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Suzuki DR600S User manual

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SUZUKI
ORGOO"
SERVICE
MANUAL
|
4
gr
i
tien
key
No
ios
2.&
#
FOREWORD
The
SUZUKI
DR6O00S
was
designed
to
offer
superior
performance
through
lightweight
design,
four
stroke-power
(TSCC
engine),
engine
counter-balancers
and
full-floating
suspen-
sion.
This
service
manual
has
been
produced
primarily
for
experienced
mechanics
whose
job
is
to
inspect,
adjust,
repair
and
service
Suzuki
Motorcycles.
Apprentice
mechanics
and
do-it-
yourself
mechanics
will
also
find
this
manual
to
be
an
extremely
useful
repair
guide.
This
manual
contains
up-to-date
information
at
the
time
of
publication.
The
rights
are
reserved
to
update
or
make
corrections
to
this
manual
at
any
time.
SUZUKI
MOTOR
CO.,LTD.
Motorcycle
Technical
Service
Department
©
COPYRIGHT
SUZUKI
MOTOR
CO.,
LTD.
1985
VIEW
OF
SUZUKI
DR6OOSF
(‘85—MODEL)
RIGHT
SIDE
LEFT
SIDE
GROUP
INDEX
GENERAL
INFORMATION
—lc
ile
FUEL
AND
LUBRICATION
SYSTEM
PERIODIC
MAINTENANCE
AND
TUNE-UP
PROCEDURES
SERVICING
ENGINE
ELECTRICAL
SYSTEM
ee.
CHASSIS
EE
SERVICING
INFORMATION
DR600SG/
DR500SG
(‘86—MODEL)
DR600RG/
DR500RG
(‘86—MODEL)
Bo
DR600RH/DR500RH
DR600SH/DR500SH
(87—MODEL)
|
10
ie
DR600SJ/DR600RJ
,.
DR500SJ/DR500RJ(
88—MODEL)
HE
APPENDIX
J
i20
DR600SK/RK
(‘'89-MODEL)
Ei
GENERAL
INFORMATION
CONTENTS
SERIAL
NUMBER
LOCATIONS
4h:
0-
on
--ae
e
FUEL
AND
OIL
RECOMMENDATIONS
0000000000000:
eee
BREAKING-IN
PROCEDURES
«+++++>--2520s--22++0duestutabrties
soxsUnass-onseas
SPECIAL
IVA
TERIA
LS
305:
0-8
ss
res
scarey
ane
eogeeae
ee
Cee
eaeaamatae>
ae
PRECAUTIONS
AND
GENERAL
INSTRUCTIONS
SPECTFICA
TIONS
005+
-02
fo
0cthies
sce
accatduaretant
dnensltses
ans
ues:
atv
Sena
1-1
GENERAL
INFORMATION
SERIAL
NUMBER
LOCATIONS
The
frame
serial
number
or
V.I.N.
(Vehicle
Identi-
fication
Number)
@
is
stamped
on
the
steering
head
pipe.
The
engine
serial
number
(2)
is
located
on
the
crankcase.
These
numbers
are
required
especially
for
registering
the
machine
and
ordering
spare
parts.
FUEL
AND
OIL
RECOMMENDA-
TIONS
FUEL
Gasoline
used
should
be
graded
85
—
95
octane
or
higher.
An
unleaded
or
low-lead
type
gasoline
is
recommended.
ENGINE
OIL
Be
sure
that
the
engine
oil
you
use
comes
under
API
classification
of
SE
or
SF
and
that
its
viscosity
rating
is
SAE
10W-40.
If
SAE
10W-40
motor
oil
is
not
available,
select
the
oil
viscosity
according
to
_
the
following
chart:
-%
-20 -10
0
10
20
30 40
=22_-4
14
32
SO
68
86
104
FRONT
FORK
OIL
Use
fork
oil
#
10.
BRAKE
FLUID
SAE
J1703,
DOT
3
or
DOT
4
Specification
and
classification:
WARNING:
*
Since
the
brake
system
of
this
motorcycle
is
filled
with
a
glycol-based
brake
fluid
by
the
manufacturer,
do
not
use
or
mix
differ-
ent
types
of
fluid
such
as
silicone-based
and
petroleum-based
fluid
for
refilling
the
system,
otherwise
serious
damage
will
result.
*
Do
not
use
any
brake
fluid
taken
from
old
or
used
or
unsealed
containers.
Never
re-use
brake
fluid
left
over
from
the
previous
servicing
and
stored
for
a
long
Period.
*
BREAKING-IN
PROCEDURES
During
manufacture
only
the
best
possible
ma-
terials
are
used
and
all
machined
parts
are
finished
to
a
very
high
standard
but
it
is
still
necessary
to
allow
the
moving
parts
to
‘‘BREAK-IN”
before
subjecting
the
engine
to
maximum
stresses.
The
future
performance
and
reliability
of
the
engine
depends
on
the
care
and
restraint
exercised
during
its
early
life.
The
general
rules
are
as
follows.
1.
Keep
to
this
break-in
throttle
position.
Below
4/5
throttle
2.
After
the
engine
has
been
operated
for
1
600
km
(1
000
miles)
the
motorcycle
can
be
subjected
to
full
throttle
operation
for
short
periods
of
time.
Up
to
1
600
km
(1
000
miles)
SPECIAL
MATERIALS
The
materials
listed
below
are
needed
for
maintenance
work
on
the
DR6OOS,
and
should
be
kept
on
hand
for
ready
use.
They
supplement
such
standard
materials
as
cleaning
fluids,
lubricants,
emery
cloth
and
the
GENERAL
INFORMATION
1-2
like.
How
to
use
them
and
where
to
use
them
are
described
in
the
text
of
this
manual.
Material
Part
Part
SUZUKI
SUPER
GREASE
“A”
99000-25010
Oil
seals
Throttle
grip
Brake
pedal
shaft
Gearshift
lever
and
shaft
Speedometer
cable,
gear-
box and
dust
seal
Wheel
bearings
Steering
stem
bearings
Sprocket
drum
bearing
Brake
camshaft,
oil
seal,
spacer,
dust
seals,
bearing
and
bushing
Brake
cam
and
pin
Shock
absorber
dust
seals
Cushion
lever
dust
seals,
spacers
and
bearings
Swingarm
dust
seals,
spacers
and
bearings
SUZUKI
SILICONE
GREASE
99000-25100
Caliper
axle
SUZUKI
MOLY
PASTE
99000-25140
Valve
stems
De-comp.
camshaft
Countershaft
and
drive-
shaft
gears
Piston
pin
Camshaft
journals
Rocker
arm
shafts
De-comp.
shafts
SUZUKI
BOND
No.
1207B
99000-31140
Mating
surfaces
of
left
and
right
halves
of
crankcase
Magneto
lead
wire
grommet
Cylinder
base
and
head
gaskets
Cylinder
head
cover
THREAD
LOCK
SUPER
1303”
99000-32030
2nd
drive
gear
Crankcase
bearing
retainers
Kick
starter
pawl
guide/
stopper
bolt
and
screw
Gearshift
arm
stopper
Cam
sprocket
bolts
Material
1-3
GENERAL
INFORMATION
Part
Part
Page
*
THREAD
LOCK
SUPER
“1360”
99000-32130
@
Gearshift
cam
stopper
3-48
Magneto
stator
coil
5-2
bolt
securing
screws
@
Gearshift
cam
guide/paw!
3-50
Front
fork
damper
rod
6-16
lifter
screws
bolts
@
Engine
oil
pump
mounting
3-54
screws
THREAD
LOCK
“1342”
99000-32050
|
@
Magneto
rotor
bolt
3-53
THREAD
LOCK
SUPER
"1305"
99000-32100
if
©
Disc
mounting
bolts
6-8
v
SUZUKI
BRAKE
FLUID
99000-23021
(0.5
L)
|e
Front
brake
GENERAL
INFORMATION
1-4
PRECAUTIONS
AND
GENERAL
INSTRUCTIONS
Observe
the
following
items
without
fail
when
disassembling
and
reassembling
motorcycles.
e
Be
sure
to
replace
packings,
gaskets,
circlips,
O-rings
and
cotter
pins
with
new
ones.
CAUTION.
Never
reuse
a
circlip.
After
a
circlip
has
been
removed
from
a
shaft,
it
should
be
discarded
and
a
new
circlip
must
be
installed.
When
installing
a
new
circlip,
care
must
be
taken
not
to
expand
the
end
gap
larger
than
required
to
slip
the
circlip
over
the
shaft.
After
installing
a
circlip,
always
insure
that
it is
completely
seated
in
its
groove
and
securely
fitted.
®
Tighten
bolts
and
nuts
from
the
ones
of
larger
diameter
to
those
of
smaller
diameter,
and
from
inside
to
outside
diagonally,
with
specified
tightening
torque.
e
Use
special
tools
where
specified.
e
Use
specified
genuine
parts
and
recommended
oils.
e
When
more
than
2
persons
perform
work
in
cooperation,
pay
attention
to
the
safety
of
each
other.
e
After
the
reassembly,
check
parts
for
tightening
condition
and
operation.
e
Treat
gasoline,
which
is
extremely
flammable
and
highly
explosive,
with
greatest
care.
Never
use
gaso-
line
as
cleaning
solvent.
Warning,
Caution
and
Note
are
included
in
this
manual
occasionally,
describing
the
following
contents.
MOORS
INNINGS
5
cha.
sere
oe
Personal
safety
of
the
rider
is
involved,
and
disregard
of
the
information
could
result
in
injury.
GATHON
oodce
te
ones
sews
For
the
protection
of
the
motorcycle,
the
instruction
or
rule
must
be
strictly
adhered
to.
DUNN
eri
tics
wesc
veoe
«tose
Advice
calculated
to
facilitate
the
repair
of
the
motorcycle
is
given
under
this
heading.
USE
OF
SUZUKI
GENUINE
PARTS
To
replace
any
part
of
the
machine,
use
a
genuine
SUZUKI
replacement
part
or
an
equivalent.
Imita-
tion
parts
or
parts
supplied
from
any
other
source
than
SUZUKI,
if
used
to
replace
SUZUKI
Parts,
can
reduce
the
machine’s
performance
and,
even
worse,
could
induce
costly
mechanical
troubles.
1-5
GENERAL
INFORMATION
SPECIFICATIONS
DIMENSIONS
AND
DRY
MASS
CO
TANCE
8
Be
oe
ea
Overall
width
Overall
height
Wheelbase
Ground
clearance
ie
ES
GIGI
ess
oa
ENGINE
eS
ee
Petre
See
eG
be
ose
See
a
des
Piston
displacement
Compression
ratio
Carburetor
Air
cleaner
Starter
system
Lubrication
system
TRANSMISSION
Clutch
Gearshift
pattern
Primary
reduction
Final
reduction
Drive
chain
2
215
mm
(87.2
in)
875
mm
(34.4
in)
1
235
mm
(48.6
in)
1
465
mm
(57.7
in)
275
mm
(10.8
in)
139
kg
(306
Ibs)
Four-stroke,
air-cooled,
OHC
94.0
mm
(3.700
in)
85.0
mm
(3.346
in)
589
cm?*
(35.9
cu.
in)
8.5:1
MIKUNI
VM38SS,
single
Polyurethane
foam
element
Primary
kick
Wet
sump
Wet
multi-plate
type
.
5-speed
constant
mesh
.
1-down,
4-up
2.310
(67/29)
2.625
(42/16)
2.416
(29/12)
1.625
(26/16)
1.263
(24/19)
1.000
(21/21)
0.826
(19/23)
TAKASAGO
RK520KSO
or
DAIDO
D.1.D.520VC-5,
108
links