User Manuals: Suzuki DR650S Dual-Sport Motorcycle

Manuals and User Guides for Suzuki DR650S Dual-Sport Motorcycle. We have 1 Suzuki DR650S Dual-Sport Motorcycle manual available for free PDF download: Service Manual

Suzuki DR650S Service Manual (188 pages)

Brand: Suzuki | Category: Motorcycle | Size: 26 MB

Group Index
2
View of DR650S
3
Left Side
3
Right Side
3
General Information
4
Serial Number Locations
5
Fuel and Oil Recommendations
5
Engine Oil
6
Front Fork Oil
6
Brake Fluid
6
Break-In Procedures
6
Special Materials
7
Precautions and General Instructions
9
Replacement Parts
9
Country of Area
10
Specifications
11
Periodic Maintenance and Tune-Up Procedures
12
Periodic Maintenance Schedule
13
Periodic Maintenance Chart
13
Lubrication Points
14
Maintenance and Tune-Up Procedures
15
Battery
15
Cylinder Head
16
Exhaust Pipe and Muffler
16
Air Cleaner Element
17
Valve Clearance
18
De-Compression Lever
19
Spark Plugs
19
Fuel Line
20
Engine Oil and Oil Filter
21
Necessary Amount of Engine Oil
21
Carburetor
22
Throttle Cable Play
22
Idle R/Min Adjustment
22
Idle R/Min
22
Clutch
23
Drive Chain
24
Brakes
25
Brake Fluid Level
25
Brake Pads
26
Brake Pedal Height
26
Rear Brake Light Switch
26
Bleeding Air from the Brake Fluid Circuit
27
Tires
28
Tire Tread Condition
28
Tire Pressure
28
Steering
29
Front Fork
29
Rear Suspension
29
Air Pressure Servicing
29
Chassis Bolts and Nuts
30
Engine
32
Engine Components Removable with the Engine in Place
33
Engine Removal
34
Engine Reinstallation
34
Engine Disassembly
37
Engine Components Inspection and Servicing
44
Cylinder Head Cover Servicing
44
Cylinder Head Cover Distortion
45
Rocker Arm Shaft O.D.
45
Rocker Arm I.D.
45
Rocker Arm and Shaft Reassembly
46
De-Comp. Shaft Reassembly
46
Cylinder Head Servicing
46
Cylinder Head Distortion
47
Valve Face Wear
47
Valve Stem Runout
48
Valve Head Radial Runout
48
Valve Guide - Valve Stem Clearance
48
Valve Stem Wear
48
Valve Guide Servicing
49
Valve and Seat Condition
50
Valve Seat Width
50
Valve Seat Servicing
50
Valev Stem End Condition
51
Valve Springs
52
Valve and Valve Spring Reassembly
52
Camshaft
53
Camshaft Cam Wear
53
Camshaft Journal Wear
53
Camshaft Runout
54
Cam Drive Chain and Balancer Drive Chain 20-Pitch Length
54
Cylinder Distortion
54
Cylinder Bore
54
Piston Diameter
55
Piston-Cylinder Clearance
55
Piston Ring-Groove Clearance
55
Piston Ring Free End Gap and Piston Ring End Gap
56
Oversize Rings
56
Piston Pin and Pin Bore
56
Conrod Small End I.D.
57
Conrod Deflection and Conrod Big End Side Clearance
57
Crankshaft Runout
58
Clutch Drive Plate
58
Clutch Driven Plate
58
Clutch Spring Free Length
58
Clutch Release Bearing
59
Clutch Release Pinion and Rack
59
Primary Driven Gear Ass'y
59
Balancer Drive Chain Tensioner
59
Kick Starter
60
Transmission
62
3Nd Drive Gear Disassembly
62
Countershaft and Driveshaft
63
Shift Fork-Groove Clearance
65
3Nd Drive Gear
65
3Rd Driven Gear Bushing
65
Crankcase Bearings
66
Engine Reassembly
67
Oil Seals
67
Crankshaft
68
Balancer Shaft
69
Gearshift Mechanism
69
Crankcase
71
Cam Driven Gear
71
Gearshift Shaft
72
Balancer
72
Magneto
74
Oil Pump
74
Cam Drive Sprocket
75
Primary Drive Gear
75
Oil Filter
77
Oil Sump Filter
78
Oil Ring
78
Top Ring and 2Nd Ring
79
Piston
79
Cylinder
80
Cylinder Head Cover
83
Cam Drive Chain Tensioner
84
Oil Return Pipe
85
Intake Pipe
85
Valve Inspection Cap and Cam Timing Inspection Cap
85
Cylinder Head Cover Bolt
86
Fuel and Lubrication System
88
Fuel Cock Removal
89
Fuel Cock Inspection and Cleaning
89
Fuel Line Inspection
89
Carburetor Construction
90
Carburetor Specifications
91
I.D. No. Location
92
Needle Valve Inspection
93
Float Height Adjustment
93
Lubrication System and Cooling System
94
Oil Pressure
94
Oil Pressure Specification
94
Oil Cooler
95
Engine Lubrication/Cylinder Head Cooling System Chart
96
Electrical System
97
Ignition System Description
98
Ignition System Inspection
98
Magneto Coil
98
Ignition Coil
98
Checking with Electro Tester
99
Charging System Description
100
Function of Regulator
100
Charging Output Check
101
AC Generator No-Load Performance
102
AC Generator Continuity Check
102
Lamps
103
Headlight
103
Turn Signal Light
104
Tail/Brake Light and License Light
104
Combination Meter
105
Switches
106
Battery Specifications
107
Initial Charging
107
Battery Servicing
108
Charging Time
108
Confirmation for Date of Manufacture
108
Recharging Operation Based on S.G. Reading
109
Service Life
109
Chassis
110
Front Wheel
111
Wheel Bearing
112
Axle Shaft
112
Wheel Rim
113
Spoke Nipple
113
Front Brake
115
Brake Pad Replacement
116
Caliper Removal and Disassembly
116
Caliper and Disc Inspection
117
Caliper Reassembly
118
Master Cylinder Removal and Disassembly
118
Master Cylinder Inspection
119
Master Cylinder Reassembly and Remounting
119
Fork Spring
122
Inner Tube and Outer Tube
122
Damper Rod Ring
122
Inner Tube Metal
122
Outer Tube Metal, Oil Seal and Dust Seal
123
Fork Oil
123
Front Fork Remounting
123
Stem Nut
128
Handlebar
128
Rear Wheel
129
Wheel Bearing and Sprocket Drum Bearing
130
Rear Sprocket
131
Rear Sprocket Damper
131
Rear Brake
133
Caliper Reassembly and Remounting
136
Rear Swingarm and Suspension
138
Bearing
141
Swingarm Pivot Shaft
142
Shock Absorber
142
Cushion Lever and Cushion Rod Bearing
142
Service Information
144
Troubleshooting
145
Wiring Diagram
152
Wire Routing
154
Cable Routing
155
Hose Routing
156
Special Tools
158
Tightening Torque
160
Tightening Torque Chart
162
Service Data
163
Emission Control Information
171
Emission Control Carburetor Components
172
Evaporative Emission Control System
173
Canister Hose Routing
174
Dr650Sm
175

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User Manuals: Suzuki DR650S Dual-Sport Motorcycle

Suzuki DR650S Service Manual (188 pages)

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