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Suzuki DL650/AK7DL650/AK8 User Manual

Suzuki DL650/AK7DL650/AK8
701 pages
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GROUP INDEX
GENERAL INFORMATION
1
PERIODIC MAINTENANCE
2
ENGINE
3
FI SYSTEM DIAGNOSIS
4
FUEL SYSTEM AND THROTTLE
BODY
5
COOLING AND LUBRICATION
SYSTEM
6
CHASSIS
7
ELECTRICAL SYSTEM
8
SERVICING INFORMATION
9
10
FOREWORD
This manual contains an introductory description on
the SUZUKI DL650 and procedures for its inspec-
tion/service and overhaul of its main components.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the motorcycle and its main-
tenance. Use this section as well as other sections
to use as a guide for proper inspection and service.
This manual will help you know the
motorcycle bet-
ter so that you can assure your customers of fast
and reliable service.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2003
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual motorcycle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedu
res. They may not represent the
actual motorcycle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI motorcy-
cles. If you do not have the proper knowledge
and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the motorcycle
unsafe for the rider and passenger.
EMISSION CONTROL
INFORMATION
99500-36135-03E
PartShark.com
877-999-5686

Table of Contents

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Suzuki DL650/AK7DL650/AK8 Specifications

General IconGeneral
BrandSuzuki
ModelDL650/AK7DL650/AK8
CategoryMotorcycle
LanguageEnglish

Summary

FOREWORD

HOW TO USE THIS MANUAL

COMPONENT PARTS AND WORK TO BE DONE

Explains exploded views and service information for components like the front wheel.

SYMBOL

ABBREVIATIONS USED IN THIS MANUAL

GENERAL INFORMATION

WARNING/CAUTION/NOTE

Explains meanings of signal words for special information and safety.

GENERAL PRECAUTIONS

Lists safety procedures for service mechanics and motorcycle reliability.

SERIAL NUMBER LOCATION

Explains where to find frame and engine serial numbers for registration and parts.

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION

Provides specifications for fuel, oil, and coolant used in the motorcycle.

SPECIFICATIONS

Contains crucial technical data for various motorcycle systems.

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

Lists recommended intervals for periodic service work to maintain peak performance and economy.

PERIODIC MAINTENANCE CHART

A chart detailing service items, intervals, and required actions (Inspect, Replace, Tighten).

LUBRICATION POINTS

Indicates major points requiring lubrication for smooth operation and longevity of motorcycle parts.

MAINTENANCE AND TUNE-UP PROCEDURES

Describes servicing procedures for items listed in the periodic maintenance requirements.

ENGINE

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE

Lists engine components that can be removed while the engine is installed on the chassis.

ENGINE REMOVAL AND INSTALLATION

Details the sequential steps for removing and reinstalling the engine from the motorcycle frame.

ENGINE DISASSEMBLY

Provides procedures for disassembling the engine, categorized into top and bottom side components.

ENGINE REASSEMBLY

Outlines the steps for reassembling the engine in reverse order of disassembly.

FI SYSTEM DIAGNOSIS

PRECAUTIONS IN SERVICING

Lists important safety points for handling FI system components and ensuring system safety.

ELECTRICAL PARTS

Provides guidelines for handling electrical connectors, emphasizing proper connection and cleanliness.

SELF-DIAGNOSIS FUNCTION

Explains self-diagnosis modes and how to check for malfunctions via LCD and FI light.

MALFUNCTION CODE AND DEFECTIVE CONDITION

Lists diagnostic trouble codes, detected items, failure conditions, and corresponding checks.

FUEL SYSTEM AND THROTTLE BODY

FUEL SYSTEM

Describes the components of the fuel delivery system and how fuel pressure is regulated.

FUEL DELIVERY SYSTEM

Details the fuel system components: tank, pump, filters, injectors, and regulator.

FUEL PUMP

Explains the construction and operation of the electric fuel pump and its ECM control.

THROTTLE BODY AND STV ACTUATOR

Outlines the construction of the throttle body and STV actuator assembly, showing component locations.

COOLING AND LUBRICATION SYSTEM

ENGINE COOLANT

Provides information on recommended coolant mixture, freezing points, and handling precautions.

COOLING CIRCUIT

Details cooling circuit components and procedures for checking tightness under pressure.

WATER PUMP

Details removal, disassembly, inspection, and reassembly procedures for the water pump.

LUBRICATION SYSTEM

Lists lubrication system components: oil pressure, filter, pump, and related parts.

CHASSIS

FRONT WHEEL

Shows the construction of the front wheel assembly, identifying components like brake discs, bearings, and axle.

FRONT FORK

Details the construction of the front fork, including spring, damper, and oil seal components.

STEERING AND HANDLEBAR

Illustrates the construction of the steering stem and handlebar assembly, including bearings and seals.

REAR WHEEL

Shows the construction of the rear wheel assembly, identifying components like axle, sprocket, and brake disc.

FRONT BRAKE

Shows the construction of the front brake system, including caliper, master cylinder, and disc components.

REAR BRAKE

Illustrates the construction of the rear brake system, including caliper, master cylinder, and disc.

ELECTRICAL SYSTEM

CAUTIONS IN SERVICING

Provides crucial safety precautions for servicing electrical components like connectors, couplers, clamps, and fuses.

BATTERY

Explains MF battery maintenance, charging precautions, and connection procedures.

CHARGING SYSTEM

Covers troubleshooting for battery drain and overcharging, including checks for generator, regulator, battery.

STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM

Details troubleshooting for starter motor, starter relay, and side-stand/ignition interlock system.

IGNITION SYSTEM

Discusses troubleshooting for no spark or poor spark, including checks for spark plugs, coils, and ECM.

SERVICING INFORMATION

TROUBLESHOOTING

Provides a table listing malfunction codes, detected items, failure conditions, and checks for troubleshooting.

ENGINE

Addresses engine starting issues (won't start, hard to start) with symptoms, causes, and remedies.

BRAKES

Covers troubleshooting for insufficient brake power, squeaking, excessive lever stroke, and fluid leakage.

ELECTRICAL

Addresses electrical issues like no spark, fouled plugs, and generator charging problems.

EMISSION CONTROL INFORMATION

EMISSION CONTROL SYSTEMS

Introduces the fuel injection system for emission level control, designed to meet applicable limits.

FUEL INJECTION SYSTEM

Explains fuel injection system components and function, including the fuel delivery system.

CRANKCASE EMISSION CONTROL SYSTEM

Describes the PCV system drawing blow-by gas into the crankcase and returning it to the combustion chamber.

EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM)

Details the PAIR system and three-way catalyst, explaining fresh air intake into the exhaust port.

EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33)

Provides inspection procedures for the evaporative emission control system for E-33 models.

DL650K5 ('05-MODEL)

SPECIFICATIONS

Lists detailed specifications for dimensions, engine, drive train, chassis, electrical, and capacities.

SERVICE DATA

Provides standard and limit values for valve, camshaft, and cylinder measurements.

DL650K6 ('06-MODEL)

SPECIFICATIONS

Lists detailed specifications for dimensions, engine, drive train, chassis, electrical, and capacities.

SERVICE DATA

Provides standard and limit values for valve, camshaft, and cylinder measurements.

DL650K7/AK7 ('07-MODEL)

SPECIFICATIONS (DL650K7)

Lists detailed specifications for dimensions, engine, drive train, chassis, electrical, and capacities for DL650K7.

SPECIFICATIONS (DL650AK7)

Lists detailed specifications for dimensions, engine, drive train, chassis, electrical, and capacities for DL650AK7.

PERIODIC MAINTENANCE SCHEDULE

Lists recommended intervals for periodic service work to maintain peak performance and economy.

MAINTENANCE AND TUNE-UP PROCEDURES

Describes servicing procedures for items that differ from the DL650K6 ('06-MODEL).

FI SYSTEM DIAGNOSIS

Details ECM terminal functions and the self-diagnosis process for FI system malfunctions.

DL650/AK8 ('08-MODEL)

SERVICE DATA (DL650K8)

Provides standard and limit values for valve, camshaft, and cylinder measurements for DL650K8.

SERVICE DATA (DL650A/AUEK8)

Provides standard and limit values for valve, camshaft, and cylinder measurements for DL650A/AUEK8.

DL650/AK9 ('09-MODEL)

SPECIFICATIONS

Lists detailed specifications for dimensions, engine, drive train, chassis, electrical, and capacities.

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