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DL650
Service manual
Suzuki DL650 Service Manual
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Also See for DL650
:
Service manual
(701 pages)
,
Owner's manual
(82 pages)
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
Component Parts
Glossary
Wire Color
Warningka Ution/Note
General Precautions
Serial Number Location
Fuel. Oil and Engine Coolant Recommendation
Fuel (for Usa and Canada)
Fuel (for Other Countries)
Engine Oil (for Usa)
Engine Oil (for Other Countries)
Brake Fluid
Front Fork Oil
Engine Coolant
Water for Mixing
Anti-Freezwengine Coolant
Liquid Amount of Watewengine Coolant
Break-In Procedures
Cylinder Identification
Information Labels
Specifications
Dimensions and Dry Mass
Engine
Drive Train
Chassis
Electrical
Capacities
Country and Area Codes
Table of Contents
Periodic Maintenance Schedule
Periodic Maintenance Chart
Lubrication Points
Maintenance and Tune-Up Procedures
Air Cleaner
Spark Plug
Valve Clearance
Fuel Line
Engine Oil and Oil Filter
Engine Idle Speed
Throttle Cable Play
Throttle Valve Synchronization
Evaporative Emission Control System (E-33 Only)
Pair (Air Supply) System
Clutch
Cooling System
Brake
Tire
Steering
Front Fork
Rear Suspension
Exhaust Pipe Bolt
Chassis Bolt and Nut
Compression Pressure Check
Compression Test Procedure
Oil Pressure Check
Table of Contents
Engine Components Removable with the Engine in Place
Engine Removal and Installation
Engine Removal
Engine Installation
Engine Disassembly
Engine Top Side
Engine Bottom Side
Engine Components Inspection and Servicing
Cylinder Head Cover
Camshaftkamshaft Journal
Cylinder Head
Cylinder
Piston and Piston Ring
Conrod and Crankshaft
Crankcase
Crankshaft Journal Bearing
Crankcase Bearing and Oil Seal
Clutch
Primary Driven Gear Assembly
Gearshift Shaftigearshift Arm
Transmission
Starter Clutch
Generator and Signal Generator
Oil Pump
Clutch Release
Engine Reassembly
Engine Bottom Side
Engine Top Side
Front Cylinde TDC of Compression Stroke
Table of Contents
Precautions in Servicing
Electrical Parts
Fuse
Ecmnarious Sensors
Electrical Circuit Inspection Procedure
Using Testers
Fi System Technical Features
Injection Time (Injection Volume)
Compensation of Injection Time (Volume)
Injection Stop Control
Fi System Parts Location
Self-Diagnosis Function
User Mode
Dealer Mode
Tps Adjustment
Fail-Safe Function
Fi System Troubleshooting
CUSTOMER COMPLAINT ANAL Ysls
Self-Diagnostic Procedures
Self-Diagnosis Reset Procedure
Malfunction Code and Defective Condition
C12" Ckp Sensor Circuit Malfunction
C13" Iap Sensor Circuit Malfunction
C14" Tp Sensor Circuit Malfunction
C15" Ect Sensor Circuit Malfunction
C21" Iat Sensor Circuit Malfunction
C23" to Sensor Circuit Malfunction
C24" or "C25" IGNITION SYSTEM MALFUNCTION
C28" Stv Actuator Circuit Malfunction
C29" Stp Sensor Circuit Malfunction
C31" Gear Position (Gp) Switch Circuit Malfunction
C32" or "C33" FUEL INJECTOR CIRCUIT MALFUNCTION
C41" Fp Relay Circuit Malfunction
C42" Ig Switch Circuit Malfunction
C49" Pair Control Solenoid Valve Circuit Malfunction
C44" H02 Sensor (H02S) Circuit Malfunction (E.02. 19)
Table of Contents
Engine Coolant
Cooling Circuit
Cooling Circuit Inspection
Removal
Inspection and Cleaning
Installation
Radiator Cap
Inspection
Water Hose
Cooling Fan
Inspection
Removal
Installation
Cooling Fan Thermo-Switch
Inspection
Installation
Ect Sensor
Removal
Inspection
Installation
Thermostat Case Assembly
Removal
Inspection
Installation
Water Pump
Removal and Disassembly
Inspection
Reassembly and Installation
Lubrication System
Oil Pressure
Oil Filter
Oil Pressure Regulator
Oil Strainer
Oil Jet
Oil Pump
Oil Pressure Switch
Oil Cooler
Removal
Inspection and Cleaning
Installation
Engine Lubrication Flow Chart
Engine Lubrication Circuit
Table of Contents
Construction
Removal
Installation
Front Wheel
Removal
Inspection and Disassembly
Reassembly and Remounting
Front Fork
Construction
Removal and Disassembly
Reassembly and Remounting
Suspension Setting
Steering and Handlebar
Construction
Removal
Inspection and Disassembly
Reassembly and Remounting
Steering Tension Adjustment
Rear Wheel
Construction
Removal
Inspection and Disassembly
Reassembly and Remounting
Rear Shock Absorber
Removal
Inspection
Rear Shock Absorber Disposal
Remounting
Suspension Setting
Rear Swingarm
Removal
Inspection and Disassembly
Reassembly
Final Inspection and Adjustment
Front Brake
Brake Pad Replacement
Brake Fluid Replacement
Caliper Removal and Disassembly
Caliper Inspection
Caliper Reassembly and Remounting
Brake Disc Inspection
Master Cylinder Removal and Disassembly
Master Cylinder Inspection
Master Cylinder Reassembly and Remounting
Rear Brake
Brake Pad Replacement
Brake Fluid Replacement
Caliper Removal and Disassembly
Caliper Inspection
Brake Disc Inspection
Caliper Reassembly and Remounting
Master Cylinder Removal and Disassembly
Master Cylinder Inspection
Master Cylinder Reassembly and Remounting
Inspection
Valve Installation
Tire Installation
Drive Chain
Drive Chain Cutting
Drive Chain Connecting
Table of Contents
Cautions in Servicing
Connector
Fuse
Semi-Conductor Equipped Part
Battery
Connecting the Battery
Wiring Procedure 8
Location of Electrical Components
Charging System
Trouble Shooting
Inspection
System
Trouble Shooting
Starter Motor Removal and Disassembly
Starter Motor Inspection
Starter Motor Reassembly
Starter Relay Inspection
Inspection
Ignition System
Troubleshooting
Inspection
Combination Meter
Removal and Disassembly
Inspection
Indicators
Lamps
Relays
Turn Signauside-Stand Relay
Starter Relay
Fuel Pump Relay
Switches
Inspection
Battery
Specifications
Initial Charging
Servicing
Recharging Operation
Table of Contents
Troubleshooting
Malfunction Code and Defective Condition
Engine
Radiator (Cooling System)
Chassis
Brakes
Battery
Speed Sensor Lead Wire Routing
Throttle Cable Routing
Clutch Cable Routing
Throttle Body Installationihose Routing
Cooling System Hose Routing
Front Brake Hose Routing
Fuel Tank Drain Hose Routing
Fuel Tank Installation
Pair (Air Supply) System Hose Routing
Seat Lock Cable Routing
Absorber Hose Routing
Battery Cushion Installation
Side-Stand Set-Up
Brake Pedaufootrest Set-Up
Engine Cap Installation
Footrest Set-Up
Handlebar Balancer Installation
Special Tools
Tightening Torque
Fi System Parts
Chassis
Tightening Torque Chart
Service Data
Emission Control Systems
Fuel Injection System
Crankcase Emission Control System
Exhaust Emission Control System (Pair System)
Noise Emission Control System
EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33)
Hoses
Pair Control Solenoid Valve
Pair (Air Supply) System Hose Routing
Heated Oxygen Sensor (H02S) Wire Routing (E-02,19)
(Only for E-33)
Hoses
Evap Canister
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Component Parts
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Fuel/Oil/Engine Coolant Recommendations
3
Table of Contents
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See also:
Owner's Manual
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SERVICE MANUAL
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Table of Contents
160
Table of Contents
245
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271
Table of Contents
358
Table of Contents
400
Table of Contents
Troubleshooting
FI SYSTEM TROUBLESHOOTING
178
CHARGING SYSTEM
364
SYSTEM
369
IGNITION SYSTEM
380
TROUBLESHOOTING
401
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This manual is also suitable for:
2004 dl650k4
Dl 650 2004
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