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DR650SE
Suzuki DR650SE Manuals
Manuals and User Guides for Suzuki DR650SE. We have
2
Suzuki DR650SE manuals available for free PDF download: Shop Manual, Service Manual
Suzuki DR650SE Service Manual (266 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 86.87 MB
Table of Contents
Group Index
3
Component Parts and Work to be Done
4
Symbol
5
General Information
6
Warning/Caution/Note
7
General Precautions
7
Suzuki DR650SET ('96 Model) Right Side
9
Suzuki DR650SET ('96 Model) Left Side
9
Serial Number Location
9
Fuel and Oil Recommendation
9
Engine Oil
10
Brake Fluid
10
Front Fork Oil
10
Break-In Procedures
10
Information Labels
11
Specifications
13
Country or Area
15
Periodic Maintenance
16
Periodic Maintenance Schedule
17
Periodic Maintenance Chart
17
Lubrication Points
18
Maintenance and Tune-Up Procedures
19
Valve Clearance
19
Spark Plugs
20
Carbon Deposit
20
Spark Plug Gap
20
Electrode's Condition
20
Air Cleaner Element
21
Carburetor
22
Throttle Cable Adjustment
22
Idle RPM Adjustment
22
Fuel Line
23
Fuel Valve Strainer
23
Clutch
23
Engine Oil and Oil Filter
24
Necessary Amount of Engine Oil
24
Drive Chain Checking
25
Drive Chain Adjusting
25
Drive Chain Cleaning and Lubricating
26
Brake Fluid Level
26
Brake Pads
27
Brake Pedal Height
27
Air Bleeding the Brake Fluid Circuit
27
Tire Tread Condition
28
Spark Arrester (for U.S.A. and Canada)
29
Steering
29
Tire Pressure
29
Front Forks
30
Rear Suspension
30
Exhaust Pipe and Muffler Bolts
30
Chassis Bolts and Nuts
31
Compression Pressure Check
33
Compression Test Procedure
33
Oil Pressure Check
34
Oil Pressure Test Procedure
34
Low Oil Pressure
34
High Oil Pressure
34
Engine
36
Engine Components Removable with the Engine in Place
37
Engine Removal
38
Engine Reinstallation
42
Engine Disassembly
45
Engine Components Inspection and Service
53
Cylinder Head Cover Service
53
Cylinder Head Cover Distortion
54
Rocker Arm Shaft O.D.
54
Rocker Arm I.D.
54
Rocker Arm and Shaft Reassembly
54
Cylinder Head Service
55
Cylinder Head Distortion
55
Valve Face Wear
56
Valve Stem Runout
56
Valve Head Radial Runout
56
Valve Stem Deflection
56
Valve Stem Wear
57
Valve Guide Servicing
57
Valve Seat Width
58
Valve Seat Servicing
58
Valve Stem End Condition
60
Valve Spring
60
Valve and Valve Spring Reassembly
60
Camshaft/Automatic De-Comp.assembly
61
Automatic De-Comp.
62
Camshaft
62
Camshaft Cam Wear
62
Camshaft Journal Wear
62
Camshaft Runout
63
Cylinder Distortion
63
Cylinder Bore
63
Piston Diameter
63
Piston-Cylinder Clearance
64
Piston Ring-Groove Clearance
64
Piston Ring Free End Gap and Ring End Gap
64
Piston Pin and Pin Bore
65
Conrod Small End I.D.
65
Conrod Deflection and Conrod Big End Side Clearance
65
Crankshaft Runout
66
Balancershaft and Gear Disassembly
67
Clutch Drive Plate
68
Balancershaft and Gear Reassembly
68
Clutch Driven Plate
69
Clutch Spring Free Length
69
Clutch Release Bearing
69
Clutch Release Pinion and Rack
69
Starter Clutch Disassembly
70
Starter Clutch Reassembly
71
Starter Torque Limiter
71
Transmission
72
2Nd Drive Gear Disassembly
72
Shift Fork - Groove Clearance
73
2Nd Drive Gear
74
3Rd Driven Gear Bushing
74
Crankcase Bearings
76
Oil Nozzle and Oil Jet Removal
76
Oil Nozzle and Oil Jet Inspection
76
Oil Nozzle and Oil Jet Reassembly
76
Oil Filter
77
Generator
77
Engine Reassembly
78
Oil Seals
78
Crankshaft
79
Balancershaft
80
Gearshift Mechanism
80
Crankcase
82
Cam Driven Gear
82
Gearshift Shaft
83
Neutral Position Indicator Switch
83
Oil Pump
84
Cam Drive Chain and Primary Drive Gear
84
Starter Clutch and Generator
87
Oil Ring
88
Top Ring and 2Nd Ring
89
Fuel and Lubrication System
95
Fuel System
96
Fuel Valve Mechanism
97
Fuel Valve/Fuel Filter Removal
97
Fuel Valve/Fuel Filter Inspection and Cleaning
98
Fuel Tank Removal
98
Carburetor Construction
99
Carburetor Specifications
100
I.D. No. Location
101
Slow System
102
Main System
103
Starter System
104
Float System
104
Carburetor Removal
105
Carburetor Disassembly
105
Carburetor Cleaning
106
Pilot Screw Removal
107
Needle Valve Inspection
108
Float Height Adjustment
108
Throttle Position Switch
108
Carburetor Reassembly and Remounting
109
Lubrication System and Cooling System
109
Engine Lubrication/Cylinder Head Cooling System Chart
110
Oil Cooler Removal
112
Chassis
113
Frame Cover and Seat Removal and Remounting
114
Front Wheel Removal
115
Front Wheel Inspection and Disassembly
116
Wheel Bearing
116
Front Axle
116
Wheel Rim
116
Front Wheel Reassembly and Remounting
117
Spoke Nipple
117
Brake Disc
118
Front Brake
119
Front Brake Pad Replacement
120
Front Brake Fluid Replacement
120
Caliper Removal and Disassembly
121
Caliper Inspection
122
Caliper Reassembly and Remounting
122
Brake Disc Inspection
123
Master Cylinder Removal and Disassembly
124
Master Cylinder Inspection
125
Master Cylinder Reassembly and Remounting
126
Front Fork Removal and Disassembly
127
Front Fork Inspection
129
Fork Spring
129
Inner Tube and Outer Tube
129
Front Fork Reassembly and Remounting
130
Damper Rod Ring
130
Inner Tube Metal
130
Outer Tube Metal, Oil Seal and Dust Seal
130
Damper Rod Bolt
131
Fork Oil
131
Front Fork Remounting
132
Steering Removal and Disassembly
133
Steering Inspection
138
Steering Reassembly and Remounting
138
Handlebars
139
Rear Wheel Removal
140
Rear Wheel Inspection and Disassembly
142
Wheel Bearing and Sprocket Drum Bearing
142
Rear Axle
143
Rear Sprocket
143
Rear Sprocket Damper
143
Rear Brake
146
Brake Pad Replacement
147
Brake Fluid Replacement
147
Rear Swingarm and Suspension
152
Rear Swingarm and Suspension Removal
153
Swingarm Inspection and Disassembly
155
Cushion Lever
156
Shock Absorber
156
Swingarm Pivot Shaft
156
Swingarm Reassembly and Remounting
157
Swingarm Bearing
157
Cushion Lever Bearing
157
Reassembling Informaiton
158
Rear Suspension Final Inspection and Adjustment
159
Shock Absorber Spring Pre-Load Adjustment
159
Spring Setting Table
159
Shock Absorber Damping Force Adjustment
159
Lowering the Seat Height
160
Optional Parts Supply
160
Special Tools
160
Front Fork
161
Rear Shock Absorber
166
Rear Shock Absorber Removal and Disassembly
167
Rear Shock Absorber Reassembly and Remounting
168
Rear Shock Absorber Spring Setting Table
168
Side Stand
169
Warning Label
170
Side Stand Removal and Installation
170
Electrical System
171
Cautions in Servicing
172
Connector
172
Coupler
172
Clamp
172
Battery
173
Connecting Battery
173
Wiring Procedure
173
Using Pocket Tester
173
Location of Electrical Components
174
Charging System Description
175
Troubleshooting
176
Battery Runs Does Quickly
176
Battery Leak Current Inspection
177
Charging Output Inspection
177
Generator Coil Continuity Inspection
178
Generator No-Load Performance Inspection
178
Regulator/Rectifier Inspection
179
Starter System Description
180
Side-Stand/Ignition Interlock System Description
180
Starter Motor will Not Run
182
Starter Motor Removal and Disassembly
183
Starter Motor Inspection
183
Carbon Brush
183
Starter Motor Reassembly
184
Commutator
184
Armature Coil Inspection
184
Oil Seal Inspection
184
Starter Relay Inspection
185
Side-Stand/Ignition Interlock System Inspection
186
Starter Relay Circuit Diagram
186
Neutral Switch
187
Side-Stand Switch
187
Side-Stand/Ignition Interlock Relay
187
Clutch Lever Position Switch
187
Ignition System Description
188
No Spark at Plugs
189
Ignition Coil Inspection
190
Power Source Coil and Pick-Up Coil
191
CDI Unit
191
Spark Plug
192
Heat Range
192
Speedometer and Pilot Indicator Removal and Disassembly
193
Speedometer and Pilot Indicator Inspection
193
Lamps
195
Headlight Bulb Replacement
195
Tail/Brake Light, Turn Signal Light and License Plate Light Bulb Replacement
196
Turn Signal Relay
197
Switches
197
Battery Specifications
198
Battery Initial Charging
198
Battery Servicing
199
Recharging Operation
200
Servicing Information
201
Troubleshooting Engine
202
Troubleshooting Carburetor
205
Troubleshooting Chassis
205
Troubleshooting Brakes
206
Electrical Troubleshooting
207
Troubleshooting Battery
208
Wiring Diagram for Canada and U.S.A.
209
Wiring Diagram for Australia
210
Wiring Diagram for Australia and Switzerland
211
Wiring Diagram for the Others
212
Wire Routing
213
Cable Routing
216
Carburetor and Air Cleaner Hose Routing
218
Pair (Air Supply) System Hose Routing
219
Front Brake Hose Routing
220
Rear Brake Hose Routing
221
Heat Shield Adhering
222
Side Stand Spring Set-Up
222
Tightening Torque Engine
226
Tightening Torque Chassis
227
Tightening Torque Chart
228
Service Data Valve + Guide
229
Service Data Camshaft + Cylinder Head
230
Service Data Cylinder + Piston + Piston Ring
230
Service Data Conrod + Crankshaft
231
Service Data Oil Pump
231
Service Data Clutch
232
Service Data Transmission + Drive Chain
232
Service Data Carburetor
233
Service Data Electrical
234
Service Data Wattage
234
Service Data Brake + Wheel
234
Service Data Suspension
235
Service Data Tire Pressure
236
Service Data Fuel + Oil
236
Emission Control Information
238
Emission Control Carburetor Components
239
Evaporative Emission Control System (California Model Only)
240
Canister Hose Routing
241
DR650SEV/W/X/Y ('97/'98/'99/'00 Model)
242
DR650SEV/W/X/Y Specifications
243
DR650SEV/W/X/Y Service Data
245
Wiring Diagram (on and after '98-Model Production)
253
DR650SEK1 ('01 Model)
254
DR650SEK1 ('01 Model) Specifications
255
DR650SEK1 ('01 Model) Service Data
256
Liquid Gasket
264
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Suzuki DR650SE Shop Manual (278 pages)
Brand:
Suzuki
| Category:
Motorcycle
| Size: 9.06 MB
Table of Contents
How to Use this Manual
4
Component Parts and Work to be Done
4
General Precautions
8
General Information
9
Right Side
10
Left Side
10
Serial Number Location
10
Brake Fluid
11
Front Fork Oil
11
Break-In Procedures
11
Information Labels
12
Country or Area
16
Periodic Maintenance Schedule
18
Periodic Maintenance Chart
18
Lubrication Points
19
Maintenance and Tune-Up Procedures
20
Valve Clearance
20
Engine
20
Spark Plug Gap
21
Air Cleaner Element
22
Throttle Cable Adjustment
23
Engine Oil and Oil Filter
25
Drive Chain
26
Brake Pads
28
Brake Pedal Height
28
Front Forks
31
Rear Suspension
31
Chassis Bolts and Nuts
32
Compression Pressure Check
34
Compression Test Procedure
34
Oil Pressure Check
35
Engine Components Removable with the Engine in Place
38
Engine Removal and Reinstallation
39
Engine Reinstallation
43
Engine Disassembly
46
Engine Components Inspection and Service
54
Cylinder Head Service
56
Cylinder Head Distortion
56
Valve Stem Deflection
57
Valve Seat Width
59
Valve Seat Servicing
59
Valve Spring
61
Camshaft Journal Wear
63
Camshaft Runout
64
Cylinder Distortion
64
Cylinder Bore
64
Piston Diameter
64
Piston -Cylinder Clearance
65
Piston Ring-Groove Clearance
65
Piston Pin and Pin Bore
66
Crankshaft Runout
67
Clutch Spring Free Length
70
Starter Clutch
71
Starter Torque Limiter
72
Crankcase Bearings
77
Oil Filter
78
Engine Reassembly
79
Oil Seals
79
Gearshift Mechanism
81
Gearshift Shaft
84
Oil Pump
85
Starter Clutch and Generator
88
Fuel System
96
Fuel and Lubrication
97
Fuel Valve/Fuel Filter Removal
97
Inspection and Cleaning
98
Specification
100
Fuel and Lubrication System
102
Slow System
102
Main System
103
Starter System
104
Float System
104
Carburetor Cleaning
106
Needle Valve Inspection
108
Float Height Adjustment
108
Reassembly and Remounting
109
Oil Pressure
109
Oil Sump Filter
109
Oil Cooler
112
Chassis
114
Front Wheel
115
Inspection and Disassembly
116
Spoke Nipple
117
Brake Disc
118
Front Brake
119
Brake Pad Replacement
120
Brake Fluid Replacement
120
Caliper Removal and Disassembly
121
Caliper Inspection
122
Caliper Reassembly and Remounting
122
Brake Disc Inspection
123
Master Cylinder Removal and Disassembl y
124
Master Cylinder Inspection
125
Master Cylinder Reassembly and Remounting
126
Front Fork
127
Removal and Disassembly
127
Fork Spring
129
Reassembly and Remounting
130
Rear Wheel
140
Rear Sprocket
143
Rear Axle Nut
145
Rear Brake
146
Caliper and Disc Inspection
149
Rear Swingarm
152
Inspection and Disassembly
155
Shock Absorber
156
Reassembly and Remounting
157
Reassembling Information
158
Final Inspection and Adjustment
159
Shock Absorber Spring Pre-Load Adjustment
159
Rear Shock Absorber
166
Side Stand
169
Side Stand Removal and Installation
170
Warning Label
170
Cautions in Servicing
172
Semi-Conductor Equipped Part
172
Electrical System
173
Connecting Battery
173
Wiring Procedure
173
Location of Electrical Components
174
Charging System
175
Troubleshooting
176
Side-Stand/Ignition Interlock System Description
180
Starter Motor Removal and Disassembl y
183
Starter Motor Inspection
183
Carbon Brush
183
Oil Seal Inspection
184
Starter Motor Reassembly
184
Starter Relay Inspection
185
15 Electrical System
186
Ignition System
188
Spark Plug
192
Removal and Disassembly
193
Bulb Replacement
195
Turn Signal Relay
197
Initial Charging
198
Recharging Operation
200
Servicing Information
202
Information
203
Cable Routing
216
Pair (Air Supply) System Hose Routing
219
Rear Brake Hose Routing
221
Heat Shield Adhering
222
Special Tools
223
Tightening Torque
226
Tightening Torque Chart
228
Service Data
229
Cylinder Head
230
Piston Ring
230
Oil Pump
231
Drive Chain
232
Specification
233
Brake + Wheel
234
Tire Pressure
236
Emission Control Information
238
Emission Control Carburetor Components
238
Evaporative Emission Control System
239
Dr650Sev/W/X/Y
241
Service Data
244
Valve + Guide
244
Cylinder Head
245
Conrod + Crankshaft
246
Brake + Wheel
249
Tire Pressure
251
Dr650Sek1 ('01-Model)
253
Specifications
254
Camshaft + Cylinder Head
256
Cylinder + Piston + Piston Ring
256
Transmission + Drive Chain
258
Cylinder Head Cover
263
Drive Train
270
Dr650Sek9 ('09-Model)
275
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