Suzuki DL650 User manual

I
SERVICE MANUAL
I

FOREWORD
Thismanual contains an introductory descriptionon
the SUZUKI
DL650 and procedures for its inspec-
tion/service and overhaulof its main components.
Other information consideredas generally known is
not included.
Read the GENERAL INFORMATION section to
familiarizeyourself withthe motorcycle and its main-
tenance. Use this section as well as other sections
to use as a guide for proper inspection and service.
Thismanual will help you know the motorcycle bet-
ter so that you can assure your customers of fast
and reliable service.
Thismanual has been prepared on the basis
of thelatestspecificationsat the timeof publi-
cation. If modificationshavebeenmade since
then, differencesmay exist between the con-
tent of thismanual and theactualmotorcycle.
illustrations in this manual are used to show
the basic principles of operation and work
procedures. 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 theproper 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
unsafefor the rider and passenger.
GENERAL INFORMATION
PERIODICMAINTENANCE
ENGINE
FI SYSTEM DIAGNOSIS
FUEL SYSTEMAND THROTTLE
BODY
COOLINGAND LUBRICATION
SYSTEM
CHASSIS
ELECTRICALSYSTEM
SERVICINGINFORMATION
EMISSION CONTROL
INFORMATION
WIRING DIAGRAM
SUZUKl MOTOR CORPORATION
O COPYRIGHT SUZUKl MOTOR CORPORATION 2003

HOW TO USE THIS MANUAL
TO LOCATEWHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holdingthe manualasshownat the rightwill allow youto find
the first pageof the sectioneasily.
4. The contents are listed on the first page of each section to
helpyou find the item and page you need.
COMPONENT PARTSAND WORK TO BE DONE
Underthe nameof each systemor unit,is its explodedview. Work instructionsandother service information
such as the tightening torque, lubricatingpoints and lockingagent points,are provided.
Example: Frontwheel
@ 1 Brakedisc
O I ~ustseal I
@ I Bearing I
@ ( Center spacer I
@ I Frontwheel
@ I Brakedisc bolt
I
@
@
Tire valve
Front axle

SYMBOL
Listedinthe table below are the symbols indicatinginstructionsand other informationnecessary for servic-
-
ing. The meaningof each symbol isalso includedinthe table.
SYMBOL
PI
DEFINITION
Torque control required.
Data besideit indicatesspecified
torque.
Apply oil. Useengineoil unless other-
wise specified.
Apply molybdenumoil solution.
(Mixtureof engine oil and SUZUKl
MOLY PASTE ina ratio of
1:1)
Apply SUZUKl SUPER GREASE "A.
99000-25030 (USA)
99000-25010 (Others)
Apply SUZUKl MOLY PASTE.
99000-25140
Apply SUZUKl SILICONE GREASE.
99000-25100
Apply SUZUKl BOND "121 5"
99000-31110 (Except USA)
Apply SUZUKl BOND
"12078".
99104-31140
(USA)
99000-31140 (Others)
Apply THREAD LOCK SUPER
"1303".
99000-32030
Apply THREAD LOCKSUPER "1322.
99000-32110
(Except USA)
Apply THREAD LOCK
"1342"
99000-32050
SYMBOL DEFINITION
Apply THREAD LOCK SUPER "1360".
99000-32130
Useenginecoolant.
Usefork oil.
99000-99001 -SS8
Apply or use brake fluid.
Measureinvoltage range.
Measure in current range.
Measurein resistance range.
Measure in diode test range.
Measurein continuitytest range.
Usespecialtool.
Indicationof service data.

ABBREVIATIONSUSEDINTHIS
MANUAL
ABDC : After Bottom DeadCenter
AC
: Alternating Current
ACL
: Air Cleaner,Air Cleaner Box
API
: American PetroleumInstitute
ATDC
: After Top DeadCenter
ATM Pressure:Atmospheric Pressure
Atmospheric Pressure Sensor
(APS)
: Air FuelMixture
B
BBDC
BTDC
B+
: Before BottomDead Center
: BeforeTop DeadCenter
: Battery Positive Voltage
C
CKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT
: Circuit
CLP Switch
: Clutch Lever Position Switch
(ClutchSwitch)
CMP Sensor
: Camshaft PositionSensor
(CMPS)
CO
: Carbon Monoxide
CPU
: Central ProcessingUnit
D
DC
DMC
DOHC
DRL
: DirectCurrent
: Dealer Mode Coupler
: DoubleOver HeadCamshaft
: DaytimeRunningLight
E
ECM : EngineControl Module
Engine Control Unit (ECU)
(FI Control Unit)
-
ECT Sensor : Engine CoolantTemperature
Sensor (ECTS),Water Temp.
Sensor (WTS)
EVAP
: Evaporative Emission
EVAP Canister: Evaporative Emission
F
FI
FP
FPR
FP Relay
G
GEN
GND
GP Switch
H
HC
I
IAP Sens
IAT Sensor
L
LCD
LED
Canister (Canister)
: Fuel Injection,Fuel Injector
: Fuel Pump
: Fuel Pressure Regulator
: Fuel Pump Relay
: Generator
: Ground
: Gear PositionSwitch
: Hydrocarbons
: Intake Air Pressure Sensor (IAPS)
: IntakeAir Temperature Sensor
(IATS)
: Ignition
: LiquidCrystal Display
: Light EmittingDiode
(MalfunctionIndicatorLamp)
: Left Hand

Max
MIL
Min
N
NOx
0
OHC
OPS
P
PCV
R
RH
ROM
S
SAE
STC System
STP Sensor
ST Valve
: MalfunctionCode
(DiagnosticCode)
: Maximum
: MalfunctionIndicatorLamp
(LED)
: Minimum
: NitrogenOxides
: Over HeadCamshaft
: Oil PressureSwitch
: PositiveCrankcase
Ventilation (CrankcaseBreather)
: Right Hand
: ReadOnly Memory
: Society of Automotive Engineers
: SecondaryThrottle Control
System (STCS)
: SecondaryThrottle Position
Sensor (STPS)
: SecondaryThrottleValve (STV)
STV Actuator
: SecondaryThrottleValve Actuator
(STVA)
T
TO Sensor : Tip Over Sensor (TOS)
TP Sensor
: Throttle Position Sensor (TPS)
v
VD : Vacuum Damper

SAE-TO-FORMER SUZUKl TERM
This table lists SAE (Societyof Automotive Engineers) J1930 terms and abbreviationswhich maybe used in
this manualin compliancewith SAE recommendations,as well as their former SUZUKl names.
SAE TERM
FULLTERM
4
Air Cleaner
B
Barometric Pressure
Battery Positive Voltage
C
Camshaft PositionSensor
Crankshaft PositionSensor
D
Data Link Connector
DiagnosticTest Mode
Diagnostic Trouble Code
E
Electronic Ignition
EngineControl Module
Engine Coolant Level
Engine Coolant Temperature
Engine Speed
EvaporativeEmission
EvaporativeEmissionCanister
F
FanControl
Fuel Level Sensor
Fuel Pump
G
Generator
Ground
ABBREVIATION
ACL
BAR0
B+
CMP Sensor
CKP Sensor
DLC
DTM
DTC
El
ECM
ECL
ECT
RPM
EVAP
EVAP Canister
FC
FP
GEN
GND
FORMER SUZUKl TERM
Air Cleaner. Air Cleaner Box
BarometricPressure,Atmospheric
Pressure(APS,AP Sensor)
Battery Voltage,
+B
Camshaft PositionSensor (CMPS)
Crankshaft Position Sensor (CKPS),
Crank Angle
Dealer Mode Coupler
-
DiagnosticCode, Malfunction Code
-
Engine ControlModule (ECM)
FIControl Unit, EngineControlUnit (ECU)
Coolant Level
Coolant Temperature, EngineCoolant Tem-
perature
Water Temperature
Engine Speed(RPM)
Evaporative Emission
- (Canister)
-
Fuel Level Sensor, Fuel Level Gauge
Fuel Pump (FP)
Generator
Ground(GND, GRD)

SAE TERM
FULL TERM
- -- - --
I
IdleSpeed Control
IgnitionControl
IgnitionControl Module
lntakeAir Temperature
M
Malfunction Indicator Lamp
ManifoldAbsolute Pressure
MassAir Flow
0
On-Board Diagnostic
Open Loop
P
ProgrammableRead Only Memory
PulsedSecondaryAir lnjection
PurgeValve
R
RandomAccess Memory
ReadOnly Memory
S
SecondaryAir lnjection
Secondary Throttle Control System
SecondaryThrottle Valve
SecondaryThrottle Valve Actuator
T
Throttle Body
ThrottleBody Fuellnjection
Throttle PositionSensor
v
Voltage Regulator
Volume Air Flow
ABBREVIATION
ISC
IC
ICM
IAT
MIL
MAP
MAF
OBD
OL
PROM
PA1R
Purge Valve
RAM
ROM
AIR
STCS
STV
STVA
TB
TBI
TP Sensor
VR
VAF
FORMER SUZUKl TERM
ElectronicSparkAdvance (ESA)
-
lntakeAir Temperature (IAT), Air Temperature
LED Lamp
Malfunction Indicator Lamp (MIL)
lntakeAir Pressure (IAP), lntakeVacuum
Air Flow
Self-Diagnosis Function
Diagnostic
-
PulseAir Control(PAIR)
Purge Valve (SPValve)
ROM
STC System (STCS)
ST Valve (STV)
STV Actuator (STVA)
Throttle Body (TB)
Throttle Body Fuel lnjection(TBI)
TP Sensor (TPS)
Voltage Regulator
Air Flow

WIRE COLOR
B : Black
BI
: Blue
Br
: Brown
Dg
: Dark green
G
: Green
Gr :Gray
Lbl
: Light blue
Lg
: Light green
0 : Orange
P :Pink
: Black with Blue tracer
: Black with Green tracer
: Black with Red tracer
: Blackwith Yellow tracer
: Blue with Green tracer
: Blue with White tracer
: Brown with Blacktracer
: Greenwith Black tracer
: Gray with Blacktracer
: Graywith White tracer
: Orangewith Blue tracer
: Orangewith Redtracer
: Orange with Yellow tracer
: Redwith Black tracer
: White with Blacktracer
: White with Green tracer
: Yellow with Black tracer
: Yellow with Greentracer
: Yellow with White tracer
B/Br
B/O
BNV
BI/B
BI/R
BIN
BrNV
GN
Gr/R
O/B
O/G
ONV
PNV
RNV
W/BI
W/R
Y/BI
Y/R
R
: Red
W : White
Y
: Yellow
: Blackwith Browntracer
: Blackwith Orange tracer
: Black with White tracer
: Bluewith Black tracer
: Blue with Red tracer
: Bluewith Yellow tracer
: Brownwith White tracer
: Greenwith Yellow tracer
: Gray with Redtracer
: Orangewith Blacktracer
: Orangewith Greentracer
: Orange with White tracer
: Pinkwith Whitetracer
: Redwith White tracer
: White with Blue tracer
: White with Redtracer
: Yellow with Blue tracer
: Yellow with Red tracer

-
. .
.-
GENERAL INFORMATION 1-1
CONTENTS
WARNINGKAUTION/NOTE ................................................................ 1 . 2
GENERALPRECAUTIONS ........................................................................... 1- 2
SUZUKIDL650K4 ('04-MODEL) ............................................................... 1- 4
SERIAL NUMBER LOCATION
...................................................................... 1- 4
........................
FUEL. OILAND ENGINE COOLANTRECOMMENDATION 1- 4
...........................................................
FUEL (FOR USAAND CANADA) 1- 4
.........................................................
FUEL (FOR OTHER COUNTRIES) 1- 4
........................................................................
ENGINE OIL (FOR USA) 1- 5
............................................
ENGINE OIL (FOR OTHER COUNTRIES) 1-
5
......................................................................................... BRAKE FLUID 1- 5
FRONT FORK OIL
.................................................................................. 1- 5
ENGINE COOLANT
............................................................................ 1- 5
WATERFOR MIXING
............................................................................ 1- 5
ANTI-FREEZWENGINE COOLANT
...................................................... 1- 6
LIQUIDAMOUNT OF WATEWENGINECOOLANT
.............................. 1- 6
BREAK-IN PROCEDURES
........................................................................... 1- 6
CYLINDERIDENTIFICATION ..................................................................... 1- 7
INFORMATIONLABELS ............................................................................... 1- 8
SPECIFICATIONS ......................................................................................... 1- 9
.............................................................
DIMENSIONSAND DRY MASS 1-
9
................................................................................................... ENGINE 1- 9
.......................................................................................... DRIVE TRAIN 1- 9
CHASSIS ................................................................................................. 1-10
ELECTRICAL
........................................................................................ 1-10
CAPACITIES
.......................................................................................... 1-10
COUNTRYAND AREA CODES
.................................................................... 1-11