1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Suzuki DR650SE models Factory Service Manual

GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE FUEL AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION GROUP INDEX 1 FOREWORD This manual contains an introductory description on SUZUKI DR650SE and procedures for its inspection/service and overhaul of its main compo- nents. Other information considered as generally known is not included. Read GENERAL INFORMATION section to famil- iarize yourself with outline of the vehicle and MAIN- TENANCE and other sections to use as a guide for proper inspection and service. This manual will help you know the vehicle better so that you can assure your customers of your optimum and quick service. * This manual has been prepared on the ba- sis of the latest specification at the time of publication. If modification has been made since then, differences may exist between the content of this manual and the actual vehicle. * Illustrations in this manual are used to show the basic principles of operation and work procedures. They may not represent the actual vehicle exactly in detail. * This manual is intended for those who have enough knowledge and skills for servicing SUZUKI vehicles. Without such knowledge and skills, you should not attempt servicing by relying on this manual only. Instead, please contact your nearby autho- rized SUZUKI motorcycle dealer. © COPYRIGHT SUZUKI MOTOR CORPORATION 1995 EMISSION CONTROL INFORMATION IMPORTANT All street-legal Suzuki motorcycles with engine displacement of 50cc or greater are subject to Environmental Protection agency emission regulations. These regulations set specific standards for exhaust emission output levels as well as particular servicing requirements. This manual includes specific information required to properly inspect and service DR650SE in accordance with all EPA regulations. It is strongly recommended that the chapter on Emission Control, Periodic Servicing and Carbu- retion be thoroughly reviewed before any type of service work is performed. Further information concerning the EPA emission regulations and U.S. Suzuki’s emission control program can be found in the U.S. SUZUKI EMIS- SION CONTROL PROGRAM MANUAL/SERVICE BULLETIN. 2 3 4 5 6 7 8

SUPPLEMENTS DR650SEV/W/X/Y (’97/’98/’99/’00-MODELS) DR650SEK1 (’01-MODEL) 9 10 11 DR650SEK2/K3/K4/K5/ K6/K7 (’02/’03/’04/’05/’06/’ 07/’08-MODELS) DR650SEK9 (’09-MODEL) 12

HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. As the title of these sections are listed on the previ- ous page as GROUP INDEX, select the section where what you are looking for belong. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. On the first page of each section, its contents are listed. Find the item and page you need. COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit, its exploded view is provided with work instruction and other service information such as the tightening torque, lubricating points and locking agent points. Example: Front wheel CD O-ring @ Housing end (inside) @ Washer set @ O-ring (2 pes) ® Starter motor ease ® Armature (f) Washer set ® Brush holder ® Brush spring ® Housing end (outside)

SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing and meaning associated with them respectively. SYMBOL DEFINITION SYMBOL DEFINITION ~ Torque control required. • Apply THREAD LOCK SUPER Data beside it indicates "1303" . specified torque. (99000-32030) 1lr Apply oil. Use engine oil unless .. Use fork oil. otherwise specified. (99000-99044-10G) ~ Apply SUZUKI SUPER GREASE a Apply or use brake fluid. IIA'I. (99000-25030) ~ Apply SUZUKI SILICONE GREASE. ~ Measure in voltage range. (99000-25100) ~ Apply SUZUKI MOLY PASTE. ~ Measure in resistance range. (99000-25140) "12078] Apply SUZUKI BOND" 1207B". ~ Measure in current range. (99104-31140) • Apply THREAD LOCK" 1342". '{ooli Use special tool. (99000-32050) tJ 13 681 Apply THREAD LOCK SUPER "1360" . (99000-32130)

1·1 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. A WARNING Indicates a potential hazard that could result in death or injury. I A CAUTION I Indicates a potential hazard that could result in vehicle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more ex- perienced mechanic for advice. GENERAL PRECAUTIONS A WARNING • Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the vehicle. • When 2 or more persons work together, pay attention to the safety of each other. • When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors. • When working with toxic or flammable materials, make sure that the area you work in is well- ventilated and that you follow all of the material manufacturer's instructions. • Never use gasoline as a cleaning solvent. • To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a while after engine operation. • After servicing fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for leaks.

GENERAL INFORMATION 1·2 I A. CAUTION I • If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. • When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. • Be sure to use special tools when instructed. • Make sure that all parts used in reassembly are clean, and also lubricated when specified. • When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type. • When removing the battery, disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal. • When performing service to electrical parts, if the service procedures not require use of battery power, disconnect the negative cable the battery. • Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller diameter, from inside to outside diagonally, to the specified tightening torque. • Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, cir- clips, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. • Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. • Do not use self-locking nuts a few times over. • Use a torque wrench to tighten fastners to the torque values when specified. Wipe off grease or oil if a thread is smeared with them. • After reassembly, check parts for tightness and operation. • To protect environment, do not unlawfully dispose of used motor oil and other fluids: batter- ies, and tires. • To protect Earth's natural resouces, properly dispose of used vehicles and parts.

1·3 GENERAL INFORMATION SUZUKI DR650SET ('96-MODEL) RIGHT SIDE LEFT SIDE *Difference between photographs and actual motorcycles depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) CD is stamped on the right side of the steering head pipe. The engine serial number @ is located on the left side of the crankcase. These numbers are required especially for registering the machine and ordering spare parts. FUEL AND OIL RECOMMENDATION FUEL (For U.S.A. model) 1. Use only unleaded gasoline of at least 87 pump octane (R; M) method or 91 octane or higher rated by the research method. 2. Suzuki recommends that customers use alcohol free, unleaded gasoline whenever possible. 3. Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted. 4. Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it. 5. If the performance of the vehicle is unsatisfactory while using blended gasoline/alcohol fuel, you should switch to alcohol-free unleaded gasoline. 6. Failure to follow these guideline could possibiy void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above. FUEL (For Canadian model) Use only unleaded gasoline of at least 87 pump octane (R ~ M) method or 91 octane or higher rated by the research method. FUEL (For the other models) Gasoline used should be graded 85-95 octane (Research Method) or higher. An unleaded gasoline type is recommended.

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1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Suzuki DR650SE models Factory Service Manual

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