Suzuki DR600S User manual

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,
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