Suzuki DR650SE Shop Manual
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This shop manual has corrections for errors found in the original document and informational additions. Items
in Red (boxed in red, red lines and red arrows) with additional text point out the changes or additions. Red
text in the bookmarks show the sections where changes/additions were made.
FOREWORD
This manual contains an introductory description
on SUZUKI DR650SE and procedures for its in-
spection/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.
IMPORTANT
All street-legal Suzuki motorcycles with engine
displacement of 50cc or greater are subject to
Environmental Protection agency emission regula-
tions. These regulations set specific standards for
exhaust emission output levels as well as particular
servicing requirements. This manual includes spe-
cific information required to properly inspect and
service DR650SE in accordance with all EPA regu-
lations. 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.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FUEL AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
EMISSION CONTROL
INFORMATION
© COPYRIGHT SUZUKI MOTOR CORPORATION 1995
Manual update/correction version 1.0
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Summary of Contents for Suzuki DR650SE

  • Page 1 FOREWORD GROUP INDEX This manual contains an introductory description on SUZUKI DR650SE and procedures for its in- spection/service and overhaul of its main compo- GENERAL INFORMATION nents. Other information considered as generally known is not included.
  • Page 3 SUPPLEMENTS DR650SEV/W/X/Y (’97/’98/’99/’00-MODELS) DR650SEK1 (’01-MODEL) DR650SEK2/K3/K4/K5/ K6/K7 (’02/’03/’04/’05/’06/’ 07/’08-MODELS) DR650SEK9 (’09-MODEL)
  • Page 4: How To Use This Manual

    XXXXXXXXX Starter Motor Changed from front wheel to starter motor.
  • Page 15 Use 2 US quarts or equiv then check level. Add more if required. Do not over fill.
  • Page 20: Maintenance And Tune-Up Procedures

    Loosen magneto cover plug with engine hot!! Use anti-seize on threads to reassemble.
  • Page 21: Spark Plug Gap

    CR10EIX (Iridium) CR10EK (Dual Ground) Other popular sparkplugs used in the DR650.
  • Page 25: Engine Oil And Oil Filter

    Use caution when changing oil. Do not over fill! Most riders find 2 US quarts is enough for an oil/filter change.
  • Page 32: Chassis Bolts And Nuts

    XXXXXX Lower shock bolt torque: 27 lb-ft, 36.6 N-m, 3.73 kg-m Use removable thread locker...
  • Page 36  ...
  • Page 42 right Engine is removed/installed from the right side.
  • Page 45 Use 2 US quarts or equiv then check oil level, add as required, do not overfill.
  • Page 84: Gearshift Shaft

    Use temp/oil rated removable thread locker on these screws! Such as Loctite 243.
  • Page 86 Driven plate # 1 Drive plate # 1 Note, drive plates are marked with # 1 or # 2 on one tab. (1 # 1 and 7 # 2's) Driven/drive plates # 2...
  • Page 91 (Rear right bolt) (Front right bolt) (Both left side bolts)
  • Page 92 * Install the cam chain tensioner chain rail and retainer bolt with sealing washer. Bolt torque: 10N-m, 1.0 kg-m, 7.0 lb-ft. Not in original text...
  • Page 152: Rear Swingarm

    Lower shock bolt torque: 27 lb- ft, 36.6 N-m, 3.73 kg-m Use removable thread locker...
  • Page 158: Reassembling Information

    Lower shock bolt torque: 27 lb-ft, 36.6 N-m, 3.73 kg-m Use removable thread locker...
  • Page 166: Rear Shock Absorber

    Lower shock bolt torque: 27 lb-ft, 36.6 N-m, 3.73 kg-m Use removable thread locker...
  • Page 192: Spark Plug

    Popular plugs used by DR650 Owners: NGK CR10EIX Iridium NGK CR10EK Dual Ground...
  • Page 209 Diagram Incorrect! Break black and yellow w/white wires here. Above slash= black, below= yellow w/white. Ref drawing in Section 9.11 (page 252) for clarification.
  • Page 227 XXXXXXX Rear shock absorber bolt (lower) 36.6 3.73...
  • Page 236: Tire Pressure

    Use 2 US quarts or equiv then check oil level, add as required, do not overfill.
  • Page 241: Dr650Sev/W/X/Y

    DR650SEV/W/X/Y (’97/’98/’99/’00-MODELS) CONTENTS SPECIFICATIONS ................9- 1 SERVICE DATA ..................9- 3 WIRING DIAGRAM ................9- 11...
  • Page 243 Use 2 US quarts or equiv then check oil level, add as required, do not overfill.
  • Page 251: Tire Pressure

    Use 2 US quarts or equiv then check oil level, add as required, do not overfill.
  • Page 253: Dr650Sek1 ('01-Model)

    DR650SEK1 (’01-MODEL) CONTENTS SPECIFICATIONS ................10- 1 SERVICE DATA .................. 10- 2 LIQUID GASKET ................10- 10...
  • Page 254: Specifications

    10-1 DR650SEK1 (’01-MODEL) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ................2 345 mm (92.3 in) ….. E-17, 28, 22 2 325 mm (91.5 in) ….. E-17, 28, 22 (Low seat) 2 255 mm (88.8 in) ….. Others 2 235 mm (88.0 in) ….. Others (Low seat) Overall width ................
  • Page 255 DR650SEK1 (’01-MODEL) 10-2 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.3) ——— (1.1) Valve clearance 0.08 – 0.13 ——— (0.003 – 0.005) (when engine is cold) 0.17 – 0.22 ——— (0.0067 – 0.0087) Valve guide to valve stem 0.010 –...
  • Page 256: Camshaft + Cylinder Head

    10-3 DR650SEK1 (’01-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.710 – 33.750 33.410 (1.3272 – 1.3287) (1.3154) 33.700 – 33.740 33.400 (1.3268 – 1.3283) (1.3150) Camshaft journal oil clearance Right & 0.032 – 0.066 0.150 Center (0.0013 –...
  • Page 257 DR650SEK1 (’01-MODEL) 10-4 ITEM STANDARD LIMIT Piston ring to groove clearance 0.180 ——— (0.0071) 0.150 ——— (0.0059) Piston ring groove width 1.230 – 1.250 ——— (0.048 – 0.049) 1.210 – 1.230 ——— (0.047 – 0.048) 2.810 – 2.830 ——— (0.110 – 0.111) Piston ring thickness 1.170 –...
  • Page 258: Transmission + Drive Chain

    10-5 DR650SEK1 (’01-MODEL) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 ——— (0.4 – 0.6) Drive plate thickness No.1 & 2.9 – 3.1 No.2 (0.11 – 0.12) (0.10) Driven plate distortion 0.10 ——— (0.004) Clutch spring free length 33.0 ———...
  • Page 259 DR650SEK1 (’01-MODEL) 10-6 CARBURETOR SPECIFICATION ITEM E-03, 28 E-33 E-18 Carburetor type MIKUNI ← ← BST40SS ← ← Bore size 40 mm I.D. No. 32E1 32E6 32E2 Idle r/min. 1 500 ± 100 r/min. 1 500 ± 50 r/min. Float height 14.7 ±...
  • Page 260 10-7 DR650SEK1 (’01-MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Ignition timing 10° B.T.D.C. at 1 500 r/min. Spark plug ND.: U31ESR-N Type N.G.K.: CR10E 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 (0.3) at 1 atm. 0.07 – 0.12 Ω Ignition coil resistance Primary B –...
  • Page 261 DR650SEK1 (’01-MODEL) 10-8 ITEM STANDARD LIMIT Master cylinder bore 12.700 – 12.743 ——— Front (0.5000 – 0.5017) 12.700 – 12.743 ——— Rear (0.5000 – 0.5017) Master cylinder piston diam. 12.657 – 12.684 ——— Front (0.4983 – 0.4994) 12.657 – 12.684 ———...
  • Page 262 10-9 DR650SEK1 (’01-MODEL) ITEM STANDARD LIMIT NOTE Rear shock absorber spring 247.5 ——— pre-set length (9.74) Rear wheel travel ——— (10.2) ——— Low seat (8.7) Swingarm pivot shaft runout ——— (0.01) TIRE PRESSURE SOLO RIDING DUAL RIDING COLD INFLATION TIRE PRESSURE kg/cm kg/cm FRONT...
  • Page 263: Cylinder Head Cover

    DR650SEK1 (’01-MODEL) 10-10 LIQUID GASKET CYLINDER HEAD COVER NOTE: SUZUKI BOND NO.1215 or NO.1207B has to be applied to the cylinder head cover and cylinder head. CYLINDER HEAD...
  • Page 264  ...
  • Page 265 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) 11-1 DR650SEK2/K3/K4/K5 /K6/K7 (’02/’03/’04/’05/’06/’07 /’08-MODELS) CONTENTS SPECIFICATIONS................11- 2 SERVICE DATA.................. 11- 3...
  • Page 266 11-2 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ................2 345 mm (92.3 in) ….. E-17, 28 2 325 mm (91.5 in) ….. E-17, 28 (Low seat) 2 255 mm (88.8 in) ….. Others 2 235 mm (88.0 in) ….. Others (Low seat) Overall width ................
  • Page 267 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) 11-3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ——— (1.3) ——— (1.1) Valve clearance 0.08 – 0.13 ——— (0.003 – 0.005) (when engine is cold) 0.17 – 0.22 ——— (0.0067 – 0.0087) Valve guide to valve stem 0.010 –...
  • Page 268 11-4 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 33.710 – 33.750 33.410 (1.3272 – 1.3287) (1.3154) 33.700 – 33.740 33.400 (1.3268 – 1.3283) (1.3150) Camshaft journal oil clearance Right & 0.032 – 0.066 0.150 Center (0.0013 –...
  • Page 269 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) 11-5 ITEM STANDARD LIMIT Piston ring to groove clearance 0.180 ——— (0.0071) 0.150 ——— (0.0059) Piston ring groove width 1.230 – 1.250 ——— (0.048 – 0.049) 1.210 – 1.230 ——— (0.047 – 0.048) 2.810 – 2.830 ——— (0.110 – 0.111) Piston ring thickness 1.170 –...
  • Page 270: Drive Train

    11-6 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) CLUTCH Unit: mm (in) ITEM STANDARD LIMIT Clutch lever play 10 – 15 ——— (0.4 – 0.6) Drive plate thickness No.1 & 2.9 – 3.1 No.2 (0.11 – 0.12) (0.10) Driven plate distortion 0.10 ——— (0.004) Clutch spring free length 33.0 ———...
  • Page 271 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) 11-7 CARBURETOR SPECIFICATION ITEM E-03, 28 E-33 E-18 Carburetor type MIKUNI ← ← BST40SS ← ← Bore size 40 mm I.D. No. 32E1 32E6 32E2 Idle r/min. 1 500 ± 100 r/min. 1 500 ± 50 r/min. Float height 14.7 ±...
  • Page 272 11-8 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Spark plug ND.: U31ESR-N Type N.G.K.: CR10E 0.7 – 0.8 (0.028 – 0.031) Spark performance Over 8 (0.3) at 1 atm. 0.07 – 0.12 Ω Ignition coil resistance Primary B – B/W Plug cap –...
  • Page 273 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) 11-9 ITEM STANDARD LIMIT Master cylinder bore 12.700 – 12.743 ——— Front (0.5000 – 0.5017) 12.700 – 12.743 ——— Rear (0.5000 – 0.5017) Master cylinder piston diam. 12.657 – 12.684 ——— Front (0.4983 – 0.4994) 12.657 – 12.684 ———...
  • Page 274 11-10 DR650SEK2/K3/K4/K5/K6/K7 (’02/’03/’04/’05/’06/’07/’08-MODELS) ITEM STANDARD LIMIT NOTE Rear shock absorber spring 247.5 ——— pre-set length (9.74) Rear wheel travel ——— (10.2) ——— Low seat (8.7) Swingarm pivot shaft runout ——— (0.01) TIRE PRESSURE SOLO RIDING DUAL RIDING COLD INFLATION TIRE PRESSURE kg/cm kg/cm FRONT...
  • Page 275: Dr650Sek9 ('09-Model)

    DR650SEK9 (’09-MODELS) 12-1 DR650SE K9 (’ 09-MODELS) CONTENTS PAGE SPECIFICATIONS..................12-2 NOTE: * Difference between K9-MODEL and K8-MODEL specification is indicated as an asterisk mark (*). * The service data is the same as the K8-MODEL.
  • Page 276 12-2 DR650SEK9 (’09-MODEL) SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..................2 255 mm (88.8 in) 2 235 mm (88.0 in)....(Low seat) Overall width..................865 mm (34.1 in) Overall height ..................1 195 mm (47.0 in) 1 155 mm (45.5 in)....(Low seat) Wheelbase ..................
  • Page 277 DR650SEK9 (’09-MODEL) 12-3 CAPACITIES Fuel tank, including reserve .............. 12.0 L (3.2/2.6 US/Imp gal)..E-33 13.0 L (3.4/2.9 US/Imp gal)..Others reserve ................3.0 L (0.8/0.7 US/Imp gal) Engine oil, change ................2 300 ml (2.4/2.0 US/Imp qt) Use 2 US quarts with filter change ..............

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