Suzuki 2004 DL650K4 Manuals

Manuals and User Guides for Suzuki 2004 DL650K4. We have 1 Suzuki 2004 DL650K4 manual available for free PDF download: Service Manual

Suzuki 2004 DL650K4 Service Manual

Suzuki 2004 DL650K4 Service Manual (467 pages)

Brand: Suzuki | Category: Motorcycle | Size: 21.35 MB

Table of Contents

Table of Contents

10
- Component Parts
  3
- Glossary
  5
- Wire Color
  9
- Warningka Ution/Note
  11
- General Precautions
  11
- Serial Number Location
  13
- Fuel. Oil and Engine Coolant Recommendation
  13
  - Fuel (for Usa and Canada)
    13
  - Fuel (for Other Countries)
    13
  - Engine Oil (for Usa)
    14
  - Engine Oil (for Other Countries)
    14
  - Brake Fluid
    14
  - Front Fork Oil
    14
  - Engine Coolant
    14
  - Water for Mixing
    14
  - Anti-Freezwengine Coolant
    15
  - Liquid Amount of Watewengine Coolant
    15
- Break-In Procedures
  15
- Cylinder Identification
  16
- Information Labels
  17
- Specifications
  18
  - Dimensions and Dry Mass
    18
  - Engine
    18
  - Drive Train
    18
  - Chassis
    19
  - Electrical
    19
  - Capacities
    19
- Country and Area Codes
  20
Table of Contents

21
- Periodic Maintenance Schedule
  22
  - Periodic Maintenance Chart
    22
  - Lubrication Points
    24
- Maintenance and Tune-Up Procedures
  25
  - Air Cleaner
    25
  - Spark Plug
    26
  - Valve Clearance
    28
  - Fuel Line
    33
  - Engine Oil and Oil Filter
    33
  - Engine Idle Speed
    35
  - Throttle Cable Play
    35
  - Throttle Valve Synchronization
    36
  - Evaporative Emission Control System (E-33 Only)
    36
  - Pair (Air Supply) System
    36
  - Clutch
    37
  - Cooling System
    38
  - Brake
    42
  - Tire
    46
  - Steering
    46
  - Front Fork
    47
  - Rear Suspension
    47
  - Exhaust Pipe Bolt
    47
  - Chassis Bolt and Nut
    48
- Compression Pressure Check
  50
  - Compression Test Procedure
    50
- Oil Pressure Check
  51
Table of Contents

52
- Engine Components Removable with the Engine in Place
  53
- Engine Removal and Installation
  54
  - Engine Removal
    54
  - Engine Installation
    62
- Engine Disassembly
  70
  - Engine Top Side
    70
  - Engine Bottom Side
    77
- Engine Components Inspection and Servicing
  87
  - Cylinder Head Cover
    87
  - Camshaftkamshaft Journal
    88
  - Cylinder Head
    91
  - Cylinder
    101
  - Piston and Piston Ring
    102
  - Conrod and Crankshaft
    104
  - Crankcase
    108
  - Crankshaft Journal Bearing
    112
  - Crankcase Bearing and Oil Seal
    117
  - Clutch
    120
  - Primary Driven Gear Assembly
    121
  - Gearshift Shaftigearshift Arm
    122
  - Transmission
    123
  - Starter Clutch
    130
  - Generator and Signal Generator
    131
  - Oil Pump
    132
  - Clutch Release
    132
- Engine Reassembly
  133
  - Engine Bottom Side
    133
  - Engine Top Side
    145
  - Front Cylinde TDC of Compression Stroke
    156
Table of Contents

160
- Precautions in Servicing
  162
  - Electrical Parts
    162
  - Fuse
    163
  - Ecmnarious Sensors
    163
  - Electrical Circuit Inspection Procedure
    165
  - Using Testers
    168
- Fi System Technical Features
  169
  - Injection Time (Injection Volume)
    169
  - Compensation of Injection Time (Volume)
    170
  - Injection Stop Control
    170
  - Fi System Parts Location
    171
- Self-Diagnosis Function
  174
  - User Mode
    174
  - Dealer Mode
    175
  - Tps Adjustment
    176
- Fail-Safe Function
  177
- Fi System Troubleshooting
  178
Table of Contents

245
- Engine Coolant
  247
- Cooling Circuit
  248
  - Cooling Circuit Inspection
    248
  - Removal
    249
  - Inspection and Cleaning
    251
  - Installation
    251
- Radiator Cap
  252
  - Inspection
    252
- Water Hose
  252
- Cooling Fan
  253
  - Inspection
    253
  - Removal
    253
  - Installation
    253
- Cooling Fan Thermo-Switch
  254
  - Inspection
    254
  - Installation
    254
- Ect Sensor
  255
  - Removal
    255
  - Inspection
    255
  - Installation
    256
- Thermostat Case Assembly
  257
  - Removal
    257
  - Inspection
    257
  - Installation
    258
- Water Pump
  259
  - Removal and Disassembly
    259
  - Inspection
    261
  - Reassembly and Installation
    262
- Lubrication System
  265
  - Oil Pressure
    265
  - Oil Filter
    265
  - Oil Pressure Regulator
    265
  - Oil Strainer
    265
  - Oil Jet
    265
  - Oil Pump
    265
  - Oil Pressure Switch
    265
- Oil Cooler
  266
  - Removal
    266
  - Inspection and Cleaning
    266
  - Installation
    267
- Engine Lubrication Flow Chart
  268
- Engine Lubrication Circuit
  269
Table of Contents

271
- Construction
  272
- Removal
  275
- Installation
  279
- Front Wheel
  280
  - Removal
    281
  - Inspection and Disassembly
    281
  - Reassembly and Remounting
    283
- Front Fork
  287
  - Construction
    287
  - Removal and Disassembly
    288
  - Reassembly and Remounting
    292
  - Suspension Setting
    296
- Steering and Handlebar
  297
  - Construction
    297
  - Removal
    298
  - Inspection and Disassembly
    301
  - Reassembly and Remounting
    302
  - Steering Tension Adjustment
    305
- Rear Wheel
  306
  - Construction
    306
  - Removal
    307
  - Inspection and Disassembly
    308
  - Reassembly and Remounting
    311
- Rear Shock Absorber
  315
  - Removal
    316
  - Inspection
    317
  - Rear Shock Absorber Disposal
    317
  - Remounting
    318
  - Suspension Setting
    319
- Rear Swingarm
  320
  - Removal
    321
  - Inspection and Disassembly
    322
  - Reassembly
    325
  - Final Inspection and Adjustment
    328
- Front Brake
  329
  - Brake Pad Replacement
    330
  - Brake Fluid Replacement
    331
  - Caliper Removal and Disassembly
    332
  - Caliper Inspection
    333
  - Caliper Reassembly and Remounting
    334
  - Brake Disc Inspection
    336
  - Master Cylinder Removal and Disassembly
    336
  - Master Cylinder Inspection
    337
  - Master Cylinder Reassembly and Remounting
    338
- Rear Brake
  339
  - Brake Pad Replacement
    340
  - Brake Fluid Replacement
    342
  - Caliper Removal and Disassembly
    342
  - Caliper Inspection
    344
  - Brake Disc Inspection
    345
  - Caliper Reassembly and Remounting
    345
  - Master Cylinder Removal and Disassembly
    346
  - Master Cylinder Inspection
    348
  - Master Cylinder Reassembly and Remounting
    348
  - Inspection
    350
  - Valve Installation
    351
  - Tire Installation
    352
- Drive Chain
  354
  - Drive Chain Cutting
    354
  - Drive Chain Connecting
    355
Table of Contents

358
- Cautions in Servicing
  359
  - Connector
    359
  - Fuse
    359
  - Semi-Conductor Equipped Part
    360
  - Battery
    360
  - Connecting the Battery
    360
  - Wiring Procedure 8
    360
- Location of Electrical Components
  362
- Charging System
  364
  - Trouble Shooting
    364
  - Inspection
    366
- System
  369
  - Trouble Shooting
    369
  - Starter Motor Removal and Disassembly
    371
  - Starter Motor Inspection
    372
  - Starter Motor Reassembly
    373
  - Starter Relay Inspection
    376
  - Inspection
    377
- Ignition System
  380
  - Troubleshooting
    380
  - Inspection
    382
- Combination Meter
  386
  - Removal and Disassembly
    386
  - Inspection
    387
  - Indicators
    389
- Lamps
  393
  - Relays
    394
  - Turn Signauside-Stand Relay
    394
  - Starter Relay
    394
  - Fuel Pump Relay
    394
  - Switches
    395
  - Inspection
    396
- Battery
  397
  - Specifications
    397
  - Initial Charging
    397
  - Servicing
    399
  - Recharging Operation
    399
Table of Contents

400
- Troubleshooting
  401
  - Malfunction Code and Defective Condition
    401
  - Engine
    403
  - Radiator (Cooling System)
    409
  - Chassis
    410
  - Brakes
    411
  - Battery
    414
  - Speed Sensor Lead Wire Routing
    419
  - Throttle Cable Routing
    420
  - Clutch Cable Routing
    421
  - Throttle Body Installationihose Routing
    422
  - Cooling System Hose Routing
    423
  - Front Brake Hose Routing
    425
  - Fuel Tank Drain Hose Routing
    427
  - Fuel Tank Installation
    428
  - Pair (Air Supply) System Hose Routing
    429
  - Seat Lock Cable Routing
    430
  - Absorber Hose Routing
    431
  - Battery Cushion Installation
    431
  - Side-Stand Set-Up
    432
  - Brake Pedaufootrest Set-Up
    432
  - Engine Cap Installation
    433
  - Footrest Set-Up
    434
  - Handlebar Balancer Installation
    434
  - Special Tools
    435
- Tightening Torque
  439
  - Fi System Parts
    440
  - Chassis
    441
  - Tightening Torque Chart
    442
- Service Data
  443
  - Emission Control Systems
    456
  - Fuel Injection System
    456
  - Crankcase Emission Control System
    457
  - Exhaust Emission Control System (Pair System)
    458
  - Noise Emission Control System
    459
  - EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33)
    459
  - Hoses
    460
  - Pair Control Solenoid Valve
    461
  - Pair (Air Supply) System Hose Routing
    462
  - Heated Oxygen Sensor (H02S) Wire Routing (E-02,19)
    462
  - (Only for E-33)
    464
  - Hoses
    464
  - Evap Canister
    465

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