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DR650SE
Suzuki DR650SE User Manual
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•
Remove
the
reservoir
cap
and
diaphragm.
•
Drain
brake
fluid.
•
Remove
the
dust
boot.
•
Remove
the
circiip
with
the
special
tool.
lim
09900-06108:
Snap
ring
pliers
•
Remove
the
piston/secondary
cup,
primary
cup
and
spring.
MASTER
CYLINDER
INSPECTION
Inspect
the
master
cylinder
bore
for
any
scratches
or
other
damage.
Inspect
the
piston
surface
for
any
scratches
or
other
damage.
Inspect
the
primary
cup,
secondary
cup
and
dust
seal
for
wear
or
damage.
CHASSIS
5·12
124
126
Table of Contents
How to Use this Manual
4
Component Parts and Work to be Done
4
General Precautions
8
General Information
9
Right Side
10
Left Side
10
Serial Number Location
10
Brake Fluid
11
Front Fork Oil
11
Break-In Procedures
11
Information Labels
12
Country or Area
16
Periodic Maintenance Schedule
18
Periodic Maintenance Chart
18
Lubrication Points
19
Maintenance and Tune-Up Procedures
20
Valve Clearance
20
Engine
20
Spark Plug Gap
21
Air Cleaner Element
22
Throttle Cable Adjustment
23
Engine Oil and Oil Filter
25
Drive Chain
26
Brake Pads
28
Brake Pedal Height
28
Front Forks
31
Rear Suspension
31
Chassis Bolts and Nuts
32
Compression Pressure Check
34
Compression Test Procedure
34
Oil Pressure Check
35
Engine Components Removable with the Engine in Place
38
Engine Removal and Reinstallation
39
Engine Reinstallation
43
Engine Disassembly
46
Engine Components Inspection and Service
54
Cylinder Head Service
56
Cylinder Head Distortion
56
Valve Stem Deflection
57
Valve Seat Width
59
Valve Seat Servicing
59
Valve Spring
61
Camshaft Journal Wear
63
Camshaft Runout
64
Cylinder Distortion
64
Cylinder Bore
64
Piston Diameter
64
Piston -Cylinder Clearance
65
Piston Ring-Groove Clearance
65
Piston Pin and Pin Bore
66
Crankshaft Runout
67
Clutch Spring Free Length
70
Starter Clutch
71
Starter Torque Limiter
72
Crankcase Bearings
77
Oil Filter
78
Engine Reassembly
79
Oil Seals
79
Gearshift Mechanism
81
Gearshift Shaft
84
Oil Pump
85
Starter Clutch and Generator
88
Fuel System
96
Fuel and Lubrication
97
Fuel Valve/Fuel Filter Removal
97
Inspection and Cleaning
98
Specification
100
Fuel and Lubrication System
102
Slow System
102
Main System
103
Starter System
104
Float System
104
Carburetor Cleaning
106
Needle Valve Inspection
108
Float Height Adjustment
108
Reassembly and Remounting
109
Oil Pressure
109
Oil Sump Filter
109
Oil Cooler
112
Chassis
114
Front Wheel
115
Inspection and Disassembly
116
Spoke Nipple
117
Brake Disc
118
Front Brake
119
Brake Pad Replacement
120
Brake Fluid Replacement
120
Caliper Removal and Disassembly
121
Caliper Inspection
122
Caliper Reassembly and Remounting
122
Brake Disc Inspection
123
Master Cylinder Removal and Disassembl y
124
Master Cylinder Inspection
125
Master Cylinder Reassembly and Remounting
126
Front Fork
127
Removal and Disassembly
127
Fork Spring
129
Reassembly and Remounting
130
Rear Wheel
140
Rear Sprocket
143
Rear Axle Nut
145
Rear Brake
146
Caliper and Disc Inspection
149
Rear Swingarm
152
Inspection and Disassembly
155
Shock Absorber
156
Reassembly and Remounting
157
Reassembling Information
158
Final Inspection and Adjustment
159
Shock Absorber Spring Pre-Load Adjustment
159
Rear Shock Absorber
166
Side Stand
169
Side Stand Removal and Installation
170
Warning Label
170
Cautions in Servicing
172
Semi-Conductor Equipped Part
172
Electrical System
173
Connecting Battery
173
Wiring Procedure
173
Location of Electrical Components
174
Charging System
175
Troubleshooting
176
Side-Stand/Ignition Interlock System Description
180
Starter Motor Removal and Disassembl y
183
Starter Motor Inspection
183
Carbon Brush
183
Oil Seal Inspection
184
Starter Motor Reassembly
184
Starter Relay Inspection
185
15 Electrical System
186
Ignition System
188
Spark Plug
192
Removal and Disassembly
193
Bulb Replacement
195
Turn Signal Relay
197
Initial Charging
198
Recharging Operation
200
Servicing Information
202
Information
203
Cable Routing
216
Pair (Air Supply) System Hose Routing
219
Rear Brake Hose Routing
221
Heat Shield Adhering
222
Special Tools
223
Tightening Torque
226
Tightening Torque Chart
228
Service Data
229
Cylinder Head
230
Piston Ring
230
Oil Pump
231
Drive Chain
232
Specification
233
Brake + Wheel
234
Tire Pressure
236
Emission Control Information
238
Emission Control Carburetor Components
238
Evaporative Emission Control System
239
Dr650Sev/W/X/Y
241
Service Data
244
Valve + Guide
244
Cylinder Head
245
Conrod + Crankshaft
246
Brake + Wheel
249
Tire Pressure
251
Dr650Sek1 ('01-Model)
253
Specifications
254
Camshaft + Cylinder Head
256
Cylinder + Piston + Piston Ring
256
Transmission + Drive Chain
258
Cylinder Head Cover
263
Drive Train
270
Dr650Sek9 ('09-Model)
275
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Suzuki DR650SE Specifications
General
Brand
Suzuki
Model
DR650SE
Category
Motorcycle
Language
English
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