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

@ Rear brake pedal

CONTROLS
KEY
This motorcyclecomes equippedwith
a main ignition key and a spare one.
Keepthe spare key in a safe place.
The key number is stamped on a
plate provided with the keys. This
number is used when making
replacement keys. Please write your
key number in the box provided for
your future reference.
I
j Key number:
SWITCH
The ignitionswitch has four positions:
"OFF" POSITION
All electrical circuits are cut off. The
engine will not start. The key can be
removed.
"ON" POSITION
The ignition circuit is completed and
the engine can now be started. The
headlight and taillight will automati-
cally be turned on when the key is in
this position. The key cannot be
removed from the ignition switch in
this position.
NOTE: Start theenginepromptly after
turning the key to the
"ON position,
or the battery will lose power due to
consumptionby theheadlight and tail-
light.
"LOCK" POSITION
To lock the steering, turn the handle-
bar all the way to the left. Push down
and turn the key to the
"LOCK posi-
tion and removethe key. All electrical
circuitsare cut off.
A6446

"P" (Parking) POSITION
(~xce~tfor-Australia)
When parking the motorcycle, loc
the steering and turn the key to thc
"P" position. The key can now b~
removed and the 'position light anc
taillight will remain lit and the steerin!
will be locked. This position is
fa
night time roadside parking tc
increasevisibility.
* Canadian model does not havc
positionlight.
NOTE: The key hole can be covered
by turning the lid for anti-theft pur-
pose.
1 Turning the ignition switch to the
"P" (PARKING) or "LOCK" posi-
tion while the motorcycle is mov-
ingcan be hazardous. Movingthe
motorcycle while the steering is
locked can be hazardous. You
could lose your balance and fall,
or youcould dropthe motorcycle.
Stop the motorcycle and place it
on the side stand if equipped
before locking the steering. Never
attempt to move the motorcycle
when thesteeringislocked.
Turn the ignition switch to "LOCK
positionand changethe lid hole posi-
tion when leavingyc5r motorcycle.

Align the lid hole position to the key
holepositionwhen insertingthe key.
INSTRUMENTPANEL
SPEEDOMETER
The speedometer indicates the road
speed in miles per hour and/or kilo-
metersper hour.
,
TURN SIGNAL INDICATOR LIGHT
0
When the turnsignals are being oper-
ated either to the right or to the left,
the indicator will flash at the same
time.
NOTE: Ifturn signal light is not oper-
atingproperly due to bulb filament or
circuit failure, the indicator light flick-
ers more quickly to notify the rider of
the existence oftrouble.
HIGH BEAM INDICATOR LIGHT @
The blueindicator light will be lit when
the headlighthighbeam is turned on.
NEUTRALINDICATOR LIGHT @
The green light will come on when the
transmission is in neutral. The light
will go out when you shift into any
gear other than neutral.
TACHOMETER @
The tachometer indicates the engine
speed in revolutions per minute (r/
min).

FUELINJECTIONSYSTEM
INDICATORICLOCK
@
FuelInjectionSystem Indicator
If the fuel injection system fails, the
red indicator light comes on and
the display
@ indicates "FI" in follow-
ingtwo modes;
A. The display @ indicates "FI" and
the clock alternately, and the red
indicator light
Q comes on and
remains lit.
B. The display @ indicates "FI" con-
tinuously and the red indicator
light
Q blinks.
The engine may continue to run in
mode
A, but mostlythe enginewill not
run in mode
B.
1 CAUTION
Riding the motorcycle with the
display indicating the problem of
the fuel injection system and with
the indicator light lit can damage
the engineandtransmission.
Whenever the red indicator light is
lit and the display indicates "FI",
have your authorized Suzuki
dealer or qualified mechanic
inspect the fuel injection system
as soonas possible.
NOTE: If thedisp1ay.indicates"F1"and
the clock alternate/)(and the red indi-
cator light comes on and remains lit,
keep the engine running and bring
your motorcycle to an authorized
Suzuki dealer. If the engine stalls, try
restarting the engine after turning the
ignitionswitchoff and on.
When the display 5 indicates
"CHEC",check following items;
Make sure that the engine stop
switch is inthe
"C)" position.
Makesure that the transmission is
in neutralor the side stand is fully
UP.
If the display still indicates 'CHEC
after above procedure. inspect the
ignition fuse and connectton of lead
wire couplers.
NOTE: The coolant temperature
meter indicates "H" when
the dsplay
shows "CHEC".

Clock
The clock indicates 12-hour mode.
Follow the procedure below to adjust
the clock.
1. Push the buttons, C3 and 0,
simultaneously until the minute
display blinks.
NOTE: When the
"ADJ" button @ is
held in the display advances continu-
ously
3. Push the "SEC' button @ to high-
lightthe hour display.
1. Adjust the hour display by pushing
the "ADJ"button
a.
5. Push the "SEC' button @ to
resumeclock mode.
OIL PRESSUREINDICATOR LIGHT
t
This indicator comes on when the
sngine oil pressure is below the nor-
~aloperating range. This should
come on when the ignition switch is
,-ON" and the engine is not running.
4s soon as the engine starts, this
shouldgo out.
CAUTION
Riding the motorcyclewith the oil
pressure indicator light lit can
damage the engine and transmis-
sion.
Whenever the oil pressure indica-
tor lights up, indicating low oil
pressure,stopthe engine immedi-
ately. Checkthe oil leveland deter-
mine if the proper amount of oil is
inthe engine. If the light still does
not go out, have your authorized
SUZUKl dealer or qualified
mechanic troubleshoot your
motorcycle.
FUEL METER @
The fuel meter indicates the amount
of fuel remaining in the fuel tank. The
fuel meter displays all 5 segments
when the fuel tank is full. The mark
flickers when the fuel level drops
below 4.5
L (4.814.0 US/lmp. qt). The
mark and segment flicker when the
fuel drops below 3.0
L (3.212.6 US1
Imp.qt).
I Flicker I
l Flicker l Flicker I
NOTE: Thefuel meter will not indicate
correctly when the motorcycle is
placed with the sidestand.

ODOMETERITRIPMETER @
The display has three functions,
odometer and two trip meters. When
the ignition switch is turned to the
"ON" position, the display indicates
the test patternshown below for three
seconds.Then the display changesto
odometer or trip meter, as indicated
beforeturning the ignitionswitch off.
TRIP 1 I=! I~I I=! rIEI rI
ODO 2 CIClLI a LI.CI
Odometer
The odometer registers the total dis-
tance that the motorcyclehas been
ridden.
The two trip meters are resettable
odometers. They can register two
kinds of distance at the same time.
For instance,trip meter 1 can register
the trip distance and trip meter
2 can
register the distance between fuel
stops.
To change the display, push the
"SEC'
button @. The display changes in the
order below.
ODO
Trip Meter
16
Odometer
l
TRIP 1
TRIP
2
Trip meter 2
To reset the trip meter to zero, push
the
"ADJ" button O for two seconds
while the display indicates the trip
meter
1 or 2 you want to reset.

Operating the display while riding
can be hazardous. Removing a
hand from the handlebars can
reduce your ability to control the
motorcycle.
Always keep both hands on the
handlebarswhile riding.
1 CAUTION
- -
Runningthe enginewith hightem-
peratureenginecoolantcancause
serious engine damage. If the
mark and indicator light come on,
stopthe engineto let itcool.
Do not run the engine until the
markand indicatorlight go off.
The coolant temperature meter indi-
cates engine coolant temperature.
When the coolant temperature
becomes high, th? mark
@ and indi-
cator light
Q come on.

LEFT HANDLEBAR
CLUTCH LEVER @
The clutch lever is used for disengag-
ing the drive to the rear wheel when
starting the engine or shifting the
transmission gear. Squeezing the
lever disengages the clutch.
HEADLIGHT FLASHER SWITCH Q
Pressthe switch to light the headlight.
The headlight high beam will be lit
when the dimmer switch is in
"LO"
position.
HAZARDWARNING SWITCH @
All four turn signal lights and indica-
tors will flash simultaneously when
the switch is turned on with the igni-
tion switch in
"ON" or "P" position.
Usethe hazardwarning lightsto warn
other traffic during emergency park-
ing or when your vehicle could other-
wise becomea traffic hazard.
DIMMER SWITCH @
"LO" position
The headlight low beam and taillight
turn on.
":D" position
The headlight high beam and taillight
turn on. The high beam indicatorlight
alsoturns on.
IORN SWITCH "b" 5
'ressthe switch to sound the horn.
URNSIGNAL LIGHT SWITCH @
loving the switch to the 'a" position
fillflash the left turn signals. Moving
le switch to the
"0" position will
ash the right turn signals. The indi-
ator lightwill also flash intermittently.
D cancel turn signal operation, push
ieswitch in.
Failureto usethe turn signals,and
failure to turn off the turn signals
can be hazardous. Other drivers
may misjudge your course and
this may result inan accident.
Always use the turn signals when
you intend to change lanes or
make a turn. Be sure to turn off
the turn signals after completing
the turn or lane change.

RIGHT HANDLEBAR
ENGINESTOP SWITCH @
"ZX" position
The ignition circuit is off. The engine
cannot start or run.
"C)" position
The ignition circuit is on and the
engine can run.
FRONT BRAKE LEVER @l
The front brake is applied by squeez-
ing the brake lever gently toward the
throttle grip. This motorcycle is
equipped with a disk brake system
and excessive pressure is not
required to slow the machine down
properly. The brake light will be lit
when the lever is squeezed inward.
Front Brake Lever
/
T
a
a
P
a
P
I€
a
a
S
a
fr
S Adjustment
'he distancebetween the throttle grip
nd the front brake lever is adjustable
mong
6 positions. To change the
osition, pushthe brake lever forward
nd turn the adjuster to the desired
osition. When changing the brake
?ver position, always be sure the
djuster stops in the proper position;
projection of the brake lever holder
hould fit into the depression of the
djuster. This motorcycle is delivered
,om the factory with its adjuster set
n position
4.
Adjusting the front brake lever
position while riding can be haz-
ardous. Removinga hand from the
handlebarscan reduceyour ability
to controlthe motorcycle.
Always keep both hands on the
handlebarswhile riding.