Suzuki DL650K5 Manuals

Manuals and User Guides for Suzuki DL650K5. We have 1 Suzuki DL650K5 manual available for free PDF download: Service Manual

Suzuki DL650K5 Service Manual

Suzuki DL650K5 Service Manual (702 pages)

Brand: Suzuki | Category: Motorcycle | Size: 25.14 MB
Table of contents
General Information1................................................................................................................................................................
Periodic Maintenance1................................................................................................................................................................
Electrical System1................................................................................................................................................................
Servicing Information1................................................................................................................................................................
Emission Control Information1................................................................................................................................................................
How To Use This Manual4................................................................................................................................................................
Abbreviations Used In This Manual6................................................................................................................................................................
Table Of Contents11................................................................................................................................................................
General Precautions12................................................................................................................................................................
Serial Number Location14................................................................................................................................................................
Suzuki Dl650k4 ('04-model)14................................................................................................................................................................
Fuel, Oil And Engine Coolant Recommendation14................................................................................................................................................................
Fuel (for Usa And Canada)14................................................................................................................................................................
Fuel (for Other Countries)14................................................................................................................................................................
Brake Fluid15................................................................................................................................................................
Front Fork Oil15................................................................................................................................................................
Engine Oil (for Usa)15................................................................................................................................................................
Engine Oil (for Other Countries)15................................................................................................................................................................
Water For Mixing15................................................................................................................................................................
Anti-freeze/engine Coolant16................................................................................................................................................................
Liquid Amount Of Water/engine Coolant16................................................................................................................................................................
Break-in Procedures16................................................................................................................................................................
Cylinder Identification17................................................................................................................................................................
Information Labels18................................................................................................................................................................
Specifications19................................................................................................................................................................
Dimensions And Dry Mass19................................................................................................................................................................
Drive Train19................................................................................................................................................................
Country And Area Codes21................................................................................................................................................................
Periodic Maintenance Schedule24................................................................................................................................................................
Periodic Maintenance Chart24................................................................................................................................................................
Lubrication Points26................................................................................................................................................................
Air Cleaner27................................................................................................................................................................
Spark Plug28................................................................................................................................................................
Valve Clearance30................................................................................................................................................................
Fuel Line35................................................................................................................................................................
Engine Oil And Oil Filter35................................................................................................................................................................
Engine Idle Speed37................................................................................................................................................................
Throttle Valve Synchronization38................................................................................................................................................................
Cooling System40................................................................................................................................................................
Drive Chain42................................................................................................................................................................
Front Fork49................................................................................................................................................................
Rear Suspension49................................................................................................................................................................
Chassis Bolt And Nut50................................................................................................................................................................
Compression Pressure Check52................................................................................................................................................................
Compression Test Procedure52................................................................................................................................................................
Oil Pressure Check53................................................................................................................................................................
Engine Components Removable With The Engine In Place56................................................................................................................................................................
Engine Removal And Installation57................................................................................................................................................................
Engine Removal57................................................................................................................................................................
Engine Installation65................................................................................................................................................................
Engine Disassembly73................................................................................................................................................................
Engine Bottom Side80................................................................................................................................................................
Engine Components Inspection And Servicing90................................................................................................................................................................
Cylinder Head Cover90................................................................................................................................................................
Camshaft/camshaft Journal91................................................................................................................................................................
Camshaft Runout93................................................................................................................................................................
Cylinder Head94................................................................................................................................................................
Piston And Piston Ring105................................................................................................................................................................
Piston Ring Groove Width106................................................................................................................................................................
Piston Ring Thickness106................................................................................................................................................................
Conrod And Crankshaft107................................................................................................................................................................
Crankshaft Journal Bearing115................................................................................................................................................................
Crankcase Bearing And Oil Seal120................................................................................................................................................................
Primary Driven Gear Assembly124................................................................................................................................................................
Gearshift Shaft/gearshift Arm125................................................................................................................................................................
Starter Clutch133................................................................................................................................................................
Generator And Signal Generator134................................................................................................................................................................
Oil Pump135................................................................................................................................................................
Engine Reassembly136................................................................................................................................................................
Engine Top Side148................................................................................................................................................................
Engine Coolant161................................................................................................................................................................
Precautions In Servicing166................................................................................................................................................................
Electrical Parts166................................................................................................................................................................
Ecm/various Sensors167................................................................................................................................................................
Electrical Circuit Inspection Procedure169................................................................................................................................................................
Using Testers172................................................................................................................................................................
Fi System Technical Features173................................................................................................................................................................
Injection Time (injection Volume)173................................................................................................................................................................
Compensation Of Injection Time (volume)174................................................................................................................................................................
Injection Stop Control174................................................................................................................................................................
Fi System Parts Location175................................................................................................................................................................
Fi System Wiring Diagram177................................................................................................................................................................
Self-diagnosis Function178................................................................................................................................................................
User Mode178................................................................................................................................................................
Dealer Mode179................................................................................................................................................................
Tps Adjustment180................................................................................................................................................................
Fi System Troubleshooting182................................................................................................................................................................
Customer Complaint Analysis182................................................................................................................................................................
Self-diagnostic Procedures184................................................................................................................................................................
Self-diagnosis Reset Procedure184................................................................................................................................................................
Malfunction Code And Defective Condition185................................................................................................................................................................
C12" Ckp Sensor Circuit Malfunction187................................................................................................................................................................
C13" Iap Sensor Circuit Malfunction189................................................................................................................................................................
C14" Tp Sensor Circuit Malfunction192................................................................................................................................................................
C15" Ect Sensor Circuit Malfunction195................................................................................................................................................................
C21" Iat Sensor Circuit Malfunction197................................................................................................................................................................
C23" To Sensor Circuit Malfunction199................................................................................................................................................................
C24" Or "c25" Ignition System Malfunction200................................................................................................................................................................
C28" Stv Actuator Circuit Malfunction201................................................................................................................................................................
C29" Stp Sensor Circuit Malfunction202................................................................................................................................................................
C31" Gear Position (gp) Switch Circuit Malfunction205................................................................................................................................................................
C32" Or "c33" Fuel Injector Circuit Malfunction206................................................................................................................................................................
C41" Fp Relay Circuit Malfunction208................................................................................................................................................................
C42" Ig Switch Circuit Malfunction208................................................................................................................................................................
C44" Ho2 Sensor (ho2s) Circuit Malfunction (e)211................................................................................................................................................................
Ckp Sensor Inspection213................................................................................................................................................................
Iap Sensor Inspection213................................................................................................................................................................
Tp Sensor Inspection213................................................................................................................................................................
Tp Sensor Removal And Installation213................................................................................................................................................................
Ect Sensor Inspection213................................................................................................................................................................
Iat Sensor Inspection214................................................................................................................................................................
Fuel System216................................................................................................................................................................
Fuel Delivery System216................................................................................................................................................................
Fuel Pump217................................................................................................................................................................
Fuel Pressure Regulator219................................................................................................................................................................
Fuel Injector219................................................................................................................................................................
Fuel Pump Control System220................................................................................................................................................................
Fuel Tank Removal221................................................................................................................................................................
Fuel Tank Lift-up221................................................................................................................................................................
Fuel Pressure Inspection222................................................................................................................................................................
Fuel Pump Inspection223................................................................................................................................................................
Fuel Pump Relay Inspection224................................................................................................................................................................
Fuel Pump And Fuel Filter Removal224................................................................................................................................................................
Fuel Mesh Filter Inspection And Cleaning226................................................................................................................................................................
Fuel Pump And Fuel Mesh Filter Installation226................................................................................................................................................................
Throttle Body And Stv Actuator228................................................................................................................................................................
Air Cleaner And Throttle Body Removal229................................................................................................................................................................
Throttle Body Disassembly232................................................................................................................................................................
Throttle Body Cleaning236................................................................................................................................................................
Throttle Body Reassembly237................................................................................................................................................................
Stv Synchronization241................................................................................................................................................................
Air Cleaner Box Installation242................................................................................................................................................................
Tp Sensor Adjustment243................................................................................................................................................................
Fast Idle Inspection244................................................................................................................................................................
Fast Idle Adjustment245................................................................................................................................................................
Cooling Circuit253................................................................................................................................................................
Cooling Circuit Inspection253................................................................................................................................................................
Inspection And Cleaning256................................................................................................................................................................
Radiator Cap257................................................................................................................................................................
Water Hose257................................................................................................................................................................
Cooling Fan258................................................................................................................................................................
Cooling Fan Thermo-switch259................................................................................................................................................................
Ect Sensor260................................................................................................................................................................
Thermostat Case Assembly262................................................................................................................................................................
Water Pump264................................................................................................................................................................
Reassembly And Installation267................................................................................................................................................................
Lubrication System270................................................................................................................................................................
Oil Pressure270................................................................................................................................................................
Oil Pressure Regulator270................................................................................................................................................................
Oil Strainer270................................................................................................................................................................
Oil Jet270................................................................................................................................................................
Oil Cooler271................................................................................................................................................................
Engine Lubrication Flow Chart273................................................................................................................................................................
Oil Pan273................................................................................................................................................................
Engine Lubrication Circuit274................................................................................................................................................................
Exterior Parts278................................................................................................................................................................
Front Wheel285................................................................................................................................................................
Removal And Disassembly293................................................................................................................................................................
Suspension Setting301................................................................................................................................................................
Steering And Handlebar302................................................................................................................................................................
Steering Tension Adjustment310................................................................................................................................................................
Rear Wheel311................................................................................................................................................................
Rear Shock Absorber320................................................................................................................................................................
Rear Shock Absorber Disposal322................................................................................................................................................................
Rear Swingarm325................................................................................................................................................................
Final Inspection And Adjustment333................................................................................................................................................................
Front Brake334................................................................................................................................................................
Brake Pad Replacement335................................................................................................................................................................
Brake Fluid Replacement336................................................................................................................................................................
Caliper Removal And Disassembly337................................................................................................................................................................
Caliper Inspection338................................................................................................................................................................
Brake Disc Inspection341................................................................................................................................................................
Master Cylinder Inspection342................................................................................................................................................................
Master Cylinder Reassembly And Remounting343................................................................................................................................................................
Rear Brake344................................................................................................................................................................
Service Limit350................................................................................................................................................................
Tire And Wheel355................................................................................................................................................................
Tire Removal355................................................................................................................................................................
Valve Installation356................................................................................................................................................................
Tire Installation357................................................................................................................................................................
Tire Pressure358................................................................................................................................................................
Drive Chain Cutting359................................................................................................................................................................
Drive Chain Connecting360................................................................................................................................................................
Cautions In Servicing364................................................................................................................................................................
Connecting The Battery365................................................................................................................................................................
Semi-conductor Equipped Part365................................................................................................................................................................
Wiring Procedure365................................................................................................................................................................
Using The Multi Circuit Tester366................................................................................................................................................................
Location Of Electrical Components367................................................................................................................................................................
Charging System369................................................................................................................................................................
Trouble Shooting374................................................................................................................................................................
Starter Motor Removal And Disassembly376................................................................................................................................................................
Starter Motor Inspection377................................................................................................................................................................
Starter Motor Reassembly378................................................................................................................................................................
Starter Relay Inspection381................................................................................................................................................................
Ignition System385................................................................................................................................................................
Troubleshooting385................................................................................................................................................................
Combination Meter391................................................................................................................................................................
Starter Relay399................................................................................................................................................................
Turn Signal/side-stand Relay399................................................................................................................................................................
Fuel Pump Relay399................................................................................................................................................................
Initial Charging402................................................................................................................................................................
Recharging Operation404................................................................................................................................................................
Radiator (cooling System)414................................................................................................................................................................
Wire Harness, Cable And Hose Routing420................................................................................................................................................................
Engine Electrical Parts Set-up423................................................................................................................................................................
Speed Sensor Lead Wire Routing424................................................................................................................................................................
Throttle Cable Routing425................................................................................................................................................................
Clutch Cable Routing426................................................................................................................................................................
Throttle Body Installation/hose Routing427................................................................................................................................................................
Cooling System Hose Routing428................................................................................................................................................................
Front Brake Hose Routing430................................................................................................................................................................
Rear Brake Hose Routing431................................................................................................................................................................
Fuel Tank Drain Hose Routing432................................................................................................................................................................
Fuel Tank Installation433................................................................................................................................................................
Seat Lock Cable Routing435................................................................................................................................................................
Head Lamp Set-up435................................................................................................................................................................
Absorber Hose Routing436................................................................................................................................................................
Battery Cushion Installation436................................................................................................................................................................
Side-stand Set-up437................................................................................................................................................................
Brake Pedal/footrest Set-up437................................................................................................................................................................
Engine Cap Installation438................................................................................................................................................................
Footrest Set-up439................................................................................................................................................................
Handlebar Balancer Installation439................................................................................................................................................................
Special Tools440................................................................................................................................................................
Tightening Torque444................................................................................................................................................................
Fi System Parts445................................................................................................................................................................
Tightening Torque Chart447................................................................................................................................................................
Service Data448................................................................................................................................................................
Throttle Body454................................................................................................................................................................
Emission Control Systems462................................................................................................................................................................
Fuel Injection System462................................................................................................................................................................
Crankcase Emission Control System463................................................................................................................................................................
Noise Emission Control System465................................................................................................................................................................
Pair (air Supply) System Inspection466................................................................................................................................................................
Pair Reed Valve466................................................................................................................................................................
Pair Control Solenoid Valve467................................................................................................................................................................
Heated Oxygen Sensor (ho2s) Wire Routing (e)468................................................................................................................................................................
Evaporative Emission Control System Inspection470................................................................................................................................................................
Only For E470................................................................................................................................................................
Evap Canister470................................................................................................................................................................
Fuel-shut Off Valve470................................................................................................................................................................
Evap Canister Hose Routing (only For E)471................................................................................................................................................................
Emission Control System503................................................................................................................................................................
Specifications (dl650k)511................................................................................................................................................................
Specifications (dl650ak)513................................................................................................................................................................
Maintenance And Tune-up Procedures516................................................................................................................................................................
Throttle Cable Play518................................................................................................................................................................
Ecm Terminal519................................................................................................................................................................
Dtc Table And Defective Condition521................................................................................................................................................................
Dtc Troubleshooting524................................................................................................................................................................
For E544................................................................................................................................................................
Fuel Discharge Amount Inspection548................................................................................................................................................................
Fuel Pump Removal And Disassembly550................................................................................................................................................................
Air Cleaner Box And Throttle Body Installation562................................................................................................................................................................
Stp Sensor Adjustment563................................................................................................................................................................
Isc Valve567................................................................................................................................................................
Fuel Level Meter Inspection571................................................................................................................................................................
Introduction Of Abs (for Dl650a)572................................................................................................................................................................
Abs Components579................................................................................................................................................................
Abs Components Location579................................................................................................................................................................
Abs Coupler Connection Diagram580................................................................................................................................................................
Abs Wiring Diagram581................................................................................................................................................................
Abs Unit System Diagram582................................................................................................................................................................
Abs Troubleshooting583................................................................................................................................................................
Troubleshooting Procedure584................................................................................................................................................................
Dtc Deleting And Abs Operation Check595................................................................................................................................................................
Sds Check597................................................................................................................................................................
Use Of Sds Diagnostic Procedures598................................................................................................................................................................
Use Of Sds Diagnosis Reset Procedure599................................................................................................................................................................
Dtc Table Of Abs605................................................................................................................................................................
Wire Harness Routing632................................................................................................................................................................
Throttle Body Installation640................................................................................................................................................................
Battery Protector Installation644................................................................................................................................................................

Advertisement

Share and save

Advertisement