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California Proposition 65 Warning WARNING Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
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Indicates a potential hazard please follow the maintenance that could result in minor or instructions closely to ensure moderate injury. emission compliance. Your Suzuki dealer has experienced techni- cians that are trained to provide NOTICE your machine with the best possi-...
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Suzuki reserves the right to make production changes at any time, without notice and without incur- ring any obligation to make the same or similar changes to vehi- cles previously built or sold.
TABLE OF CONTENTS THE SPORT OF MOTORCYCLING FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS CONTROLS, EQUIPMENT AND ADJUSTMENTS BREAK-IN AND INSPECTION BEFORE RIDING RIDING TIPS ACCESSORY USE AND MOTORCYCLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE PROCEDURE AND MOTORCYCLE CLEANING CONSUMER INFORMATION SPECIFICATIONS INDEX...
THE SPORT OF MOTORCYCLING MOST ACCIDENTS CAN BE AVOIDED ............. 1-2 IF YOU DON’T HAVE A HELMET, BUY A HELMET AND WEAR IT EVERY TIME YOU RIDE ..............1-2 IF A COLLISION IS IMMINENT, DO SOMETHING! ........... 1-3 SPECIAL SITUATIONS REQUIRE SPECIAL CARE .......... 1-4 KNOW YOUR LIMITS ..................
Ride defensively. Wise motorcy- THE SPORT OF clists use a strategy of assuming MOTORCYCLING they are invisible to other drivers, even in broad daylight. Pay care- Your motorcycle and this owner’s ful attention to other motorists, manual have been designed by especially intersections, people like you who enjoy motor-...
IF A COLLISION IS IMMINENT, Emergency stopping and swerv- ing are techniques that you DO SOMETHING! should practice and master before Many riders fear locking up their you find yourself in an emergency brakes or haven’t learned to situation. The best place to prac- swerve to avoid an accident.
SPECIAL SITUATIONS REQUIRE Riding motorcycle safely requires that your mental and SPECIAL CARE physical skills are fully part of the Of course, there are some times experience. should when full-force braking is not the attempt to operate a motor vehi- correct technique.
PRACTICE AWAY FROM TRAFFIC CARRYING A PASSENGER Your riding skill and your mechan- Carrying a passenger, when done ical knowledge form the founda- correctly, is a great way to share tion for safe riding practices. We the joy of motorcycling. You will suggest that you practice riding have to alter your riding style your motorcycle in a non-traffic...
Motorcycle Safety Foundation. Your Suzuki dealer can help you locate fundamental advanced riding skills course nearest you, or owners in the USA can call toll-free 1-800-446-9227. Good riding on your new Suzuki !
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10% ethanol ( ). Make station. If the situation is not sure this gasoline-ethanol blend improved by changing, consult has octane ratings no lower than your Suzuki dealer. those recommended for gasoline. • If pinking or knocking is experi- enced,...
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NOTE: • To help minimize air pollution, Suzuki recommends that you use oxygenated fuels. • Be sure that any oxygenated fuel you use has octane rat- ings of at least 87 pump octane ((R+M)/2 method).
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ENGINE OIL JASO T903 The JASO T903 standard is an Suzuki recommends the use of index to select engine oils for 4- SUZUKI PERFORMANCE stroke motorcycle MOTOR OIL or equivalent engine engines. Motorcycle and ATV oil. If SUZUKI PERFORMANCE 4...
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Energy Conserving ENGINE COOLANT SOLUTION Suzuki does not recommend the Use “SUZUKI SUPER LONG use of “ENERGY CONSERVING” LIFE COOLANT” or “SUZUKI or “RESOURCE CONSERVING” LONG LIFE COOLANT”. oils. Some engine oils which have “SUZUKI SUPER LONG LIFE an API classification of SH, SJ or COOLANT”...
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“SUZUKI SUPER LONG LIFE to 55% (–40°C/–40°F) or 60% COOLANT” is pre-mixed to the (–55°C/–67°F) coolant. The mix- proper ratio. Add only “SUZUKI ing ratio should not exceed 60% SUPER LONG LIFE COOLANT” coolant. if coolant level drops. It is not nec- essary to dilute “SUZUKI SUPER...
CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS ..................3-2 KEY ........................3-5 IGNITION SWITCH ....................3-5 INSTRUMENT PANEL ..................3-8 LEFT HANDLEBAR ................... 3-22 RIGHT HANDLEBAR ..................3-28 FUEL TANK CAP ....................3-30 GEARSHIFT LEVER ..................3-31 REAR BRAKE PEDAL ..................3-32 SEAT LOCK .......................
CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS DL650A 1 Clutch lever 2 Left handlebar switches 3 Instrument panel 4 Front brake fluid reservoir 5 Right handlebar switches 6 Throttle grip 7 Front brake lever 8 Output terminal 9 Fuel tank cap 0 Ignition switch DL650XA...
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DL650A A Air cleaner B Spark plugs C Fuses D Battery E Tools F Gearshift lever G Side stand H Footrests I Seat lock J Passenger footrests DL650XA...
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DL650A K Rear brake fluid reservoir L Engine oil filler cap M Rear brake pedal N Engine oil drain plug O Engine oil inspection window P Engine oil filter DL650XA...
IGNITION SWITCH Two keys come with this motorcy- The ignition switch has 4 posi- cle. tions: Keep the spare key in a safe “OFF” Position place. All electrical circuits are off. The engine will not start. The key can be removed. “ON”...
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WARNING Turning the ignition switch to the “P” (PARKING) or “LOCK” position while the motorcycle is moving can be hazardous. Moving the motorcycle while the steering is locked can be hazardous. You could lose your balance and fall, or you could “P”...
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If the motorcycle falls down, turn the ignition switch off immediately. Ask your autho- rized Suzuki dealer to inspect the motorcycle for unseen damage. IGNITION In order to align the lid with the keyhole, the same procedure is used.
INSTRUMENT PANEL WARNING Changing the display while riding hazardous. Removing a hand from the han- 1000 r/min dlebars can reduce your ability km/h to control the motorcycle. GEAR TRIP Never change the display while RANGE riding. Keep both hands on the handlebars.
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“ there is a proper amount of oil display appears and the indicator light 4 comes on. and the light still does not go out, have your authorized Suzuki dealer or a qualified mechanic inspect your motor- cycle.
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You should have the “ON” and goes off after the system checked by an autho- motorcycle speed exceeds 5 rized Suzuki dealer as soon km/h (3 mph). as possible. • The indicator comes on and...
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“FI” and the odometer/ rized Suzuki dealer or a quali- trip meter reading, and the fied mechanic inspect the fuel malfunction indicator light 6 injection system as soon as comes on and remains lit.
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Gear Position Indicator 8 The gear position indicator indi- cates gear position. This indica- displays “N” when transmission is in neutral. 1000 r/min km/h NOTE: When the display indi- GEAR TRIP cates “CHEC” in the odometer display area, the gear position RANGE indicator does not indicate a num- ber but indicates “–”.
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Thermometer 0 Neutral Indicator Light “N” A The green light will come on when the transmission is in neutral. The light will go out when you shift into any gear other than neutral. thermometer shows ” B Freeze Indicator Light “ ambient air temperature, when The freeze indicator light B starts the ignition switch is in the “ON”...
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If the ABS indicator light does not come on when the ignition switch is turned on, you should have the system checked by an authorized Suzuki dealer as soon as possible. 3-14...
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” F Coolant Temperature Meter Fuel Meter “ “” E The fuel meter indicates the The coolant temperature is dis- amount of fuel remaining in the played by an LCD segment tem- fuel tank. The fuel meter displays perature meter water all 6 segments when the fuel tank...
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To change the display, push the left handlebar MODE switch (Down). The display changes in the order below. 1000 r/min km/h GEAR Instantaneous fuel TRIP consumption RANGE Instantaneous Fuel Trip meter 1 or 2 Consumption Meter/Average average fuel consumption Fuel Consumption Meter/ Driving Range Meter/Voltmeter RANGE The display has 4 functions;...
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Instantaneous fuel Instantaneous fuel consumption meter and consumption meter average fuel consumption The instantaneous fuel consump- meter tion meter displays the fuel con- To change between “MPG” and sumption value only when the “km/L (L/100 km)”, set the meter motorcycle is moving. However, J to odometer, then press and when the motorcycle is stopping, hold the ADJUST button 1 for 2...
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Driving range meter The driving range meter displays estimated driving range (distance) based on the remaining fuel within the range from 0 to 999 km 1000 r/min (mile). The driving range is recal- km/h culated when you refuel, but the GEAR TRIP indication may not change when...
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Clock I Voltmeter The voltmeter displays the battery voltage within the range of 10.0 to 16.0 V. Time is shown when the ignition Traction Control System Display switch is in the “ON” position. The clock has a 12-hour display. Fol- The setting of the traction control low the procedure below to adjust system is indicated by OFF, 1 or...
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NOTE: • Set the meter to odometer, then press hold ADJUST button 1 for 2 sec- onds to switch between km and 1000 r/min mile. At this time, speedometer km/h will be changed between km/h GEAR TRIP and mph and the instantaneous fuel consumption meter will be RANGE changed between km/L (L/100...
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Odometer Instrument panel light The odometer registers the total brightness distance that the motorcycle has Set the meter to instrument panel been ridden. odometer light brightness. Pushing ADJUST button 1 will change the ranges from 0 to 999999 km or from 0 to 624999 miles.
Dimmer Switch 2 LEFT HANDLEBAR “ ” position The headlight low beam and tail- light turn on. “ ” position Push the dimmer switch forward, the headlight low beam, high beam and taillight turn on. The high beam indicator light also turns on.
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Mode Switch 3 WARNING Use the MODE SWITCH to change the speedometer display Failure to use the turn signals, setting and traction control sys- and failure to turn off the turn tem setting. signals can be hazardous. Refer INSTRUMENT Other drivers may misjudge PANEL and TRACTION CON- your course and this may...
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WARNING Relying too much on the trac- tion control system can be haz- ardous. The traction control system cannot provide control to limit rear wheel spin under certain conditions. The system cannot control rear wheel spin result- ing from high speed cornering, excessive bank angle, braking operation or engine braking effect.
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NOTE: The traction control system can • When the traction control sys- be set to OFF, Mode 1 or Mode 2. controlling engine <OFF> power output, engine The traction control system does sound and exhaust sound will not control engine power output change.
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Mode setting 1. Press the traction control sys- tem switch 6 for mode selec- tion. 2. Press the Mode switch (UP, DOWN) 3 and change the indication on the traction con- trol system display in the meter cluster to the desired mode. The display changes in the order below.
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NOTE: • Be sure to keep the throttle fully closed when changing the mode. If the change of mode is not possible because the throt- tle is not fully closed, a seg- ment of the selected mode on the traction control system dis- play blinks.
RIGHT HANDLEBAR Front Brake Lever Adjustment The distance between the throttle Engine Stop Switch 1 grip and the front brake lever is adjustable to 5 positions. “ ” position To change the position, push the The ignition circuit is off. The brake lever forward and turn the engine cannot start or run.
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Suzuki dealer for checking. starter circuit. The engine can only be started if: • When the neutral indicator •...
FUEL TANK CAP Suzuki Easy Start System Suzuki Easy Start System permits engine start by simple one-push action on the electric starter switch. When the transmission is in neutral, the engine can be started without squeezing the clutch lever. When the transmis-...
GEARSHIFT LEVER Fuel level Filler neck This motorcycle has a 6-speed WARNING transmission which operates as shown. To shift properly, squeeze If you overfill the fuel tank, fuel the clutch lever and close the may overflow when it expands throttle at the same time you due to engine heat or heating operate the gearshift lever.
REAR BRAKE PEDAL SEAT LOCK To remove the seat, insert the Depressing the rear brake pedal ignition key into the lock and turn will apply the rear disk brake. The it clockwise. Raise the rear end of brake light will be illuminated the seat and slide it backward.
SIDE STAND WARNING Riding with the side stand incompletely retracted result in an accident when you turn left. Check operation of the side stand/ignition interlock sys- tem before riding. Always retract the side stand com- An interlock system is provided to pletely before starting off.
REAR SUSPENSION Damping Force Adjustment Spring Pre-load Adjustment rebound damping force adjuster 2 is located at the bot- rear suspension damper unit. To adjust the damp- ing force, set the adjuster to the standard setting first and then adjust it to the desired position. To set the damping force adjuster to the standard position: 1.
• Keep away from fire and heat. • Read owner’s manual for more information. NOTE: Ask your Suzuki dealer to dispose of the rear suspension unit. 1. Remove the caps 1 and bolts 2 and then remove the wind- shield 3.
OUTPUT TERMINAL 2. Move the windshield up or down to the desired windshield If your DL650A/XA has an output position. terminal, use charging a mobile 3. Reinstall the windshield in the phone only (voltage and wattage reverse order of removal. should be less than 12V and 12W).
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WARNING When using the output termi- nal, if its electrical devices are not properly installed and con- nected, they may interfere with movement of the handlebars, causing loss of control or causing the devices to fall off. Before riding, turn the handle- bars to the right and to the left to make it sure that there is no interference with handlebar...
BREAK-IN AND INSPECTION BEFORE RIDING BREAK-IN ......................4-2 INSPECTION BEFORE RIDING ................4-3...
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Breaking in the New Tires BREAK-IN AND New tires need proper break-in to INSPECTION BEFORE assure maximum performance, RIDING just as the engine does. Wear in the tread surface by gradually increasing your cornering lean BREAK-IN angles over the first 160 km (100 The first 800 km (500 miles) is the miles) before attempting maxi- most important in the life of your...
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Allow the Engine Oil to INSPECTION BEFORE RIDING Circulate before Riding WARNING Allow sufficient idling time after warm or cold engine start up Failure to inspect your motor- before revving the engine or plac- cycle before riding and to prop- ing the transmission in gear.
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Check the condition of the motor- Clutch • Correct lever play cycle to help make sure that you ( 7-32) • Smooth and progressive action do not have mechanical problems or get stranded somewhere when Brakes • Proper pedal and lever (...
RIDING TIPS STARTING THE ENGINE ..................5-2 STARTING OFF AND SHIFTING ................ 5-3 USING THE TRANSMISSION ................5-4 RIDING ON HILLS ....................5-6 STOPPING AND PARKING ................5-6 CARRYING A PASSENGER ................5-10...
NOTE: This motorcycle has an the indicator, consult your interlock system for the ignition Suzuki dealer for checking. circuit and the starter circuit. The engine can only be started if: • When the neutral indicator •...
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Suzuki Easy Start System NOTICE Suzuki Easy Start System permits engine start by simple one-push After starting the engine, open- action on the electric starter ing the throttle or running the switch. When the transmission is motorcycle with the oil pres-...
STARTING OFF AND SHIFTING WARNING WARNING Sudden side winds, which can occur when being passed by Riding at excessive speeds larger vehicles, at tunnel exits increases your chances of los- or in hilly areas, can cause you ing control of the motorcycle, to lose control of the motorcy- which can result in an acci- cle.
USING THE TRANSMISSION WARNING The transmission is provided to keep engine operating Downshifting when engine smoothly in its normal operating speed is too high can: speed range. The gear ratios • cause the rear wheel to skid have been carefully chosen to and lose traction due to meet the characteristics of the increased engine braking,...
RIDING ON HILLS NOTICE • When climbing steep hills, the motorcycle may begin to slow Improper gearshift lever opera- down and show lack of power. tion can damage the transmis- At this point, you should shift sion. to a lower gear so that the engine will again be operating •...
STOPPING AND PARKING NOTE: In some situations, a motorcycle with ABS may require a longer stopping distance to stop Anti-lock Brake System (ABS) on loose or uneven surfaces than This model is equipped with an an equivalent motorcycle without Anti-lock Brake System (ABS) ABS.
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How the ABS Works WARNING ABS works by electronically con- trolling braking pressure. A com- Failure to use good judgment puter monitors wheel rotation with ABS can be hazardous. speed. If the computer detects ABS cannot make up for bad that a braked wheel has slowed road conditions, bad judge- suddenly, indicating a skidding sit-...
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STOPPING AND PARKING WARNING 1. Turn the throttle grip away from you to close the throttle com- Hard braking on wet, loose, pletely. rough, or other slippery sur- 2. Apply the front and rear brakes faces can cause wheel skid evenly and at the same time.
5. Park the motorcycle on a firm, CARRYING A PASSENGER flat surface where it will not fall Before you invite someone to be a over. passenger on your motorcycle, you need to be thoroughly familiar CAUTION with motorcycle operation. Adjust tire pressures and suspension A hot muffler can cause severe according to the Tire Pressure...
It is not possible center of gravity as is feasible. for Suzuki to test each accessory Check that the mounting brack- on the market or combinations of ets and other attachment hard- all the available accessories;...
• Certain accessories displace LOADING LIMIT the rider from his or her normal WARNING riding position. This limits the freedom of movement of the rider and may limit control abil- Overloading or improper load- ity. ing can cause loss of motorcy- •...
LOADING GUIDELINES WARNING This motorcycle primarily intended to carry small items Placing objects in the space when you are not riding with a behind the fairing can interfere passenger. Follow the loading with steering and can cause guidelines below: loss of control.
(*). You may perform the unmarked maintenance items by referring to the instructions in this section, if you have mechanical experience. If you are not sure how to do any of the jobs, ask your Suzuki dealer to do the maintenance.
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Breathing carbon When replacing parts on your monoxide can cause death or motorcycle, use only genuine severe injury. Suzuki replacement parts or Never start the engine or let it their equivalent. run indoors or where there is little or no ventilation.
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– Throttle cable play ( 7-26) * Throttle valve synchronization I (CA. only) – – “SUZUKI SUPER LONG Replace every 4 years or 48000 km (29000 miles) LIFE COOLANT” (Blue) “SUZUKI LONG LIFE * Engine coolant COOLANT” (Green) or an (...
TOOLS FUEL TANK LIFT 1. Place the motorcycle on the side stand. 2. Remove the seat by referring to the SEAT LOCK section. A tool kit is supplied and located under the seat. 3. Remove the fasteners. 4. Remove the bolts. 5.
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6. Slide and unhook the front 9. Slide the fuel tank side covers 3 forward to slip off the hooks. side covers. 7. Remove the fasteners and bolts. Remove the front fuel tank cover 2. 10.Disconnect the connector and the hook. 11.Remove the wiring harness.
FUEL TANK REMOVAL Lift the fuel tank by referring to the FUEL TANK LIFT section. 13.Remove the bolts. 1. Disconnect the hoses and coupler. 14.Remove hooks remove the bolt. Remove the prop 4 and rubber cushion. 15.Remove the rubber cushion from the prop 4.
LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of your motor- cycle and also for safe riding. It is a good practice to lubricate the motorcycle after a long rough ride and after getting it wet it in the rain or after washing it.
BATTERY WARNING The battery is a sealed type bat- tery and requires no maintenance Batteries produce flammable of fluid level and gravity. But have hydrogen which your dealer check the charging explode if exposed to flames or condition of the battery periodi- sparks.
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Battery Removal WARNING To remove the battery, follow the procedure below: Batteries contain toxic sub- 1. Place the motorcycle on the stances including sulfuric acid side stand. and lead. They could cause 2. Remove the seat by referring injury to humans or could dam- to the SEAT LOCK section.
The recycling of element. materials will help to conserve natural resources. more Never run the engine without detailed information about dispos- ing or recycling of the used bat- the air cleaner element in tery, consult your Suzuki dealer. place. 7-11...
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Air Cleaner Element Removal NOTICE 1. Lift the fuel tank by referring to the FUEL TANK REMOVAL Failure to inspect the air section. cleaner element frequently if the vehicle is used in dusty, wet, or muddy conditions can damage your motorcycle. The cleaner element become clogged under these...
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Installation Reinstall the cleaned element or cleaner element reverse order of removal. Be absolutely sure that the element is securely in position and is seal- ing properly. NOTICE A torn air cleaner element will 5. Carefully use an air hose to allow dirt to enter the engine blow the dust from the air cleaner element.
A white or dark insula- tor indicates that the engine may need adjustment, or another plug type may be needed. Consult your Suzuki dealer or a qualified mechanic if your plug insulator is not a light brown color. NOTICE 1.
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Standard CAUTION NOTE: If the above-named plugs A hot radiator and hot engine are not available, consult your Suzuki dealer. can burn you. NOTE: This motorcycle uses a Wait until the radiator and resistor-type spark plug to avoid engine are cool enough to...
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Front Side 1. Remove the fuel tank side cov- ers by referring to the FUEL TANK REMOVAL section. 2. Remove the radiator mounting bolt 1 and slide the radiator forward. NOTE: Do not extract the radiator hose. 3. Pull off the spark plug cap. 4.
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Rear Side NOTICE 1. Remove the fuel tank by refer- ring FUEL TANK Dirt can damage the moving REMOVAL section. engine parts of your motorcy- cle if it enters an open spark plug hole. Cover the spark plug hole while the spark plug is out of the hole.
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Spark Plug Inspection Installation To install a spark plug, turn it in as far as possible with your fingers, then tighten it with a wrench. NOTICE Improper installation of the spark plug can damage your motorcycle. An overly-tight or cross-threaded spark plug will 0.8 –...
FUEL HOSE NOTE: When installing the spark plug caps, point the arrow marks Inspect the fuel hose for damage on the spark plug caps to the and fuel leakage. If any defects exhaust side. are found, the fuel hose must be replaced.
ENGINE OIL NOTICE Engine life depends on oil amount and quality. Daily oil level checks Operating the motorcycle with and periodic changes are two of too little or too much oil can the most important maintenance damage the engine. items to be performed. Place the motorcycle on level Engine Oil Level Check ground.
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Engine Oil and Filter Change Change the engine oil and oil filter at the scheduled time. The engine should always be warm when the oil is changed so the oil will drain easily. The procedure is as fol- lows: 3. Remove the oil filler cap 1. 4.
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Turning the engine while drain- ing the engine oil will cause oil 5. Turn the oil filter 4 counter- film shortage and adversely clockwise with a Suzuki “cap affect the engine. type” oil filter wrench or a “strap type” filter wrench of the Do not use the electric starter proper size.
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Be sure to use a genuine Suzuki oil filter or an equiva- 6. Wipe off the mounting surface lent one designed for your 5 on the engine where the motorcycle.
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Engine damage may occur if Tighten the filter 2 turns or to specified torque. you use oil that does not meet Suzuki’s specifications. 9. Mark the top dead center posi- tion on the “cap type” filter Be sure to use the oil specified wrench or on the oil filter.
If it is lower than the your Suzuki dealer or a qualified “L” line, add oil until the oil level mechanic to inspect and repair is between the “L” line and the the motorcycle.
THROTTLE CABLE PLAY Throttle Cable Boots boots The throttle cable has boots. Check that the boots are fit securely. Do not apply water directly to the boots when wash- 2.0 – 4.0 mm ing. Wipe off dirt from the boots (0.08 –...
ENGINE COOLANT To add specified engine coolant: 1. Lift the fuel tank by referring to the FUEL TANK LIFT section. Coolant Level 2. Remove the filler cap and add Remove the seat to check the specified engine coolant coolant level. The engine coolant through the filler hole until it solution should be between the reaches the “F”...
We recom- mend that you take your motorcy- NOTE: About 1950 ml (2.1 US qt) cle to an authorized Suzuki dealer of coolant will required when fill- if the drive chain needs to be ing the radiator and reservoir replaced.
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Chain replacement requires a special riveting tool Good Worn and a high-quality, non-joint- clip type chain. Ask an autho- rized Suzuki dealer or a quali- fied mechanic to perform this work. • Excessively worn teeth • Broken or damaged teeth •...
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Drive Chain Cleaning and NOTICE Oiling 1. Remove dirt and dust from the Some drive chain lubricant drive chain. Be careful not to contains solvents and addi- damage the seal ring. tives which could damage the 2. Clean the drive chain with a seal rings in the drive chain.
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Drive Chain Adjustment 1. Place the motorcycle on the side stand. 20 – 30 mm (0.8 – 1.2 in) Inspect the drive chain slack before each use of the motorcycle. 2. Loosen the axle nut 1. Place the motorcycle on the side 3.
NOTE: Any maintenance of the fluid leakage. If any defects are clutch other than the clutch cable found, ask your Suzuki dealer to play should be performed by your replace the brake hose with a new Suzuki dealer.
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Brake Fluid WARNING Brake fluid will gradually absorb moisture through the brake hoses. Brake fluid with high water content lowers the boiling point and can cause brake system (including ABS) malfunction due to corrosion of brake components. Boiling FRONT brake fluid or brake system (including ABS) malfunction could result in an accident.
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Brake Pads WARNING Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with skin or eyes. Solution can be poison- ous to animals. If brake fluid is swallowed, do not induce vomiting. Immedi- ately contact a poison control FRONT center or a physician.
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Suzuki dealer or quali- formance which could result in fied service mechanic. an accident. NOTE: After replacing either the...
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Rear Brake Pedal Adjustment NOTICE The rear brake pedal position must be properly adjusted at all An incorrectly adjusted brake times or the disk brake pads will pedal may force brake pads to rub against the disk causing dam- continuously rub against the age to the pads and to the disk disk, causing damage to the surface.
TIRES WARNING WARNING Failure to perform break-in of the tires could cause tire slip The tires on your motorcycle and loss of control, which form the crucial link between could result in an accident. your motorcycle and the road. Failure to take the precautions Use extra care when riding on below may result in an accident...
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Tire Pressure and Loading DL650XA Proper tire pressure and proper LOAD SOLO DUAL tire loading are important factors. RIDING RIDING TIRE Overloading your tires can lead to tire failure and loss of motorcycle 225 kPa 225 kPa FRONT 2.25 kgf/cm 2.25 kgf/cm control.
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• Ask your Suzuki dealer or a qualified mechanic to per- When you replace a tire, use a tire form tire repair, replacement, of the size and type listed below.
SPOKE WHEELS (DL650XA) WARNING Wheel Rim Inspection Failure to follow the instruc- tions below for tubeless tires may result in an accident due to tire failure. Tubeless tires require different service proce- dures than tube tires. • Tubeless tires require an air- tight seal between the tire bead and wheel rim.
FRONT WHEEL REMOVAL WARNING 1. Place the motorcycle on the side stand. If the side stand/ignition inter- lock system is not working properly, it is possible to ride the motorcycle with the side stand in the down position. This may interfere with rider control during a left turn and could cause an accident.
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5. Loosen the axle shaft 3 tem- porarily. NOTE: A special tool is necessary to loosen the shaft 3. The special tool is available at a Suzuki dealer. 6. Place an accessory service stand or equivalent under the swingarm to help stabilize the 9.
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Suzuki dealer to check the restored. Also check that the bolts and nuts. wheel rotates freely. Front axle tightening torque: ...
REAR WHEEL REMOVAL CAUTION A hot muffler can burn you. Wait until the muffler cools before removing the axle nut. NOTICE 3. Remove the axle nut 1. 4. Place an accessory service Removing the rear wheel with- stand or equivalent under the out use of an accessory stand swingarm to lift the rear wheel can result in your motorcycle...
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6. Draw out the axle shaft. 9. Pull the rear wheel assembly rearward. NOTE: Never depress the rear brake pedal with the rear wheel removed. It is very difficult to force the pads back into the caliper assembly. 10.To replace the wheel, reverse the complete sequence listed above.
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Also check that the are not sure of the proper wheel rotates freely. procedure, have your autho- rized Suzuki dealer or a qual- ified mechanic do this. Rear axle nut tightening torque: 100 N·m (10.0 kgf-m, 72.5 lbf-ft) 7-47...
LIGHT BULB REPLACEMENT HEADLIGHT/POSITION LIGHT To replace the headlight bulb and The wattage rating of each bulb is position light bulb, perform the fol- shown in the following chart. lowing step: When replacing a burned out bulb, always use the same watt- To remove the instrument panel age rating.
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Headlight High beam bulb 1. Disconnect the coupler 1. Turn the socket 2 counter- clockwise and remove it. 3. Move the instrument panel to the arrowed direction. 2. Pull off the bulb 3 from the socket. NOTICE The headlight bulb’s life may 4.
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Low beam bulb Position Light 1. Turn the socket 1 counter- clockwise and remove it. 1. Turn the cap 1 counterclock- wise and remove it. 2. Disconnect the coupler. 2. Pull off the bulb 2 from the socket. 3. Unhook the bulb holder spring 2 and pull out the bulb 3.
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Headlight Beam Adjustment Turn Signal Light The headlight beam can be To replace the turn signal light adjusted both right and left or up bulb, follow these directions. and down if necessary. High Beam 1. Remove the screw and take off the lens.
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License Plate Light To replace the license plate light bulb, follow the procedure steps: 3. Push in on the bulb, twisting it to the left, and pull it out. 4. To fit the replacement bulb, push it in and twist it to the right while pushing.
If a blown fuse is found, then the electrical problem must inspected and repaired before replacing the blown fuse with a new fuse. Consult your Suzuki 1. Disconnect the coupler while dealer for the electrical system pushing the release knob. check and repair. WARNING...
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FUSE LIST • 30A MAIN fuse protects all electrical circuits. • 15A HEAD-HI fuse protects the headlight high beam and speedometer. • 15A HEAD-LO fuse protects the headlight low beam. • 10A FUEL fuse protects the ISC, ECM, speedometer, fuel pump and injectors.
FRONT BRAKE LEVER FITTING CLUTCH LEVER FITTING Align the dot mark on the handle- Align the dot mark on the handle- bar with the mating surface of the bar with the mating surface of the lever holder A. lever holder A. 7-55...
CATALYTIC CONVERTER NOTICE The purpose of the catalytic con- verter is to minimize the amount Improper motorcycle opera- of harmful pollutants in your tion can cause catalyst or other motorcycle’s exhaust. motorcycle damage. leaded fuel motorcycles equipped with catalytic converters To avoid damage to the catalyst is prohibited because lead deacti- or other related components,...
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WARNING If you park or operate the motorcycle in areas where there are combustible materi- als such as dry grass or leaves, these materials may come in contact with the catalytic con- verter or other hot exhaust components. This can cause a fire.
TROUBLESHOOTING FUEL SYSTEM CHECK ..................8-2 IGNITION SYSTEM CHECK ................8-3...
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NOTICE injection system, take your machine to an authorized Suzuki Improper repairs or adjust- dealer. Refer to the “INSTRU- ments may damage the motor- MENT PANEL” section for an cycle instead of fixing it. Such...
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Suzuki dealer. machine authorized Suzuki dealer. Refer to the “INSTRUMENT PANEL” sec- tion for an explanation of the malfunction indicator. 3. Check the ignition system for intermittent spark.
STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE ..................9-2 PROCEDURE FOR RETURNING TO SERVICE ..........9-3 CORROSION PREVENTION ................9-3 MOTORCYCLE CLEANING ................9-4 INSPECTION AFTER CLEANING ............... 9-6...
Suzuki recommends that you entering. trust this maintenance work to your Suzuki dealer. If you wish to BATTERY service the machine for storage 1. Remove the battery from the yourself, follow the general guide-...
PROCEDURE FOR RETURNING CORROSION PREVENTION TO SERVICE It is important to take good care of your motorcycle to protect it from 1. Clean the entire motorcycle. corrosion and keep it looking new 2. Remove the oily rags from the for years to come. air cleaner intake and muffler outlet.
Do not use gone through to the bare hard materials which metal, have a Suzuki dealer scratch the paint. make the repair. 2. Wash the entire motorcycle • Store your motorcycle in a dry, with a mild detergent or car well-ventilated area.
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“touch-up” the dam- discolored so as to obstruct view. age following the procedure When replacing the windshield, below: use a Suzuki replacement wind- a. Clean all damaged spots shield. and allow them to dry. b. Stir the paint and “touch- up”...
Speedometer Display Cleaning INSPECTION AFTER CLEANING When the speedometer display is For extended life of your motorcy- to be cleaned, wipe gently using a cle, lubricate it according to the moist cloth. “LUBRICATION POINTS” section. WARNING NOTICE When the speedometer display Operating the motorcycle with is wiped or rubbed aggres- wet brakes can be hazardous.
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CONSUMER INFORMATION WARRANTIES ....................10-2 EMISSION CONTROL SYSTEMS ..............10-3 REPORTING SAFETY DEFECTS ..............10-4 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ...... 10-5 ON-BOARD MOTORCYCLE COMPUTER DATA INFORMATION ....10-6 SERIAL NUMBER LOCATION ................10-7 LOCATION OF LABELS ................... 10-8 10-1...
Suzuki limited warranties and the CONSUMER Federal and California Emission INFORMATION Control System Limited Warranty may not cover damage caused by modifications that would change WARRANTIES the original vehicle specifications The warranties for your motorcy- including, without limitation, modi- cle are explained in a separate...
If parts replacement is necessary, replace These regulations set specific the parts with Genuine Suzuki standards for exhaust emission parts or their equivalent. Installing output levels and fuel permeation improper replacement parts or...
REPORTING SAFETY To contact Suzuki Motor of Amer- ica, Inc., owners in the continental DEFECTS United States can call toll-free 1- If you believe that your vehicle 800-444-5077, or write to: Suzuki has a defect which could cause a Motor of America, Inc. Motorcy- crash or could cause injury or cle Customer Service P.O.
1. The removal or rendering inop- Whenever replacing parts on your erative by any person other motorcycle, Suzuki recommends than for purposes of mainte- that you use genuine Suzuki nance, repair, or replacement, replacement parts or their equiva- of any device or element of lent.
Suzuki may use as engine speed and throttle the data for research conducted position are monitored to pro- by Suzuki, make the data avail- vide emission control and to able for outside research if need provide optimum fuel econ- is shown and confidentiality is omy.
SERIAL NUMBER LOCATION Write down the serial numbers here for your future reference. You need to know the frame and engine serial numbers to get title Frame No.: documents for your motorcycle. You also need these numbers to help your dealer when you order Engine No.: parts.
The owner’s manual contains important safety information and instructions which should be read carefully before operating the vehicle. If the vehicle has been resold, obtain the owner’s manual from the previous owner or contact your local SUZUKI dealer for assistance. 10-8...
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V E H I C L E E M I S S I O N C O N T R O L I N F O R M A T I O N S U Z U K I M O T O R C O R P O R A T I O N D I S P L A C E M E N T : E N G I N E F A M I L Y : P E R M E A T I O N F A M I L Y :...
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DL650A DUAL RIDING SOLO RIDING COLD TIRE PRESSURE kgf/cm kgf/cm FRONT 2.25 2.25 REAR 2.50 2.80 FRONT REAR TIRE SIZE 110/80R19M/C 59H 150/70R17M/C 69H TYPE BRIDGESTONE TW101 J TW152 F DL650XA SOLO RIDING DUAL RIDING COLD TIRE PRESSURE PILOTE SEUL AVEC PASSAGER PRESSION DES PNEUS A FROID...
SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..........2275 mm (82.5 in) Overall width............ 835 mm (32.9 in) ... DL650A 910 mm (35.8 in) ... DL650XA Overall height ..........1405 mm (55.3 in) Wheelbase ............1560 mm (61.4 in) Ground clearance..........170 mm (6.7 in) Curb mass ............
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ELECTRICAL Ignition type .............Electronic ignition (Transistorized) Spark plug ............NGK MR8E-9 Battery .............12V 36.0kC(10Ah)/10HR Generator ............Three-phase A.C. generator Main fuse............30A Fuse ..............15/15/15/15/10/10/3A ABS fuse ............25/15A Headlight high beam ........12V 65W H9 Headlight low beam.........12V 55W H7 Position light ............12V 5W Brake light/Taillight...........LED License plate light..........12V 5W Turn signal light ..........12V 21W Speedometer light ...........LED...
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INDEX ACCESSORIES AND EMISSION CONTROL LOADING ....... 1-5 SYSTEMS ......10-3 ACCESSORY INSTALLATION ENGINE COOLANT .....7-27 GUIDELINES......6-2 ENGINE COOLANT ACCESSORY USE ....6-2 SOLUTION ......2-5 AIR CLEANER ..... 7-11 ENGINE IDLE SPEED INSPECTION......7-25 ENGINE OIL ....2-4 7-20 BATTERY....... 7-9 BE EXTRA SAFETY- CONSCIOUS ON BAD FRONT BRAKE LEVER...
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IF A COLLISION IS IMMINENT, MAINTENANCE DO SOMETHING! ....1-3 SCHEDULE ......7-2 IF YOU DON’T HAVE A HELMET, MODIFICATION .....6-5 BUY A HELMET, AND WEAR IT MOST ACCIDENTS CAN BE EVERY TIME YOU RIDE ..1-2 AVOIDED .......1-2 IGNITION SWITCH ....3-5 MOTORCYCLE IGNITION SYSTEM CLEANING ......9-4...
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REAR BRAKE PEDAL ..3-32 TAMPERING WITH NOISE REAR WHEEL CONTROL SYSTEM REMOVAL......7-45 PROHIBITED......10-5 REPORTING SAFETY THROTTLE CABLE DEFECTS......10-4 PLAY ........7-26 RIDING ON HILLS ....5-6 TIRES ........7-37 RIGHT HANDLEBAR ... 3-28 TOOLS ........7-5 SEAT LOCK ......3-32 USING THE SERIAL NUMBER TRANSMISSION ....5-5...
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