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General| Brand | Suzuki |
|---|---|
| Model | DL 650 2004 |
| Category | Motorcycle |
| Language | English |
Overview of motorcycle, precautions, recommendations, and specifications.
Schedule and chart for regular service work to maintain peak performance.
Procedures for engine service, inspection, and overhaul.
Troubleshooting and diagnosis for the Fuel Injection system.
Details on fuel delivery, pump, injectors, and throttle body systems.
Information on engine coolant, radiator, oil, and lubrication systems.
Components and maintenance related to the motorcycle frame and suspension.
Information on battery, charging, ignition, and lighting systems.
General servicing procedures, special tools, and specifications.
Information on emission control systems like PAIR and EVAP.
Electrical wiring diagram for troubleshooting and reference.
Overview of component parts and related service information like torque specs.
Explanation of signal words like WARNING, CAUTION, and NOTE used for safety and clarity.
Important safety and repair procedures for mechanics and the motorcycle.
Introduction to the specific DL650 model covered by the manual.
Location of the frame and engine serial numbers for identification.
Recommended types and specifications for fuel, oil, and engine coolant.
Specification and classification for the brake fluid used.
Recommended fork oil type for the front suspension.
Recommended engine coolant and mixing instructions.
Specification for water used with engine coolant.
Details on the function and use of anti-freeze/engine coolant.
Specified capacity for the cooling system.
Recommended procedures for breaking in the new engine.
Identification of engine cylinders as NO.1 and NO.2.
Locations and types of various information labels on the motorcycle.
Detailed technical specifications for engine, drive train, chassis, and electrical systems.
Codes for applicable countries and areas for model variations.
Recommended intervals for periodic service work.
Chart detailing intervals and actions for periodic maintenance items.
Identification of major lubrication points on the motorcycle.
Servicing procedures for periodic maintenance items like air cleaner and spark plugs.
Inspection and replacement procedures for the air cleaner element.
Inspection and replacement procedures for spark plugs.
Inspection and adjustment procedures for valve clearance.
Inspection and replacement intervals for the fuel line.
Procedures for changing engine oil and replacing the oil filter.
Inspection and adjustment of engine idle speed.
Inspection and adjustment procedures for throttle cable play.
Inspection of throttle valve synchronization.
Inspection of the evaporative emission control system for specific models.
Inspection of the PAIR (air supply) system.
Inspection of clutch operation and cable play.
Inspection, coolant level check, and coolant change procedures.
Inspection, cleaning, lubrication, and adjustment of the drive chain.
Inspection of brake fluid level, hoses, and pads.
Inspection of tire tread condition and tire pressure.
Inspection and adjustment of steering system for smooth operation.
Inspection of front forks for oil leakage or damage.
Inspection of rear suspension for oil leakage or damage.
Tightening procedures for exhaust pipe and muffler bolts.
Table of tightening torques for various chassis bolts and nuts.
Procedure for checking engine compression pressure.
Procedure for checking engine oil pressure.
Lists engine components that can be removed while the engine is installed.
Step-by-step procedures for removing and reinstalling the engine.
Detailed instructions for disassembling engine components.
Procedures for disassembling engine components located on the top side.
Procedures for disassembling engine components located on the bottom side.
Inspection and servicing procedures for various engine components.
Inspection and servicing of camshafts and journals for wear and runout.
Procedures for cylinder head disassembly, inspection, and servicing.
Inspection and measurement procedures for the cylinder.
Inspection and measurement of piston and piston ring dimensions.
Inspection and measurement of connecting rod and crankshaft components.
Procedures for transmission disassembly and inspection of gears and shafts.
Inspection, disassembly, and reassembly of the starter clutch.
Inspection and reassembly of the generator and CKP sensor.
Inspection procedure for the oil pump.
Inspection of clutch release components.
Important safety precautions when servicing the FI system.
Guidelines for handling connectors, couplers, and clamps in the electrical system.
Precautions regarding fuse replacement and usage.
Precautions for handling high-precision ECM and sensors.
General methods for checking electrical circuits for open and short circuits.
Procedure for checking circuit continuity using a multimeter.
Procedure for checking circuit voltage using a multimeter.
Method for checking wire harnesses for short circuits to ground.
Guidelines for using testers and probes correctly.
Overview of factors determining fuel injection time and compensations.
Factors influencing fuel injection time based on sensor signals.
Signals affecting fuel injection time compensation.
Systems that control fuel injection stop, like tip-over and rev limiter.
Diagram showing the location of various FI system components.
Electrical wiring diagram for the FI system.
Explanation of the self-diagnosis function modes and indicators.
How the user can interpret malfunction codes displayed on the LCD and FI light.
Procedure for accessing dealer mode to check memorized malfunction codes.
Table listing malfunction codes, detected items, and failure conditions.
Procedure for adjusting the Throttle Position Sensor.
Description of the fail-safe function and its modes of operation.
Guide for troubleshooting FI system issues based on customer complaints.
Form for recording customer complaints for proper analysis.
Steps for performing self-diagnosis to identify malfunctions.
Procedure to reset self-diagnosis codes after repairs.
Troubleshooting steps for Crankshaft Position Sensor circuit malfunction.
Troubleshooting steps for Intake Air Pressure Sensor circuit malfunction.
Troubleshooting steps for Throttle Position Sensor circuit malfunction.
Troubleshooting steps for Engine Coolant Temperature Sensor circuit malfunction.
Troubleshooting steps for Intake Air Temperature Sensor circuit malfunction.
Troubleshooting steps for Tip Over Sensor circuit malfunction.
Troubleshooting ignition system malfunctions.
Troubleshooting steps for Secondary Throttle Valve Actuator circuit malfunction.
Troubleshooting steps for Secondary Throttle Position Sensor circuit malfunction.
Troubleshooting steps for Gear Position Switch circuit malfunction.
Troubleshooting steps for Fuel Injector circuit malfunction.
Troubleshooting steps for Fuel Pump Relay circuit malfunction.
Troubleshooting steps for Ignition Switch circuit malfunction.
Troubleshooting steps for PAIR Control Solenoid Valve circuit malfunction.
Troubleshooting steps for Heated Oxygen Sensor circuit malfunction.
Overview of the fuel system and its components.
Description of the fuel delivery system and its components.
Construction and operation of the electric fuel pump.
Function and construction of the fuel pressure regulator.
Description of the fuel injector's construction and operation.
How the ECM controls the fuel pump operation.
Steps for lifting the fuel tank for access.
Procedures for safely removing the fuel tank.
Procedures for installing the fuel tank.
Steps for inspecting fuel pressure and identifying causes of low or high pressure.
Procedures for inspecting fuel pump operation and discharge amount.
Inspection procedure for the fuel pump relay.
Procedures for removing the fuel pump assembly and fuel filter.
Inspection and cleaning of the fuel mesh filter.
Procedures for installing the fuel pump and fuel mesh filter.
Diagram and parts list for the throttle body and STV actuator.
Steps for removing the air cleaner box and throttle body.
Procedures for removing the throttle body assembly.
Steps for disassembling the throttle body.
Procedures and precautions for cleaning the throttle body.
Items to check for damage or clogging in the throttle body.
Procedures for reassembling the throttle body.
Procedure for synchronizing the Secondary Throttle Valve.
Procedures for installing the throttle body assembly.
Procedure for adjusting the STP sensor positioning.
Installation of the air cleaner box.
Procedure for adjusting the TP sensor positioning.
Inspection of the fast idle system operation.
Procedure for adjusting the fast idle speed.
Procedure for synchronizing the throttle valves using vacuum gauges.
Steps for calibrating vacuum balancer gauges.
Details on engine coolant mixture, capacity, and handling precautions.
Overview of the cooling circuit and inspection for leaks.
Procedures for radiator removal, inspection, cleaning, and installation.
Inspection of the radiator cap's valve opening pressure.
Inspection of water hoses for cracks or leaks.
Inspection, removal, and installation procedures for the cooling fan.
Inspection, removal, and installation of the cooling fan thermo-switch.
Inspection, removal, and installation of the Engine Coolant Temperature sensor.
Procedures for removing, inspecting, and installing the thermostat case.
Procedures for water pump removal, disassembly, inspection, and reassembly.
Information on oil pressure, filter, regulator, strainer, jet, pump, and switch.
Procedures for oil cooler removal, inspection, cleaning, and installation.
Flow chart illustrating the engine lubrication system.
Diagram of the engine lubrication circuit for the front and rear cylinders.
Construction details of exterior parts like fairings and windshield.
Construction, removal, inspection, and reassembly of the front wheel.
Construction, removal, inspection, and reassembly of the front fork.
Construction, removal, inspection, and adjustment of the steering and handlebar assembly.
Construction, removal, inspection, and reassembly of the rear wheel.
Construction, removal, inspection, and disposal of the rear shock absorber.
Construction, removal, inspection, and reassembly of the rear swingarm.
Construction, pad replacement, fluid replacement, and caliper procedures.
Inspection of brake discs for thickness and runout.
Procedures for removing and disassembling the master cylinder.
Procedures for reassembling and remounting brake calipers.
Procedures for cutting, joining, and adjusting the drive chain.
General precautions for servicing electrical components.
Guidelines for connecting and inspecting electrical connectors.
Guidelines for disconnecting and connecting electrical couplers.
Proper methods for clamping wire harnesses.
Precautions regarding fuse inspection and replacement.
Precautions for handling parts with built-in semiconductors like ECM.
Information on MF battery maintenance, charging, and handling.
Procedures for disconnecting and connecting battery terminals.
Guidelines for routing wire harnesses.
Instructions and precautions for using a multi-circuit tester.
Diagrams showing the location of various electrical components.
Troubleshooting guide for battery drain and charging issues.
Troubleshooting steps for common charging system problems.
Troubleshooting for starter and interlock system issues.
Troubleshooting steps when the starter motor does not operate.
Troubleshooting steps when the starter motor runs but the engine doesn't turn.
Procedures for removing and disassembling the starter motor.
Inspection of starter motor components like brushes, commutator, coils, and seals.
Procedures for reassembling the starter motor.
Inspection procedure for the starter relay.
Inspection of side-stand and gear position switches.
Inspection of the side-stand switch.
Inspection of the gear position switch.
Removal and installation of the turn signal/side-stand relay.
Troubleshooting and inspection of the ignition system for spark issues.
Causes and remedies for ignition system problems.
Procedure for measuring ignition coil primary peak voltage.
Procedure for measuring ignition coil primary and secondary resistance.
Procedure for measuring CKP sensor peak voltage.
Procedure for measuring CKP sensor resistance.
Removal, disassembly, and inspection of the combination meter.
Troubleshooting the odometer display.
Troubleshooting and resetting the trip meter.
Steps to reset the trip meter.
Inspection of the engine coolant temperature meter.
Inspection of the fuel level gauge resistance.
Inspection of the fuel level meter display.
Procedure to check the oil pressure indicator light.
Inspection and troubleshooting of the speedometer and speed sensor.
Specifications and beam adjustment for headlights, brake lights, and turn signals.
How to adjust headlight beam vertically and horizontally.
Inspection of turn signal, side-stand, starter, and fuel pump relays.
Removal and inspection of the ignition switch.
Guide to diagnosing and resolving common engine and chassis issues.
Table correlating malfunction codes with detected items and failure conditions.
Troubleshooting steps for engine starting, idling, stalling, and power issues.
Possible causes and remedies for engine starting problems.
Causes and remedies for poor engine idling.
Causes and remedies for the engine stalling frequently.
Identifying and addressing sources of engine noise.
Causes and remedies for poor engine performance at high speeds.
Troubleshooting issues related to engine deceleration.
Causes and remedies for engine overheating.
Causes and remedies for dirty exhaust or excessive smoke.
Causes and remedies for clutch slippage.
Causes and remedies for clutch dragging.
Causes and remedies for transmission shifting problems.
Troubleshooting issues related to the radiator and cooling system.
Causes and remedies for engine overheating.
Causes and remedies for engine overcooling.
Troubleshooting common chassis-related issues.
Causes and remedies for heavy steering.
Causes and remedies for wobbly handlebars.
Causes and remedies for a wobbly front wheel.
Causes and remedies for a soft front suspension.
Causes and remedies for a stiff front suspension.
Causes and remedies for noise in the front suspension.
Causes and remedies for a wobbly rear wheel.
Causes and remedies for a soft rear suspension.
Causes and remedies for a stiff rear suspension.
Causes and remedies for noise in the rear suspension.
Troubleshooting issues related to brakes, including power, squeaking, lever stroke, and fluid leaks.
Causes and remedies for insufficient brake power.
Causes and remedies for brake squeaking.
Causes and remedies for excessive brake lever stroke.
Causes and remedies for brake fluid leakage.
Causes and remedies for brake drag.
Troubleshooting electrical issues like no spark or poor spark.
Causes and remedies for ignition system problems.
Causes and remedies for spark plugs fouling with carbon.
Causes and remedies for spark plugs fouling prematurely.
Causes and remedies for spark plug electrode overheating or burning.
Troubleshooting generator charging issues.
Causes for low charging rate despite the generator charging.
Causes for generator overcharging.
Causes for unstable charging.
Troubleshooting steps when the starter button is ineffective.
Information on battery sulfation, quick discharge, and charging issues.
Diagrams showing the routing of wire harnesses, cables, and hoses.
List and images of special tools required for servicing.
Lists tightening torque specifications for engine and FI system components.
Table of service data including valve, piston, and crankshaft specifications.
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