engine can now be started. The headlight and taillight will automati- cally be turned on when the key is in this position. The key cannot be removed from the ignition switch in this position.
  • Page 20 If the motorcycle falls down, turn “P” (Parking) POSITION the ignition switch off immedi- When parking the motorcycle, lock ately. Ask your authorized Suzuki the steering and turn the key to the dealer to inspect the motorcycle “P” position. The key can now be for unseen damage.

  • Page 21: Instrument Panel

    INSTRUMENT PANEL GEAR km/h TRIP L/100kmkm/LMPG USIMP ˚C The fuel injection system indicator light 8, freeze indicator light A, cool- ant temperature indicator/oil pres- sure indicator light B, LCD’s and tachometer needle work as follows to confirm their function when the igni- tion switch is turned to the “ON”...
  • Page 22 TACHOMETER 3 The tachometer indicates the engine speed in revolutions per minute (r/min). GEAR POSITION INDICATOR 4 The gear position indicator indicates GEAR gear position. This indicator displays km/h TRIP L/100kmkm/LMPG USIMP “N” when the transmission is in neu- ˚C tral.
  • Page 23 If the ABS indicator light does not authorized Suzuki dealer as come on when the ignition switch is soon as possible. turned on, you should have the sys- tem checked by an authorized Suzuki dealer as soon as possible. 2-11...
  • Page 24 Suzuki dealer. If the engine stalls, try restarting the engine after turn- A. The display E indicates “FI” in the ing the ignition switch off and on. odometer display area and the •...
  • Page 25 COOLANT TEMPERATURE METER “” 0 The coolant temperature is displayed by an LCD segment temperature indi- cator 0, water temperature mark C, When the display indicates “CHEC” in and indicator light B. the odometer display area, check fol- lowing items; When coolant temperature...
  • Page 26 METER SELECT rized Suzuki dealer or a qualified switch. mechanic inspect your motorcy- cle. 2-14...
  • Page 27 CLOCK AND THERMOMETER D Thermometer The thermometer shows the ambient air temperature. ˚C The thermometer display will be Time or ambient air temperature is changed between °C and °F accord- shown when the ignition switch is in ing to the fuel economy setting when the “ON”...
  • Page 28 km/h NOTE: • Set the meter to odometer, then GEAR press and hold the ADJUST but- km/h TRIP L/100kmkm/LMPG USIMP ton 1 for 2 seconds to switch ˚C between km and mile. At this time, speedometer will be changed between km/h and mph. •...
  • Page 29 To change the display, push the left Odometer handlebar METER SELECT switch. The odometer registers the total dis- The display changes in the order tance that the motorcycle has been below. ridden. The odometer ranges from 0 to 999999. NOTE: The odometer display locks at 999999 when the total distance exceeds 999999.
  • Page 30 • km/L (L/100 km) “km/L” mode TRIP GEAR km/h TRIP L/100kmkm/LMPG USIMP ˚C TRIP “L/100 km” mode Press and hold the ADJUST button 1 for 2 seconds to change “km/L” mode Fuel economy meter to “L/100 km” mode. Trip 1 fuel econ- Fuel economy meter displays fuel omy mode change will affect trip 2 economy ratio of trip 1 and trip 2.
  • Page 31 FUEL METER “” F Instrument panel light brightness Set the meter to instrument panel The fuel meter indicates the amount light brightness, then press and hold of fuel remaining in the fuel tank. The the ADJUST button 1 for 2 seconds fuel meter displays all 5 segments ...

  • Page 32: Left Handlebar

    DIMMER SWITCH 2 LEFT HANDLEBAR “” position The headlight low beam and taillight turn on. “” position The headlight high beam and taillight turn on. The high beam indicator light also turns on. Headlight flasher switch Press the dimmer switch of “” posi- tion to flash the headlight high beam.
  • Page 33 HAZARD WARNING SWITCH “” 3 TURN SIGNAL LIGHT SWITCH “” 6 All four turn signal lights and indica- tors will flash simultaneously when Moving the switch to the “” position the switch is turned on with the igni- will flash the left turn signals. Moving tion switch in the “ON”...

  • Page 34: Right Handlebar

    RIGHT HANDLEBAR Front Brake Lever Adjustment ENGINE STOP SWITCH 1 The distance between the throttle grip “” position and the front brake lever is adjustable The ignition circuit is off. The engine to 5 positions. To change the position, cannot start or run. push the brake lever forward and turn the adjuster to the desired position.
  • Page 35 THROTTLE GRIP 4 ELECTRIC STARTER SWITCH “” Engine speed is controlled by the This switch is used for operating the position of the throttle grip. Twist it starter motor. With the ignition switch toward you to increase engine speed. in the “ON” position, the engine stop Turn it away from you to decrease switch in “”...

  • Page 36: Fuel Tank Cap

    FUEL TANK CAP  WARNING If you overfill the fuel tank, fuel may overflow when it expands due to engine heat or heating by the sun. Fuel that overflows can catch fire. Stop adding fuel when the fuel level reaches the bottom of the filler neck.

  • Page 37: Gearshift Lever

    GEARSHIFT LEVER REAR BRAKE PEDAL This motorcycle has a 6-speed trans- Depressing the rear brake pedal will mission which operates as shown. To apply the rear disk brake. The brake shift properly, squeeze the clutch light will be illuminated when the rear lever and close the throttle at the brake is operated.

  • Page 38: Seat Lock

    SEAT LOCK WARNING Failure to install the seat properly could allow the seat to move and cause loss of rider control. Latch the seat securely in its proper position. A small and light article such as rain gear or a windbreaker can be placed under the seat.

  • Page 39: Helmet Holder

    HELMET HOLDER SIDE STAND There is a helmet holders under the An interlock system is provided to cut seat. To use them, remove the seat, off the ignition circuit when the side hook your helmet fastener ring to the stand is down and the transmission is holder and refit the seat.

  • Page 40: Suspension Adjustment

    SUSPENSION ADJUSTMENT  WARNING The standard settings for both front and rear suspensions are selected to Riding with the side stand incom- meet various riding conditions such pletely retracted can result in an as low to high motorcycle speed and accident when you turn left.
  • Page 41 FRONT SUSPENSION Spring Pre-load Adjustment To change the spring pre-load, turn the adjuster 1 clockwise or counter- clockwise. Turning the adjuster clock- wise will increase the spring pre-load. Turning the adjuster counterclockwise will decrease the spring pre-load. There are 4 grooved lines on the side of the adjuster 1 for reference.
  • Page 42 Mishandling can cause explosion. • Keep away from fire and heat. • Read owner’s manual for more information. NOTE: Ask your Suzuki dealer to dis- pose of the rear suspension unit. To adjust the rear suspension spring pre-load, turn the adjuster 1. Turning...

  • Page 43: Windshield Height Adjustment

    Damping Force Adjustment WINDSHIELD HEIGHT ADJUSTMENT windshield height adjusted in 3 positions. To change windshield height, follow the proce- dure below. The rebound damping force adjuster 2 is located at the bottom of the rear suspension damper unit. To adjust the damping force, set the adjuster to the standard setting first and then adjust it to the desired position.
  • Page 44  WARNING Moving the motorcycle with its windshield interfering with the rear view mirror can be hazardous. You could lose your balance and fall. After adjusting the windshield height and the rear view mirror position, turn the handlebar right 2. Remove the caps. Move the wind- and left to check that the wind- shield up and down to desired shield does not interfere with the...

  • Page 45: Fuel, Engine Oil And Coolant Recommendations

    FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS FUEL OCTANE RATING ..................3-2 OXYGENATED FUEL RECOMMENDATION ............3-2 ENGINE OIL ......................3-4 COOLANT ......................3-5...

  • Page 46: Fuel Octane Rating

    OXYGENATED FUEL FUEL, ENGINE OIL AND RECOMMENDATION COOLANT (Canada and EU) RECOMMENDATIONS Oxygenated fuels which meet the minimum octane requirement and the FUEL OCTANE RATING requirements described below may unleaded gasoline with be used in your motorcycle without octane rating higher jeopardizing the New Vehicle Limited (Research method).
  • Page 47 Suzuki and may not be covered under the Be careful not to spill any fuel New Vehicle Limited Warranty or the when filling the fuel tank.

  • Page 48: Engine Oil

    ENGINE OIL JASO T903 The JASO T903 standard is an index Use Suzuki genuine engine oil or to select engine oils for 4-stroke equivalent. If Suzuki genuine engine motorcycle and ATV engines. Motor- oil is not available, select a proper...

  • Page 49: Coolant

    Energy Conserving COOLANT Suzuki does not recommend the use Use “SUZUKI SUPER LONG LIFE “ENERGY CONSERVING” COOLANT” or “SUZUKI LONG LIFE “RESOURCE CONSERVING” oils. COOLANT”. “SUZUKI SUPER Some engine oils which have an API LONG LIFE COOLANT” classification of SH or higher have an “SUZUKI LONG LIFE COOLANT”...
  • Page 50 Required amount of water/coolant SUZUKI SUPER LONG LIFE Solution capacity (total): 1950 ml COOLANT (Blue) (2.1/1.7 US/Imp. qt) “SUZUKI SUPER LONG LIFE COOL- ANT” is pre-mixed to the proper ratio. 975 ml Water (1.0/0.9 US/Imp. qt) Add only “SUZUKI SUPER LONG LIFE COOLANT”...

  • Page 51: Break-In (Running-In) And Inspection Before Riding

    BREAK-IN (RUNNING-IN) AND INSPECTION BEFORE RIDING MAXIMUM ENGINE SPEED RECOMMENDATION ..........4-2 VARY THE ENGINE SPEED ................4-2 BREAKING IN THE NEW TIRES ................ 4-2 AVOID CONSTANT LOW SPEED ..............4-2 ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING ......4-3 OBSERVE YOUR FIRST AND MOST CRITICAL SERVICE ......
  • Page 52 160 km (100 miles) before attempting ing maximum life and performance maximum performance. Avoid hard from your new Suzuki. The following acceleration, hard cornering, and guidelines explain proper break-in hard braking for the first 160 km (100 procedures.
  • Page 53 ALLOW THE ENGINE OIL TO INSPECTION BEFORE RIDING CIRCULATE BEFORE RIDING  WARNING Allow sufficient idling time after warm or cold engine start up before apply- Failure to inspect your motorcy- ing load or revving the engine. This cle before riding and to properly allows time for the lubricating oil to maintain your...
  • Page 54 Before riding the motorcycle, be sure Suspension Smooth movement to check the following items. Never ( 2-28) underestimate importance Fuel Enough fuel for the planned these checks. Perform all of them ( 2-9) distance of operation before riding the motorcycle. Drive chain •...

  • Page 55: Riding Tips

    RIDING TIPS STARTING THE ENGINE ..................5-2 STARTING OFF ....................5-3 USING THE TRANSMISSION ................5-4 RIDING ON HILLS ....................5-5 STOPPING AND PARKING ................5-6...

  • Page 56: Starting The Engine

    RIDING TIPS  WARNING STARTING THE ENGINE Exhaust gas contains carbon Before attempting to start the engine, monoxide, a dangerous gas that is make sure: difficult to detect because it is col- 1. The transmission is in neutral. orless and odorless. Breathing 2.

  • Page 57: Starting Off

    STARTING OFF  WARNING  WARNING Sudden side winds, which can occur when being passed by Riding excessive speeds larger vehicles, at tunnel exits or increases your chances of losing in hilly areas, can cause you to control of the motorcycle, which lose control of the motorcycle.

  • Page 58: Using The Transmission

    USING THE TRANSMISSION WARNING The transmission is provided to keep the engine operating smoothly in its Downshifting when engine speed normal operating speed range. The is too high can: gear ratios have been carefully cho- • cause the rear wheel to skid and sen to meet the characteristics of the lose traction due to increased engine.

  • Page 59: Riding On Hills

    RIDING ON HILLS NOTICE • When climbing steep hills, the motorcycle may begin to slow Revving the engine into the red down and show lack of power. At zone can cause severe engine this point you should shift to a damage.

  • Page 60: Stopping And Parking

    STOPPING AND PARKING NOTE: In some situations, a motorcy- cle with ABS may require a longer Anti-lock Brake System (ABS) stopping distance to stop on loose or This model is equipped with an Anti- uneven surfaces than an equivalent lock Brake System (ABS) designed to motorcycle without ABS.
  • Page 61 How the ABS Works WARNING ABS works by electronically control- ling braking pressure. A computer Failure to use good judgment with monitors wheel rotation speed. If the ABS can be hazardous. ABS can- computer detects that a braked wheel not make up for bad road condi- has slowed suddenly, indicating a tions, bad judgement, or improper skidding situation, the computer will...
  • Page 62 Stopping and Parking WARNING 1. Twist the throttle grip away from yourself to close the throttle com- Hard braking on wet, loose, rough, pletely. or other slippery surfaces can 2. Apply the front and rear brakes cause wheel skid and loss of con- evenly and at the same time.
  • Page 63 5. Park the motorcycle on a firm, flat 6. Turn the ignition key to the “OFF” surface where it will not fall over. position. 7. Turn the handlebars all the way to  CAUTION the left and lock the steering for security.

  • Page 65: Inspection And Maintenance

    INSPECTION AND MAINTENANCE MAINTENANCE SCHEDULE ................6-2 TOOLS ......................... 6-5 FUEL TANK LIFT ....................6-5 LUBRICATION POINTS ..................6-11 BATTERY ......................6-12 AIR CLEANER ....................6-14 SPARK PLUGS ....................6-18 FUEL HOSE ....................... 6-22 ENGINE OIL ....................... 6-22 ENGINE IDLE SPEED INSPECTION ..............6-27 THROTTLE CABLE PLAY ................

  • Page 66: Maintenance Schedule

    Suzuki dealer to do the nance section. Your Suzuki dealer maintenance. can provide you with further guide- lines.
  • Page 67 If you have any when electric circuit questions regarding maintenance shorted. intervals, consult your Suzuki dealer or a qualified mechanic. Turn off the ignition switch before servicing the electric parts to avoid short-circuit damage. NOTICE Poorly-made replacement parts can cause your motorcycle to wear more quickly and may shorten its useful life.
  • Page 68 – – – Throttle cable play ( 6-27) * Throttle valve synchronization – – – “SUZUKI SUPER LONG LIFE Replace every 4 years or 48000 km (29000 miles) COOLANT” (Blue) * Engine coolant “SUZUKI LONG ( 6-29) LIFE COOLANT” (Green) or non-gen- –...

  • Page 69: Tools

    TOOLS RIGHT A tool kit is supplied and located under the seat. FUEL TANK LIFT 1. Place the motorcycle on the side stand. 2. Remove the seat by referring to the SEAT LOCK section. LEFT 3. Remove the right and left bolts. Unhook the right and left hooks and pull the side frame cover 1.
  • Page 70 6. Raise the fairings 2 with a hand 4. Remove the bolts and fasteners. to separate it from the front tank cover 3. 5. Pull off the front tank cover hooks. Covers have hooks at the circled places. 7. Unhook the hooks and remove the front tank cover 3.
  • Page 71 RIGHT RIGHT LEFT LEFT 8. Remove the fuel tank side cover 9. Loosen instrument panel bolts. bolts. Push down the instrument panel at around the circled place to unhook the hooks.
  • Page 72 RIGHT 10. Push the fairing 2 at around the LEFT circled place with thumbs and roll up the fairing to unhook the 11. The fuel tank cover has fasteners hooks. behind the cover at the rectangle mark places. Pull up the fuel tank side covers 4 to unfasten the fas- teners.
  • Page 73 12. The fuel tank side cover has a fas- tener behind the cover at the cir- cled place. Move the fuel tank side cover 4 backward to slip off the hook. RIGHT LEFT...
  • Page 74 RIGHT 15. Remove the bolt. Remove the prop 6 and two cushion. LEFT 13. Remove the right and left fairing 16. Support the fuel tank with the bolts. prop. 14. Remove the bolts. Remove the fuel tank fitting bracket 5. 6-10...

  • Page 75: Lubrication Points

    LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of your motorcycle and also for safe riding. It is a good practice to lubricate the motorcycle after a long rough ride and after get- ting it wet it in the rain or after wash- ing it.

  • Page 76: Battery

    BATTERY  WARNING This battery is a sealed type battery and requires no maintenance of fluid Batteries produce flammable level and gravity. But have your dealer hydrogen gas which can explode check the charging condition of the if exposed to flames or sparks. battery periodically.
  • Page 77 BATTERY REMOVAL  WARNING To remove the battery, follow proce- dure below: Batteries contain toxic sub- 1. Place the motorcycle on the side stances including sulfuric acid stand. and lead. They could cause injury 2. Remove the seat by referring to to humans or could damage the the SEAT LOCK section.

  • Page 78: Air Cleaner

    The recycling element. of materials will help to conserve nat- ural resources. For more detailed Never run the engine without the information about disposing or recy- air cleaner element in place. cling of the used battery, consult your Suzuki dealer. 6-14...
  • Page 79 NOTICE Failure to inspect the air cleaner element frequently if the vehicle is used in dusty, wet, or muddy con- ditions can damage your motorcy- cle. The air cleaner element can become clogged under these con- ditions, and engine damage may result.
  • Page 80 9. Reinstall the cleaned element or new air cleaner element in reverse order of removal. Be absolutely sure that the element is securely in position and is sealing properly. NOTICE A torn air cleaner element will allow dirt to enter the engine and can damage the engine.
  • Page 81 Air Cleaner Drain Plug 2. Remove the plug and drain water and oil at the periodic mainte- nance interval. The air cleaner drain plug is located beneath the air cleaner box. 1. Loosen the clamp bolts 1. Pull up the air cleaner box 2. 6-17...

  • Page 82: Spark Plugs

    SPARK PLUGS REMOVAL To remove the spark plugs, follow the procedure below: Front Side 1. Remove the seat and fuel tank side covers by referring to the SEAT LOCK and FUEL TANK LIFT section. 3. Remove the radiator mounting bolt 2 and slide the radiator for- ward.
  • Page 83 NOTE: Be careful not to damage the Rear Side radiator fins. 1. Lift the fuel tank by referring to the FUEL TANK LIFT section.  CAUTION A hot radiator and hot engine can burn you. Wait until the radiator and engine are cool enough to touch with bare hands before starting this work.
  • Page 84 Use one of the spark plugs listed or their equivalent. Consult your Measure the spark plug gap A with a Suzuki dealer if you are not sure wire type feeler gauge. The standard which spark plug is correct for spark plug gap is 0.8 – 0.9 mm (0.031 your type of usage.
  • Page 85 Installation NOTICE Improper installation of the spark plug can damage your motorcycle. An overly-tight or cross-threaded spark plug will damage the alumi- num threads of the cylinder head. Carefully turn the spark plug by NOTE: When installing the spark plug hand into the threads.

  • Page 86: Fuel Hose

    FUEL HOSE ENGINE OIL Long engine life depends much on the selection of a quality oil and the periodic changing of the oil. Daily oil level checks and periodic changes are two of the most important mainte- nance items to be performed. ENGINE OIL LEVEL CHECK Follow the procedure below to inspect the engine oil level.
  • Page 87 NOTICE Operating the motorcycle with too little or too much oil can damage the engine. Place the motorcycle on level ground. Check the oil level with the engine oil inspection window before each use of the vehicle. Be sure the engine oil level is always 3.
  • Page 88 NOTE: Recycle or properly dispose of 4. Turn the oil filter 4 counterclock- used oil. wise with a Suzuki “cap type” oil filter wrench or a “strap type” filter wrench of the proper size. 5. Wipe off the mounting surface 5 on the engine where the new filter will be seated with a clean rag.
  • Page 89 8. Mark the top dead center position on the “cap type” filter wrench or Be sure to use a genuine Suzuki on the oil filter. Use an oil filter oil filter or an equivalent one wrench to tighten the filter 2 turns designed for your motorcycle.
  • Page 90 21 N·m (2.1 kgf-m, 15.0 lbf-ft) NOTE: If you do not have a proper oil NOTE: About 2400 ml (2.5/2.1 US/ filter wrench, have your Suzuki dealer lmp. qt) of oil will be required when perform this service. changing oil only.

  • Page 91: Engine Idle Speed Inspection

    1400 r/min when the engine is warm. NOTE: If the engine idle speed is not within the specified range, ask your Suzuki dealer or a qualified mechanic to inspect and repair the motorcycle. 2.0 – 4.0 mm (0.08 – 0.16 in) To adjust the cable play: 1.

  • Page 92: Clutch

    4. Minor adjustment can now be made with the adjuster 2. 5. Tighten the lock nuts, 1 and 3, after finishing adjustment. NOTE: Any maintenance of the clutch other than the clutch cable play should be performed by your Suzuki dealer. 6-28...

  • Page 93: Coolant

    COOLANT 1. Lift the fuel tank by referring to the FUEL TANK LIFT section. COOLANT LEVEL 2. Remove the filler cap and add specified engine coolant through Remove the seat to check the coolant the filler hole until it reaches the level.

  • Page 94: Drive Chain

    It does not use a master link. We recommend that you take your motor- CHANGING THE COOLANT cycle to an authorized Suzuki dealer Change the coolant periodically. or a qualified mechanic if the drive chain needs to be replaced.
  • Page 95 Do not use a joint-clip type chain. Chain replacement requires a spe- cial riveting tool and a high-qual- ity, non-joint-clip type chain. Ask an authorized Suzuki dealer or a qualified mechanic to perform this work. 6-31...
  • Page 96 DRIVE CHAIN CLEANING AND NOTICE OILING 1. Remove dirt and dust from the Some drive chain lubricant con- drive chain. Be careful not to dam- tains solvents and additives which age the seal ring. could damage the seal rings in the 2.
  • Page 97 DRIVE CHAIN ADJUSTMENT 1. Place the motorcycle on the side Adjust the drive chain slack to the stand. proper specification. The chain may require more frequent adjustments than indicated in the periodic mainte- nance schedule depending upon your riding conditions. WARNING Too much chain slack can cause the chain to come off the sprock-...

  • Page 98: Brakes

    Proper operation of fluid leakage. If any defects are found, brake systems are vital to safe riding. ask your Suzuki dealer to replace the Be sure to perform the brake inspec- brake hose with a new one. tion as scheduled.
  • Page 99  WARNING NOTICE The use of any fluid except DOT4 Spilled brake fluid can damage brake fluid from a sealed con- painted surfaces and plastic parts. tainer can damage the brake sys- tem and lead to an accident. Be careful not to spill any fluid when filling the brake fluid reser- Clean filler cap before removing.
  • Page 100 FRONT dent. If you need to replace brake pads, have your Suzuki dealer do this work. Inspect and maintain the brake pads as recommended.  WARNING If you ride this motorcycle after...
  • Page 101 NOTE: Do not squeeze/depress the REAR BRAKE PEDAL brake lever/pedal when the pads are ADJUSTMENT not in their positions. It is difficult to The rear brake pedal position must be push the pistons back and brake fluid properly adjusted at all times or the leakage may result.

  • Page 102: Tires

    REAR BRAKE LIGHT SWITCH TIRES  WARNING The tires on your motorcycle form the crucial link between your motorcycle and the road. Failure to take the precautions below may result in an accident due to tire failure. • Check tire condition and pres- sure before each ride, and To adjust the brake light switch, raise adjust pressure if necessary.
  • Page 103 TIRE PRESSURE AND LOADING  WARNING Proper tire pressure and proper tire loading are important factors. Over- Failure to perform break-in of the loading your tires can lead to tire fail- tires could cause tire slip and loss ure and loss of vehicle control. of control, which could result in an accident.
  • Page 104 TIRE CONDITION AND TYPE Proper tire condition and proper tire type affect vehicle performance. Cuts or cracks in the tires can lead to tire failure and loss of vehicle control. Worn tires are susceptible to puncture failures and subsequent loss of vehi- cle control.
  • Page 105 Tubeless tires require different service procedures than tube • Ask your Suzuki dealer or a tires. qualified mechanic to perform tire repair, replacement, and bal- • Tubeless tires require an air-...

  • Page 106: Side Stand/Ignition Interlock System

    Have your motorcycle inspected by an authorized Suzuki dealer or a qualified service mechanic. 6-42...

  • Page 107: Front Wheel Removal

    NOTE: A special tool is necessary to bolt. loosen the shaft 3. The special tool is available at Suzuki dealer. 6. Place an accessory service stand or equivalent under the swingarm to help stabilize the rear end.
  • Page 108  WARNING Failure to extend brake pads after installing the wheel can cause poor braking performance and may result in an accident. Before riding, “pump” the brake lever repeatedly until the brake pads are pressed against the brake disks and proper lever 8.

  • Page 109: Rear Wheel Removal

    If you do not have a torque wrench or do not know how to use one, ask NOTICE your authorized Suzuki dealer to check the bolts and nuts. Removing the rear wheel without use of an accessory stand can...
  • Page 110 3. Remove the axle nut 1. 6. Draw out the axle shaft. 4. Place an accessory service stand or equivalent under the swingarm to lift the rear wheel slightly off the ground. NOTICE Improper jacking may cause dam- age to the oil filter. Do not place the jack under the oil filter when jacking up the motorcy- 7.
  • Page 111 • Torque bolts and nuts to the assembly 3. proper specifications. If you are not sure of the proper proce- dure, have your authorized Suzuki dealer or a qualified mechanic do this. Rear axle nut tightening torque: 100 N·m (10.0 kgf-m, 72.5 lbf-ft) WARNING Failure to extend brake pads after 9.

  • Page 112: Light Bulb Replacement

    LIGHT BULB REPLACEMENT HEADLIGHT/POSITION LIGHT To replace the headlight bulb and The wattage rating of each bulb is position light bulb, perform the follow- shown on the table below. When ing step: replacing a burned out bulb, always use the exact same wattage rating. To remove the instrument panel Using other than the specified rating assembly:...
  • Page 113 HEADLIGHT 1. Disconnect the socket 1 from the headlight and remove the rubber cap 2. 3. Move the instrument panel to the arrowed direction to unhook the hooks. 4. To install the instrument panel assembly, reverse the complete sequence listed. 2.
  • Page 114 POSITION LIGHT HEADLIGHT BEAM ADJUSTMENT The headlight beam can be adjusted both right and left or up and down if necessary. 1. Disconnect the coupler 1. Turn the socket 2 counterclockwise and remove it. To adjust the beam right and left: Turn the adjuster 1 clockwise or counterclockwise.
  • Page 115 TURN SIGNAL LIGHT BRAKE LIGHT/TAILLIGHT To replace the turn signal light bulb, To change the brake light/taillight follow these directions. bulb, perform the following steps: 1. Remove the seat by referring to the SEAT LOCK section. 1. Remove the screw and take off the lens.
  • Page 116 LICENSE PLATE LIGHT To replace the license plate light bulb, follow the procedure steps: 3. Push in on the bulb, twisting it to the left, and pull it out. 4. To fit the replacement bulb, push it in and twist it to the right while 1.

  • Page 117: Fuses

    The main fuse is located under the fuse with a new fuse. Consult your seat. One 30A spare fuse is located in Suzuki dealer for the electrical system the fuse box. check and repair. WARNING Replacing a fuse with incorrect amperage rating or substitute, e.g.

  • Page 118: Front Brake Lever Fitting

    FUSE LIST FRONT BRAKE LEVER FITTING • 30A MAIN fuse protects all electri- cal circuits. • 15A HEAD-HI fuse protects the headlight high beam and speed- ometer. • 15A HEAD-LO fuse protects the headlight low beam. • 10A FUEL fuse protects the ISC, ECM, speedometer, fuel pump and injectors.

  • Page 119: Clutch Lever Fitting

    CLUTCH LEVER FITTING CATALYTIC CONVERTER The purpose of the catalytic converter is to minimize the amount of harmful pollutants your motorcycle’s exhaust. Use of leaded fuel in motor- cycles equipped with catalytic con- verters is prohibited because lead deactivates pollutant-reducing components of the catalyst system.
  • Page 120  WARNING NOTICE Improper motorcycle operation If you park or operate the motorcy- can cause catalyst or other motor- cle in areas where there are com- cycle damage. bustible materials such as dry grass or leaves, these materials To avoid damage to the catalyst or may come in contact with the cat- other related components, you alytic converter or other hot...

  • Page 121: Troubleshooting

    TROUBLESHOOTING FUEL SUPPLY CHECK ..................7-2 IGNITION SYSTEM CHECK ................7-3 ENGINE STALLING ..................... 7-3...
  • Page 122 This troubleshooting guide is provided system, take your machine to an to help you find the cause of some authorized Suzuki dealer. Refer to the common complaints. “INSTRUMENT PANEL” section for an explanation of the fuel injection sys- NOTICE tem indicator.
  • Page 123 “ON” machine to an authorized Suzuki position, the engine stop switch in dealer. Refer to the “INSTRU- the “” position, the transmission MENT PANEL” section for an in neutral, and the clutch disen- explanation of the fuel injection gaged.

  • Page 125: Storage Procedure And Motorcycle Cleaning

    STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE ..................8-2 PROCEDURE FOR RETURNING TO SERVICE ..........8-3 CORROSION PREVENTION ................8-3 MOTORCYCLE CLEANING ................8-4 INSPECTION AFTER CLEANING ............... 8-6...

  • Page 126: Storage Procedure

    For this reason, motorcycle by referring to the Suzuki recommends that you trust BATTERY section. this maintenance work to your Suzuki 2. Clean the outside of the battery dealer. If you need to service the with a mild detergent and remove...

  • Page 127: Procedure For Returning To Service

    PROCEDURE FOR CORROSION PREVENTION RETURNING TO SERVICE It is important to take good care of your motorcycle to protect it from cor- • Clean the entire motorcycle. rosion and keep it looking new for • Reinstall the battery by referring years to come.

  • Page 128: Motorcycle Cleaning

    If the chips or scratches have or brush. Do not use hard materi- gone through to the bare metal, als which can scratch the paint. have a Suzuki dealer make the 2. Wash the entire motorcycle with a repair. mild detergent or car wash soap •...
  • Page 129 “touch-up” the damage follow- obstruct view. When replacing the ing the procedure below: windshield, use a Suzuki replacement a. Clean all damaged spots and windshield. allow them to dry. b. Stir the paint and “touch-up” the damaged spots lightly with a small brush.

  • Page 130: Inspection After Cleaning

    Waxing the Motorcycle INSPECTION AFTER CLEANING After washing the motorcycle, waxing For extended life of your motorcycle, and polishing are recommended to lubricate according to “LUBRICATION further protect and beautify the paint. POINTS” section. • Only use waxes and polishes of good quality.

  • Page 132: Specifications

    SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..........2290 mm (90.2 in) Overall width............ 835 mm (32.9 in) Overall height ..........1405 mm (55.3 in) Wheelbase ............1560 mm (61.4 in) Ground clearance..........175 mm (6.9 in) Seat height ............835 mm (32.9 in) Curb mass ............
  • Page 133 ELECTRICAL Ignition type .............Electronic ignition (Transistorized) Spark plug ............NGK CR8EIA-9 or DENSO IU24D Battery.............12V 36.0 kC(10 Ah)/10 HR Generator ............Three-phase A.C. generator Main fuse............30A Fuse ..............15/15/10/10/15/15A ABS fuse ............25/15A Headlight ............12V 60/55W (H4) × 2 Position light ............12V 5W × 2 Brake light/Taillight...........12V 21/5W License plate light..........12V 5W Turn signal light ..........12V 21W...
  • Page 134 INDEX ACCESSORY USE AND FRONT BRAKE LEVER MOTORCYCLE LOADING ....1-2 FITTING......... 6-54 AIR CLEANER....... 6-14 FRONT WHEEL REMOVAL ..6-43 ALLOW THE ENGINE OIL TO FUEL........2-24 CIRCULATE BEFORE RIDING ..4-3 FUEL HOSE ........6-22 AVOID CONSTANT FUEL OCTANE RATING ....3-2 LOW SPEED ........
  • Page 135 LABELS ........... 1-5 SAFE RIDING RECOMMENDATION LEFT HANDLEBAR ....... 2-20 FOR MOTORCYCLE RIDERS ..1-4 LIGHT BULB REPLACEMENT..6-48 SEAT LOCK........2-26 LOCATION OF PARTS ....2-2 SERIAL NUMBER LOCATION ..1-6 LUBRICATION POINTS ....6-11 SIDE STAND ......... 2-27 SIDE STAND/IGNITION INTERLOCK SYSTEM ....
  • Page 139 Part No. 99011-11J63-01A May, 2014 EN © COPYRIGHT SUZUKI MOTOR CORPORATION 2014 Printed in Japan...

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