dr650se

GENERALINFORMATIONPERIODICMAINTENANCEENGINEFUELANDLUBRICATIONSYSTEMCHASSISELECTRICALSYSTEMSERVICINGINFORMATIONGROUPINDEX1FOREWORDThismanualcontainsanintroductorydescriptiononSUZUKIDR650SEandproceduresforitsin-spection/serviceandoverhaulofitsmaincompo-nents.Otherinformationconsideredasgenerallyknownisnotincluded.ReadGENERALINFORMATIONsectiontofamil-iarizeyourselfwithoutlineofthevehicleandMAIN-TENANCEandothersectionstouseasaguideforproperinspectionandservice.Thismanualwillhelpyouknowthevehiclebettersothatyoucanassureyourcustomersofyouroptimumandquickservice.*Thismanualhasbeenpreparedontheba-sisofthelatestspecificationatthetimeofpublication.Ifmodificationhasbeenmadesincethen,differencesmayexistbetweenthecontentofthismanualandtheactualvehicle.*Illustrationsinthismanualareusedtoshowthebasicprinciplesofoperationandworkprocedures.Theymaynotrepresenttheactualvehicleexactlyindetail.*ThismanualisintendedforthosewhohaveenoughknowledgeandskillsforservicingSUZUKIvehicles.Withoutsuchknowledgeandskills,youshouldnotattemptservicingbyrelyingonthismanualonly.Instead,pleasecontactyournearbyautho-rizedSUZUKImotorcycledealer.©COPYRIGHTSUZUKIMOTORCORPORATION1995EMISSIONCONTROLINFORMATIONIMPORTANTAllstreet-legalSuzukimotorcycleswithenginedisplacementof50ccorgreateraresubjecttoEnvironmentalProtectionagencyemissionregula-tions.Theseregulationssetspecificstandardsforexhaustemissionoutputlevelsaswellasparticularservicingrequirements.Thismanualincludesspe-cificinformationrequiredtoproperlyinspectandserviceDR650SEinaccordancewithallEPAregu-lations.ItisstronglyrecommendedthatthechapteronEmissionControl,PeriodicServicingandCarbu-retionbethoroughlyreviewedbeforeanytypeofserviceworkisperformed.FurtherinformationconcerningtheEPAemissionregulationsandU.S.Suzuki’semissioncontrolprogramcanbefoundintheU.S.SUZUKIEMIS-SIONCONTROLPROGRAMMANUAL/SERVICEBULLETIN.2345678Downloadedfrom(’97/’98/’99/’00-MODELS)DR650SEK1(’01-MODEL)91011DR650SEK2/K3/K4/K5/K6/K7(’02/’03/’04/’05/’06/’07/’08-MODELS)DR650SEK9(’09-MODEL)12Downloadedfrom­ouspageasGROUPINDEX,selectthesectionwherewhatyouarelookingforbelong.3.Holdingthemanualasshownattherightwillallowyoutofindthefirstpageofthesectioneasily.4.Onthefirstpageofeachsection,itscontentsarelisted.Findtheitemandpageyouneed.COMPONENTPARTSANDWORKTOBEDONEUnderthenameofeachsystemorunit,itsexplodedviewisprovidedwithworkinstructionandotherserviceinformationsuchasthetighteningtorque,lubricatingpointsandlockingagentpoints.Example:FrontwheelCDO-ring@Housingend(inside)@Washerset@O-ring(2pes)®Startermotorease®Armature(f)Washerset®Brushholder®Brushspring®Housingend(outside)Downloadedfrom~Torquecontrolrequired.•ApplyTHREADLOCKSUPERDatabesideitindicates1303.specifiedtorque.(99000-32030)1lrApplyoil.Useengineoilunless..Useforkoil.otherwisespecified.(99000-99044-10G)~ApplySUZUKISUPERGREASEaApplyorusebrakefluid.IIA'I.(99000-25030)~ApplySUZUKISILICONEGREASE.~Measureinvoltagerange.(99000-25100)~ApplySUZUKIMOLYPASTE.~Measureinresistancerange.(99000-25140)12078]ApplySUZUKIBOND1207B.~Measureincurrentrange.(99104-31140)•ApplyTHREADLOCK1342.'{ooliUsespecialtool.(99000-32050)tJ13681ApplyTHREADLOCKSUPER1360.(99000-32130)Downloadedfrom·1GENERALINFORMATIONWARNING/CAUTION/NOTEPleasereadthismanualandfollowitsinstructionscarefully.Toemphasizespecialinformation,thesymbolandthewordsWARNING,CAUTIONandNOTEhavespecialmeanings.Payspecialatten­tiontothemessageshighlightedbythesesignalwords.AWARNINGIndicatesapotentialhazardthatcouldresultindeathorinjury.IACAUTIONIIndicatesapotentialhazardthatcouldresultinvehicledamage.NOTE:Indicatesspecialinformationtomakemaintenanceeasierorinstructionsclearer.Pleasenote,however,thatthewarningsandcautionscontainedinthismanualcannotpossiblycoverallpotentialhazardsrelatingtotheservicing,orlackofservicing,ofthemotorcycle.InadditiontotheWARNINGSandCAUTIONSstated,youmustusegoodjudgementandbasicmechanicalsafetyprinciples.Ifyouareunsureabouthowtoperformaparticularserviceoperation,askamoreex­periencedmechanicforadvice.GENERALPRECAUTIONSAWARNING•Properserviceandrepairproceduresareimportantforthesafetyoftheservicemechanicandthesafetyandreliabilityofthevehicle.•When2ormorepersonsworktogether,payattentiontothesafetyofeachother.•Whenitisnecessarytoruntheengineindoors,makesurethatexhaustgasisforcedoutdoors.•Whenworkingwithtoxicorflammablematerials,makesurethattheareayouworkiniswell­ventilatedandthatyoufollowallofthem