Suzuki DR650SEM2 2021 Assembly And Service Manual
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Suzuki DR650SEM2 2021 Assembly And Service Manual

Suzuki DR650SEM2 2021 Assembly And Service Manual

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Assembly and Pre-Delivery
Service Guide
This motorcycle has been designed and produced utilizing Suzuki's most modern technology. The fin-
est product, however, cannot perform properly unless it is correctly assembled and serviced. This ser-
vice guide has been produced to aid you in properly assembling and servicing this motorcycle.
Please read this service guide and follow its instructions carefully. To emphasize special information,
the symbol
and the words WARNING, CAUTION, NOTICE and NOTE have special meanings. Pay
particular attention to messages highlighted by these signal words:
Indicates a potential hazard that could result in death or serious injury.
Indicates a potential hazard that could result in minor or moderate injury.
Indicates a potential hazard that could result in motorcycle or equipment damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Any assembly and pre-delivery set-up performed on any Suzuki motorcycle by the dealer shall be
deemed by your Suzuki distributor to be performed at the dealer's sole risk and responsibility. The
Suzuki distributor disclaims any and all liability, obligation or responsibility for any defects resulting from
said assembly and pre-delivery set-up, and for any claims, demands or causes of action for damage to
property or for personal injuries resulting from the Dealer's assembly and pre-delivery set-up of Suzuki
motorcycle.
This Assembly and Pre-Delivery Service Guide may contain photographs of products sold in other mar-
kets. The assembly and pre-delivery service procedures in this guide, however, apply to this market.
IMPORTANT: CHECK the Vehicle Identification Number (VIN) for Safety Recalls and Emission
Recalls. IT IS YOUR RESPONSIBILITY to perform an applicable recall BEFORE you deliver the
vehicle to the customer.
M2
DR650SEM2
FOREWORD
Copyright © SUZUKI MOTOR CORPORATION 2021 All Rights Reserved
99505-32E02-03E
October '13 03

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Summary of Contents for Suzuki DR650SEM2 2021

  • Page 1 Any assembly and pre-delivery set-up performed on any Suzuki motorcycle by the dealer shall be deemed by your Suzuki distributor to be performed at the dealer’s sole risk and responsibility. The Suzuki distributor disclaims any and all liability, obligation or responsibility for any defects resulting from said assembly and pre-delivery set-up, and for any claims, demands or causes of action for damage to property or for personal injuries resulting from the Dealer’s assembly and pre-delivery set-up of Suzuki...
  • Page 2 PREPARATION WORKSHOP  CAUTION Assembling the vehicle in poor working condi- tion can be hazardous. Place the packed vehicle on a level floor where it is clean and spacious. A: Packed vehicle B: Working space SELF PROTECTION  CAUTION Assembling the vehicle without proper clothes and protective gear can be hazardous.
  • Page 3 Remove the strap. Take out the front wheel assembly from the crate base. A: Strap B: Front wheel assembly Remove the bolts of the bracket. Remove the bolts to take off the rear wheel holding bracket. A: Bolt B: Rear wheel holding bracket Remove the bolts from the crate.
  • Page 4 Remove the bolts A holding the upper side of the strut Carefully remove the struts B. NOTE: Be careful not to damage the motorcycle when separating the strut. A: Bolt B: Strut Lift and slide the steel frame A to separate it from the crate base B.

  • Page 5: Location Of Parts

    LOCATION OF PARTS Check all the components which have been removed from the base of the crate. Item Part Name Q’ty Remarks Item Part Name Q’ty Remarks Headlight cover Front fender Screw 6 × 12 mm Flange bolt (with washer) 6 ×...
  • Page 6 Parts listed in the preceding page are installed respectively into the positions as follows. E E M...

  • Page 8: Removing The Bracket

    The photograph shown indicates the parts dismounted from the motorcycle in addition to the items shown in the preceding page. A: Front brake master cylinder B: Throttle assembly Right switch C: Clutch cable D: Choke cable Left switch E: Speedometer drive gearbox F: Rear turn signal light (Left) The certification of vehicle pre-delivery form must be filled out in duplicate for every motorcycle.
  • Page 9 Remove the bolt to take off the front brake master cyl- inder from the bracket. NOTE: • Keep the position of front brake master cylinder with its cap facing upwards until it is installed. • The bolt is not necessary to assemble the motor- cycle.
  • Page 10 Loosen the handlebar right switch retaining screws and throttle housing retaining screws. Insert the handlebar right switch and throttle assembly onto the handlebars. A: Throttle assembly B: Right switch C: Handlebars Install the handlebars assembly with the two clamps and the four bolts. NOTE: Align the dot mark on the handlebars with the mat- ing surface of the front side of left clamp.

  • Page 11: Right Switch

    NOTE: • The line drawings on page 49, 50 and 51 show the proper routing of the control cables, hose and wirings. • Refer to them in addition to following the instruc- tions carefully. A: Front brake hose B: Throttle cables C: Clutch cable D: Right switch wiring harness E: Left switch wiring harness...

  • Page 12: Front Brake Master Cylinder

    FRONT BRAKE MASTER CYLINDER Install the front brake master cylinder onto the handle- bars. NOTE: • Install the holder in position according to the mark “UP”. • Align the dot mark on the handlebars with the master cylinder-to-holder fitting surface. A: Holder B: Front brake master cylinder C: 6 ×...

  • Page 13: Left Switch

    LEFT SWITCH Pass the choke cable through the hole of left switch housing. Insert the choke cable into the recess of choke lever. Fit the left switch housing to the handlebars. NOTE: Before installing the cable, grease the cable end. NOTICE Improper installing of the choke lever can dam- age the switch.

  • Page 14: Clutch Cable

    CLUTCH CABLE Pass the clutch cable through the rubber boot. A: Clutch cable B: Rubber boot Turn the clutch lever adjuster and lock nut in as far as possible and align the slots. Insert the inner cable end into the recess in the clutch lever, then pull on the outer cable housing and insert it into the adjuster.
  • Page 15 CLUTCH LEVER POSITION SWITCH LEAD WIRE AND FRONT TURN SIGNAL WIRE HARNESS Route the clutch lever position switch lead wire cor- rectly. NOTE: The routing of clutch lever position switch lead wire is the same as that of handlebar left switch wiring harness.
  • Page 16 RIGHT CLAMP Clamp the right switch wiring harness with strap. A: Strap L:120 mm B: Handlebars C: Right switch wiring harness LEFT Clamp the left switch wiring harness and clutch lever position switch lead wire with strap. A: Strap L:120 mm B: Handlebars C: Left switch wiring harness D: Clutch lever position switch lead wire...

  • Page 17: Headlight Cover

    HEADLIGHT COVER Install the headlight cover. A: Headlight cover B: Stepped washer OD:16.0 mm ID:6.5 mm T:4.5 mm C: 6 × 12 mm screw HANDLEBAR BALANCER Assemble the handlebar balancer parts as shown. A: Balancer weight B: 6 × 55 mm screw C: Washer OD:16.0 mm ID:6.5 mm T:4.0 mm D: Rubber cushion E: 6 mm spacer nut...
  • Page 18 RIGHT KNUCKLE COVER Install the right side knuckle cover correctly. A: Knuckle cover B: 5 × 10 mm screw C: Washer OD:16.0 mm ID:5.5 mm D: Washer OD:16.0 mm ID:6.5 mm E: 6 mm self-lock nut LEFT Install the left side knuckle cover correctly. A: Knuckle cover B: 6 mm crown nut C: Washer OD:20.0 mm ID:6.5 mm (Black)
  • Page 19 REAR TURN SIGNAL LIGHT (LEFT) Set the rear turn signal light at correct direction. Fit the projection on the turn signal light to the hole of turn signal light bracket. Install the turn signal light with the nut. A: Rear turn signal light B: Projection C: Bracket D: Hole...
  • Page 20 RIGHT REAR TURN SIGNAL LIGHT (RIGHT) Install the clamp to the hole of the frame. A: Clamp B: Frame C: Hole Clamp the rear turn signal lead wire and license plate light lead wire. Fix the clamp by pushing the center pin. A: Rear turn signal lead wire B: License plate light lead wire C: Clamp...

  • Page 21: Front Fender

    FRONT FENDER Fit the collared spacer into the hole of the front fender. A: Front fender B: Collared spacer OD:17.0 mm ID:6.5 mm T:6.0 mm FRONT FRONT Install the front fender to the front fork lower bracket. A: Front fender B: Collared spacer OD:17.0 mm ID:6.5 mm T:6.0 mm C: 6 ×...
  • Page 22 TAKING OUT THE MOTORCYCLE Bind a hoist band around the handlebar clamps as shown in the photograph. NOTE: Lift the motorcycle a little by using a hoist to pre- vent the motorcycle from falling down. NOTICE Binding a hoist band to the handlebar or grips can damage the motorcycle parts.

  • Page 23: Front Wheel

    FRONT WHEEL Loosen the axle holder nuts. Remove the front axle from the fork legs. A: Axle holder nut B: Front axle Mount the front wheel assembly properly. A: Right fork leg B: Speedometer drive gearbox C: Left fork leg D: Front wheel spacer E: Front axle LEFT...
  • Page 24 LEFT Attach the front wheel spacer to the front wheel hub. Carefully insert the front brake disc plate between the caliper brake pads. NOTE: • When attaching the front wheel spacer, be care- ful not to damage the oil seal lip. •...
  • Page 25 Place the motorcycle on the side-stand, then remove the hoist hook. Extract the side stand. Move the front fork up and down hard 4 or 5 times. Tighten the axle holder nuts to the specified torque.  Front axle holder nut: 10 N·m (1.0 kgf-m, 7.0 lbf-ft) NOTE: •...
  • Page 26 SPEEDOMETER CABLE GUIDE Remove the screw. Remove the speedometer cable from the speedometer drive gearbox. A: Speedometer drive gear box B: Screw C: Speedometer cable Pass the speedometer cable through the two guides. A: Speedometer cable B: Cable guide C: Cable guide Install the cable guide to the front fender.

  • Page 27: Rear View Mirror

    REAR VIEW MIRROR Install the rear view mirror and tighten lock nuts securely after positioning them properly. NOTE: 90° Set the center line of the rear view mirror stay at 90° from the center line of the motorcycle.  Rear view mirror lock nut B: 28 N·m (2.8 kgf-m, 20.0 lbf-ft) NOTE: •...
  • Page 28 FRAME COVER (RIGHT) Install the frame cover (right) after completion of ser- vicing for the battery. A: Frame cover OWNER’S MANUAL Draw out the vinyl cover A. A: Vinyl cover Store the owner’s manual A on the seat. Reinstall the vinyl cover B. Fix the owner’s manual A by using the rubber band A: Owner’s manual B: Vinyl cover...
  • Page 29 SERVICING BATTERY NOTE: The battery is located under the seat. Remove the screw B. Remove the frame cover A. A: Frame cover B: Screw, Stepped washer C: Boss (Air cleaner box) D: Hole (Frame cover grommet) E: Lug Remove the bolts B. Remove the seat A.
  • Page 30 Measure the battery voltage by using the multi circuit tester. If the voltage reading is less than 12.4 V, charge the battery with a battery charger. NOTE: • For charging the battery, make sure to use the charger specially designed for MF battery. (If there is not MF battery charger be charged from current and time described in the battery) Otherwise, the battery may be overcharged...
  • Page 31 Please charge complementary regularly. Battery voltage (In the ambient temperature 25°C every three months.) NOTE: 5°C (41 °F) Different according to a storage state. 25°C (77 °F) 12.4 40°C (104 °F) Charge fully at the time of a voltage check regularly not to be less than 12.4V during a storage.
  • Page 32 Charge the battery before delivering to a customer. After charging the battery, install the battery in the motorcycle as follows. NOTICE Connecting the battery lead wires with the igni- tion switch ON can damage the motorcycle. Turn off the ignition switch before connecting or disconnecting the battery lead wires.
  • Page 33 NOTE: • Check the rubber cushions are installed in the correct position before installing the battery. • When installing the battery, be careful not to peel off the rubber cushion. A: Rubber cushion B: Battery box 1. Temporarily remove the terminal bolts from the bat- tery terminals.
  • Page 34 Reinstall the battery holder A. A: Battery holder B: Bolt Reinstall the seat A. Insert the seat hook B into the seat hook retainer C. A: Seat assembly B: Seat hook C: Seat hook retainer Tighten the bolts B. A: Seat B: Bolt...
  • Page 35 FRAME COVER (RIGHT AND LEFT) Install the rubber cushion to the frame cover (right). A: Frame cover (Right) B: Rubber cushion INSIDE Insert the hole of the frame cover to the boss of the air cleaner box. Insert the lug at the rear end of the frame cover between the rear fender and frame.

  • Page 36: Brake Fluid

    FRONT REAR BRAKE FLUID Hold the motorcycle vertically and keep the handlebars straight. Check the brake fluid level in both the front and rear LOWER LOWER UPPER UPPER master cylinder reservoirs. If the fluid level is below the “LOWER” level, add the correct type of brake fluid.
  • Page 37 FRONT BRAKE AIR BLEEDING Any air which may have been trapped in the brake fluid circuit must be bled completely. If the brake lever or brake pedal feels spongy or weak, then most likely there is air in the brake fluid circuit. If air bleed is necessary, carry out the following proce- dure.

  • Page 38: Throttle Cable

    THROTTLE CABLE This motorcycle has a twin throttle cable system. Cable A is for pulling cable and cable B is for return- ing. Check the free play in the throttle cable. Throttle cable play: 0.5–1.0 mm (0.02–0.04 in) If adjustment is necessary, carry out the following pro- cedure.

  • Page 39: Rear Brake Pedal

    CLUTCH CABLE Check the clutch lever play at the clutch lever end when squeezing the lever until pressure is felt. Clutch lever play: 10–15 mm (0.4–0.6 in) NOTE: Minor adjustments can now be made with the clutch lever adjuster A. If adjustment is necessary, carry out the following pro- cedure.

  • Page 40: Drive Chain

    DRIVE CHAIN Check the drive chain slack. Drive chain slack: 30–45 mm (1.2–1.8 in) If adjustment is necessary, carry out the following pro- cedure. 1. Loosen the axle nut. 2. Adjust the slack in the drive chain by turning the right and left chain adjuster.

  • Page 41: Front Suspension

    FRONT SUSPENSION Move the front forks up and down several times. Inspect for smooth movement and oil leakage. REAR SUSPENSION Move the rear suspension up and down several times. Inspect for smooth movement and oil leakage.

  • Page 42: Tire Pressure

    TIRE PRESSURE Check the air pressure of the front and rear tires by using an accurate air gauge. The pressure should be as indicated in the table below. COLD INFLATION TIRE PRESSURE SOLO RIDING DUAL RIDING 150 kPa 175 kPa FRONT 1.50 kgf/cm 1.75 kgf/cm...

  • Page 43: Spoke Nipple

    SPOKE NIPPLE Check the tension to verify the tightness of the spoke nipples. The tension of the spokes can be checked by squeezing the spokes with your fingers. If a spoke nip- ple is loose, the spoke will bend more than the others. Retighten the spoke nipples with a spoke nipple wrench so as all spokes have same tension.

  • Page 44: Engine Oil

    ENGINE OIL NOTE: This motorcycle is shipped from factory with the engine filled with engine oil. NOTICE Operating the engine with too little or too much oil can damage the engine. Hold the motorcycle vertically. Check the oil level with the engine oil level inspection win- dow before each use of the motorcycle.
  • Page 45 Engine oil Suzuki recommends the use of SAE 10W-40 engine oil. Oil quality is a major contributor to your engine’s per- formance and life. Always select good quality engine oil. Suzuki recommends the use of SUZUKI GENUINE MOTOR OIL or equivalent engine oil.

  • Page 46: Idle Speed Adjustment

    IDLE SPEED ADJUSTMENT Check the engine idle speed. Engine idle speed: 1 400–1 600 r/min NOTE: If the engine idle speed is not within the specified range, inspect and repair the motorcycle following Service Manual indication. GENERATOR COVER Check the tightening torque of generator cover bolt. ...

  • Page 47: Clutch Cover

    CLUTCH COVER Check the tightening torque of clutch cover bolt.  Clutch cover bolt: 10 N·m (1.0 kgf-m, 7.0 lbf-ft) FUEL NOTE: • Use only unleaded gasoline of at least 87 pump octane (R/2+M/2 method). • Oxygenated fuel can be used, if the ethanol (grain alcohol) contain is not greater than 10%.

  • Page 48: Tightening Torque List

    TIGHTENING TORQUE TIGHTENING TORQUE LIST Item Part Name N·m kgf-m lbf-ft Item Part Name N·m kgf-m lbf-ft FRONT FORK BRAKE Handlebar clamp bolt 16.5 Rear brake push rod lock nut 13.0 Handlebar holder nut 18.0 Brake caliper air bleeder valve 0.75 Steering stem head nut 65.0...

  • Page 49: Tightening Torque Chart

    TIGHTENING TORQUE CHART Thread diameter Unit Bolt type (Nominal diameter) N·m kgf-m lbf-ft “A” [mm] 0.15 0.30 0.55 21.0 32.5 47.0 10.5 76.0 A equivalent of 4T strength bolt without flange 16.0 115.5 Thread diameter Unit Bolt type (Nominal diameter) N·m kgf-m lbf-ft...

  • Page 50: Cable Routing

    CABLE ROUTING Throttle cables Choke cable Front fender Front brake hose Clip Clutch cable Cable guide Speedometer cable Throttle cables Front brake hose Front brake hose Clutch cable Choke cable Clamp Clutch cable Guide Clamp Clamp Clamp...

  • Page 51: Harness Routing

    HARNESS ROUTING Pass the clutch cable over the wiring harness. Clamp Clamp Handlebar switch lead wire (R) Handlebar switch lead wire (L) Clutch lever position switch lead wire Choke cable Front turn signal lead wire Headlight socket cover Clutch cable Wiring harness Throttle cables Front turn signal lead wire...
  • Page 52 Clamp Clamp Wiring harness Wiring harness Clutch cable Generator lead wire Throttle cable Neutral switch lead wire Choke cable Rear brake switch lead wire Clamp Wiring harness Clutch cable Guide Starter motor Neutral switch lead wire Rear brake switch lead wire Horn White tape Battery - lead wire...

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