Suzuki DR650SE

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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)

Main Page

How to Use this Manual4
Component Parts and Work to be Done4
General Precautions8
General Information9
Right Side10
Left Side10
Serial Number Location10
Brake Fluid11
Front Fork Oil11
Break-In Procedures11
Information Labels12
Country or Area16
Periodic Maintenance Schedule18
Periodic Maintenance Chart18
Lubrication Points19
Maintenance and Tune-Up Procedures20
Valve Clearance20
Engine20
Spark Plug Gap21
Air Cleaner Element22
Throttle Cable Adjustment23
Engine Oil and Oil Filter25
Drive Chain26
Brake Pads28
Brake Pedal Height28
Front Forks31
Rear Suspension31
Chassis Bolts and Nuts32
Compression Pressure Check34
Compression Test Procedure34
Oil Pressure Check35
Engine Components Removable with the Engine in Place38
Engine Removal and Reinstallation39
Engine Reinstallation43
Engine Disassembly46
Engine Components Inspection and Service54
Cylinder Head Service56
Cylinder Head Distortion56
Valve Stem Deflection57
Valve Seat Width59
Valve Seat Servicing59
Valve Spring61
Camshaft Journal Wear63
Camshaft Runout64
Cylinder Distortion64
Cylinder Bore64
Piston Diameter64
Piston -Cylinder Clearance65
Piston Ring-Groove Clearance65
Piston Pin and Pin Bore66
Crankshaft Runout67
Clutch Spring Free Length70
Starter Clutch71
Starter Torque Limiter72
Crankcase Bearings77
Oil Filter78
Engine Reassembly79
Oil Seals79
Gearshift Mechanism81
Gearshift Shaft84
Oil Pump85
Starter Clutch and Generator88
Fuel System96
Fuel and Lubrication97
Fuel Valve/Fuel Filter Removal97
Inspection and Cleaning98
Specification100
Fuel and Lubrication System102
Slow System102
Main System103
Starter System104
Float System104
Carburetor Cleaning106
Needle Valve Inspection108
Float Height Adjustment108
Reassembly and Remounting109
Oil Pressure109
Oil Sump Filter109
Oil Cooler112
Chassis114
Front Wheel115
Inspection and Disassembly116
Spoke Nipple117
Brake Disc118
Front Brake119
Brake Pad Replacement120
Brake Fluid Replacement120
Caliper Removal and Disassembly121
Caliper Inspection122
Caliper Reassembly and Remounting122
Brake Disc Inspection123
Master Cylinder Removal and Disassembl y124
Master Cylinder Inspection125
Master Cylinder Reassembly and Remounting126
Front Fork127
Removal and Disassembly127
Fork Spring129
Reassembly and Remounting130
Rear Wheel140
Rear Sprocket143
Rear Axle Nut145
Rear Brake146
Caliper and Disc Inspection149
Rear Swingarm152
Inspection and Disassembly155
Shock Absorber156
Reassembly and Remounting157
Reassembling Information158
Final Inspection and Adjustment159
Shock Absorber Spring Pre-Load Adjustment159
Rear Shock Absorber166
Side Stand169
Side Stand Removal and Installation170
Warning Label170
Cautions in Servicing172
Semi-Conductor Equipped Part172
Electrical System173
Connecting Battery173
Wiring Procedure173
Location of Electrical Components174
Charging System175
Troubleshooting176
Side-Stand/Ignition Interlock System Description180
Starter Motor Removal and Disassembl y183
Starter Motor Inspection183
Carbon Brush183
Oil Seal Inspection184
Starter Motor Reassembly184
Starter Relay Inspection185
15 Electrical System186
Ignition System188
Spark Plug192
Removal and Disassembly193
Bulb Replacement195
Turn Signal Relay197
Initial Charging198
Recharging Operation200
Servicing Information202
Information203
Cable Routing216
Pair (Air Supply) System Hose Routing219
Rear Brake Hose Routing221
Heat Shield Adhering222
Special Tools223
Tightening Torque226
Tightening Torque Chart228
Service Data229
Cylinder Head230
Piston Ring230
Oil Pump231
Drive Chain232
Specification233
Brake + Wheel234
Tire Pressure236
Emission Control Information238
Emission Control Carburetor Components238
Evaporative Emission Control System239
Dr650Sev/W/X/Y241
Service Data244
Valve + Guide244
Cylinder Head245
Conrod + Crankshaft246
Brake + Wheel249
Tire Pressure251
Dr650Sek1 ('01-Model)253
Specifications254
Camshaft + Cylinder Head256
Cylinder + Piston + Piston Ring256
Transmission + Drive Chain258
Cylinder Head Cover263
Drive Train270
Dr650Sek9 ('09-Model)275

Suzuki DR650SE - Page 3

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