Suzuki DL650 User manual

OWNER'S MANUAL
SUZUKl
NSD Ref. P4023/9

IMPORTANT
BREAK-IN(RUNNING-IN)
INFORMATIONFOR YOUR
MOTORCYCLE
The first 1600km (1000 miles)are the
most important in the life of your
motorcycle. Proper break-inoperation
during this time will helpensure maxi-
mum life and performance from your
new motorcycle. Suzuki parts are
manufactured of high quality materi-
als, and machined parts are finished
to close tolerances. Proper break-in
operation allows the machined sur-
faces to polish each other and mate
smoothly.
Motorcycle reliability and perfor-
mance depend on special care and
restraint exercised duringthe break-in
period. It is especially important that
you avoid operating the engine in a
manner which could expose the
engine parts to excessiveheat.
Please refer to the BREAK-IN (RUN-
NING-IN) sectionfor specific break-in
recommendations.
WARNINGICAUTIONINOTE
Please readthis manualand follow its
instructions carefully. To emphasize
special informationthe words WARN-
ING, CAUTION and NOTE carry spe-
cial meaningsand shouldbe carefully
reviewed.
The personal safety of the rider
may be involved. Disregarding
this information could result in
injury to the rider.
CAUTION
These instructions point out spe-
cial service proceduresor precau-
tions that must be followed to
avoiddamaging the machine.
NOTE: ThisDrovides s~ecialinforma
tion to maki maintenance easier or
important instructions clearer.

FOREWORD
Motorcyclingis one of the most exhil-
arating sports and to ensure your
riding enjoyment. you should become
thoroughly familiar with the informa-
tion presentedin this Owner's Manual
before ridingthe motorcycle
.
The proper care and maintenance
that your motorcycle requires is out-
lined in this manual
. By following
these instructions explicitly you will
ensure a long trouble free operating
life for your motorcycle
. Your autho-
rized Suzuki dealer has experienced
techniciansthat are trained to provide
your machine with the best possible
service with the righttools and equip-
ment
.
All information. illustrations. photo-
graphs and specifications contained
inthis manualare basedon the latest
product information available at the
time of publication
. Due to improve-
ments or other changes. there may
be some discrepancies in this man-
ual
. Suzuki reservesthe rightto make
changes at any time
.
Please note that this manual applies
to all specifications or all respective
destinations and explains all equip-
ment
. Therefore. your model may
have different standard features than
shown inthis manual
.
SUZUKl MOTOR CORPORATION
0 COPYRIGHT SUZUKl MOTOR
CORPORATION
2003
TABLE OF
2
CONTENTS
CONSUMER INFORMATION ............ 4
ACCESSORY USE AND
MOTORCYCLE LOADING
........................ 4
SAFE RIDING RECOMMENDATION
FOR MOTORCYCLE RIDERS
................... 6
SERIAL NUMBER LOCATION .................. 7
LOCATION OFPARTS ....................... 8
CONTROLS ........................................ I I
KEY ....................................................... 11
IGNITIONSWITCH
.................................. 11
INSTRUMENT PANEL
............................. 13
LEFT HANDLEBAR
................................. 18
RIGHT HANDLEBAR
............................... 19
FUEL TANK CAP
..... :: ............................ 21
GEARSHIFT LEVER
................................ 22
REAR BRAKE PEDAL
............................ 22
SEAT LOCK
............................................ 23
HELMET HOLDER
................................... 23
SIDE STAND
........................................... 24
SUSPENSION ADJUSTMENT
................ 25
WINDSHIELD HEIGHT
ADJUSTMENT
....................... .. ........... 27
FUEL. ENGINE OIL AND
COOLANT RECOMMENDATION...
28
FUEL ........................................................ 28
ENGINE OIL
............................................. 29
COOLANT
................................................ 29
BREAK-IN (RUNNING-IS ............... 30
MAXIMUM ENGINE SPEED
RECOMMENDATION
.............................. 30
VARY THE ENGINE SPEED
................... 30
BREAKING INTHE
NEW TIRES ............. 30
...........
AVOID CONSTANT LOW SPEED 31
ALLOW THE
EM 011 TO
CIRCULATE BEFORE
Wl)(G ............... 31
OBSERVE YOUR
RRST AND MOST
CRITICAL
SERVICE ...................... 31
INSPECTIOS BEFORE RIDING ....... 31
...................................... RIDING TIPS 33
.................... STARTING M W(ilE , 33

STARTING OFF ..................................... 33
USINGTHETRANSMISSION ................. 34
RIDINGON HILLS ................................... 35
STOPPINGAND PARKING ..................... 36
INSPECTION AND
................................
MAINTENANCE 37
MAINTENANCESCHEDULE .................. 37
TOOLS ..................................................... 40
FUELTANK LIFT .................................... 40
LUBRICATIONPOINTS .......................... 41
BAllERY ................................................ 42
AIR CLEANER ......................................... 43
SPARK PLUGS ...................................... 45
FUELHOSE ............................................. 47
ENGINEOIL ............................................. 48
IDLESPEED ............................................ 51
......................
THROllLECABLE PLAY 52
COOLANT ................................................ 53
DRIVECHAIN .......................................... 54
CLUTCH ................................................... 57
BRAKES .................................................. 58
TIRES ....................................................... 62
SIDESTANDnGNlTlON
INTERLOCKSWITCH
............................ 65
....................
FRONT WHEEL REMOVAL 66
......................
REAR WHEEL REMOVAL 6E
...............
LIGHTBULBREPLACEMENT 6f
FUSES ..................................................... 7i
TROUBLESHOOTING ...................... 7:
............
MOTORCYCLE CLEANING 74
..................
STORAGE PROCEDURE 7C
SPECIFICATIONS ............................. 7t

CONSUMER
INFORMATION
ACCESSORYUSEAND
MOTORCYCLE LOADING
Accessory Use
The addition of unsuitable accesso
ries can leadto unsafe operatingcon
ditions. It is not possiblefor Suzuki tc
test each accessory on the market o
combinations of all the availablt
accessories; however, your deale
can assist you in selecting qualit!
accessories and installing them cor
rectly. Use extreme caution wher
selecting and installing the accesso
ries on your motorcycle and consul
your Suzuki dealer if you have an!
questions.
Improper accessory installation
can make your motorcycle unsafe
and can leadto an accident.
Use Suzuki genuine accessories
or equivalent,designed and tested
for your motorcycle. Follow the
guidelines inthis section.
Accessory installation
guideline
Install - aerodynamic afled~ng
accessories, such
as a fainng,
windshield, backrests, saddle-
bags, and travel trunks.
as low as
possible, as close to
the motorcy-
cle and as near the centerof grav-
ity as is feasible.
Check that the
mounting brackets and other
attachment hardware are rigidly
mounted.
lnspect for proper ground clear-
ance and bank angle. Inspectthat
the accessory does not interfere
with the operation of the suspen-
sion, steering or other control
operations.
Accessories fined to the handle-
bars or the front fork area can cre-
ate serious stability problems.
This extra weight will cause the
motorcycle to be less responsive
to your steering control. The
weight may also cause oscillations
in the front end and lead to insta-
bility problems. Accessories
added to the handlebars or front
fork of the machine should be as
light as possible and kept to
a
minimum.
Select an accessory which does
not limit the freedom of rider
movement.
Select an electric accessory
which does not exceed motorcy-
cle's electrical system capacity.
Severe overloads may damage
the wiring harness or create haz-
ardoussituations.
Do not pull a trailer or sidecar.
This motorcycleis not designedto
pull a trailer or sidecar.

Loading Limit
Overloading or improper loading
can cause loss of motorcyclecon-
trol and this may result in an acci-
dent.
Follow loading limits and loading
guidelinesinthis manual.
Never exceedthe G.V.W. (GrossVehi
cle Weight) of this motorcycle. Thc
G.V.W. is the combined weight of thc
machine, accessories, payload an(
rider. When selecting your access0
ries, keep in mind the weight of tht
rider as well as the weight of tht
accessories.The additional weight
a
the accessories may not only creatc
an unsafe riding condition but m$
also affect the ridingstability.
G.V.W.: 420 kg (926 Ibs)
at the tire pressure(cold)
Front:2.25 kgf/cm2(33 psi)
Rear:2.80 kgf/cm2(41 psi)
Loading Guidelines
This motorcycle is primarily intended
to carry small itemswhen you are not
riding with a passenger. Follow the
guidelines below to carry a passenger
or cargo:
~iancethe load betweenthe left
and right side of the motorcycle
and fasten it securely.
Keep cargo weight low and close
to the center of the motorcycleas
possible.
Do not attachlargeor heavy items
to the handlebars, front forks or
rear fender.
Do not install a luggage carrier or
a luggage box protruding over the
tail end of the motorcycle.
Do not carry any items that pro-
trude over the tail end of the
motorcycle.
Check that both tires are properly
inflated to the specified tire pres-
sure for your loading conditions.
Refer to page62.
Improperly loading your motorcy-
cle can reduce your ability to bal-
ance and steer the motorcycle.
You should ride at reduced
speeds, less than 130 kmlh (80
mph),when the cargo is loadedor
accessoryisfitted.
Adjust suspensionsetting as nec-
essary.

MODIFICATION
Modification of the motorcycle, 01
removal of original equipment ma)
renderthe vehicle unsafeor illegal.
The frame of this motorcycleis madc
of an aluminium alloy. Therefore
never make any modificationssucha$
drilling or welding to the frame as
i.
weakens the strength of the framc
significantly. Failureto heedthiswarn.
ing could result in an unsafe vehiclc
operating condition and subsequen
accident. Suzukiwill not be responsi'
ble in any way for personal injury
01
damage to the motorcyclecaused b)
frame modifications.Bolt on access0
ries that do not modify the frame ir
any way may be installed providec
that the GVW is not exceeded.
Modification to an aluminurn alloy
frame, such as drilling or welding,
weakens the frame. This could
result in an unsafe operating con-
dition and may lead to an acci-
dent.
Never make any modifications to
the frame.
SAFE RIDING RECOMMENDATION
FOR MOTORCYCLERIDERS
Motorcycle riding is great fun and an
exciting sport. Motorcycle riding also
requires that some extra precautions
be taken to ensure the safety of the
rider and passenger. These precau-
tions are:
WEAR A HELMET
Motorcycle safety equipment starts
with a quality helmet.One of the most
serious injuries that can happen is a
head injury. ALWAYS wear a properly
approved helmet. You should also
wear suitable eye protection.
RIDING APPAREL
Loose, fancy clothing can be uncom-
fortable and unsafe when riding your
motorcycle. Choose good quality
motorcycleriding apparel when riding
your motorcycle.
INSPECTION BEFORE RIDING
Review thoroughly the instructions in
the "INSPECTION BEFORE RIDING"
section of this manual. Do not forget
to performan entire safety inspection
to ensure the safety of the rider and
its passenger.
FAMILIARIZEYOURSELF WITH
THE MOTORCYCLE
Your riding skill and your mechanical
knowledge form the foundation for
safe riding practices.We suggestthat
you practice riding your motorcycle in
a non-traffic situation until you are
thoroughlyfamiliar with your machine
and its controls. Remember practice
makes perfect.

KNOW YOUR LIMITS
Ride within the boundaries of your
own skill at all times. Knowing these
limitsand staying within them will help
you to avoid accidents.
BE EXTRA SAFETY CONSCIOUS
ON BAD WEATHER DAYS
Riding on bad weather days, espe-
cially wet ones, requires extra cau-
tion. Braking distances double on a
rainy day. Stay off the paintedsurface
marks, manhole covers and greasy
appearing areasasthey can beespe-
cially slippery. Useextreme caution at
railway crossings and on metal grat-
lngs and bridges. Whenever in doubt
about roadcondition, slow down
!
RIDE DEFENSIVELY
The most commontype of motorcycle
accident occurs when a car traveling
towardsa motorcycleturns roundcor-
ner in front of the motorcyclist. Ride
defensively. Wise motorcyclist uses a
strategy of assumingthey are invisible
to other drivers, even in broad day-
light. Wear bright, reflecting clothing.
Turn on the headlight and taillight
every time even on a bright, sunny
day to attractdriver's attention.Do not
ride inanother driver's blindspot.
SERIAL NUMBER LOCATION
The frame andlor engine serial num-
bers are usedto register the motorcy-
cle. They are also usedto assist your
dealer when ordering parts or refer-
ring to special service information.
The frame number
@l is stamped on
the steering head tube. The engine
serial number is stamped on the
crankcase assembly.
Please write down the numbers in the
box providedbelowfor your future ref-
erence.
Framenumber:
I I
Enginenumber:
P509-106089

LOCATION OF PARTS
CC Clutchlever
Q Left handlebarswitches
@ Ignitionswitch
@ Speedometer
Indicatorlights
@ Tachometer
CE Front brakefluid reservoir
@ Right handlebarswitches
@ Throttle grip
0 Front brakelever
O Fueltank cap

42 Tools
@l Gearshift lever
@ Sidestand
Seat lock