Suzuki DL650 Manuel utilisateur

SERVICE

MANUAL

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

SUZUKl

MOTOR CORPORATION

2003

HOW TO USE THIS MANUAL

TO LOCATEWHAT YOU ARE LOOKING FOR:

The text of this manual is divided into sections.

The section titles are listed in the GROUP INDEX.

Holdingthe manualasshownat the rightwill allow youto find

the first pageof the sectioneasily.

The contents are listed on the first page of each section to

helpyou find the item and page you need.

COMPONENT PARTSAND WORK TO

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

Brakedisc

~ustseal

Bearing

(

Center spacer

Frontwheel

Brakedisc bolt

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

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

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

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

BBDC

BTDC

B+

Before BottomDead Center

BeforeTop DeadCenter

Battery Positive Voltage

CKP Sensor

Crankshaft Position Sensor

(CKPS)

CKT

Circuit

CLP Switch

Clutch Lever Position Switch

(ClutchSwitch)

CMP Sensor

Camshaft PositionSensor

(CMPS)

Carbon Monoxide

CPU

Central ProcessingUnit

DMC

DOHC

DRL

DirectCurrent

Dealer Mode Coupler

DoubleOver HeadCamshaft

DaytimeRunningLight

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

FPR

FP Relay

GEN

GND

GP Switch

IAP Sens

IAT Sensor

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

NOx

OHC

OPS

PCV

ROM

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)

TO Sensor

Tip Over Sensor (TOS)

TP Sensor

Throttle Position Sensor (TPS)

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

Air Cleaner

Barometric Pressure

Battery Positive Voltage

Camshaft PositionSensor

Crankshaft PositionSensor

Data Link Connector

DiagnosticTest Mode

Diagnostic Trouble Code

Electronic Ignition

EngineControl Module

Engine Coolant Level

Engine Coolant Temperature

Engine Speed

EvaporativeEmission

EvaporativeEmissionCanister

FanControl

Fuel Level Sensor

Fuel Pump

Generator

Ground

ABBREVIATION

ACL

BAR0

B+

CMP Sensor

CKP Sensor

DLC

DTM

DTC

ECM

ECL

ECT

RPM

EVAP

EVAP Canister

GEN

GND

FORMER SUZUKl TERM

Air Cleaner. Air Cleaner Box

BarometricPressure,Atmospheric

Pressure(APS,AP Sensor)

Battery Voltage,

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

IdleSpeed Control

IgnitionControl

IgnitionControl Module

lntakeAir Temperature

Malfunction Indicator Lamp

ManifoldAbsolute Pressure

MassAir Flow

On-Board Diagnostic

Open Loop

ProgrammableRead Only Memory

PulsedSecondaryAir lnjection

PurgeValve

RandomAccess Memory

ReadOnly Memory

SecondaryAir lnjection

Secondary Throttle Control System

SecondaryThrottle Valve

SecondaryThrottle Valve Actuator

Throttle Body

ThrottleBody Fuellnjection

Throttle PositionSensor

Voltage Regulator

Volume Air Flow

ABBREVIATION

ISC

ICM

IAT

MIL

MAP

MAF

OBD

PROM

PA1R

Purge Valve

RAM

ROM

AIR

STCS

STV

STVA

TBI

TP Sensor

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

Black

Blue

Brown

Dark green

Green

Gr :Gray

Lbl

Light blue

Light green

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

Gr/R

O/B

O/G

ONV

PNV

RNV

W/BI

W/R

Y/BI

Y/R

Red

White

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

................................................................

GENERALPRECAUTIONS

...........................................................................

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-

.........................................................................................

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

...........................................................................

CYLINDERIDENTIFICATION

.....................................................................

INFORMATIONLABELS

...............................................................................

SPECIFICATIONS

.........................................................................................

.............................................................

DIMENSIONSAND DRY MASS 1-

...................................................................................................

ENGINE 1-

..........................................................................................

DRIVE TRAIN 1-

CHASSIS

.................................................................................................

1-10

ELECTRICAL

........................................................................................

1-10

CAPACITIES

..........................................................................................

1-10

COUNTRYAND AREA CODES

....................................................................

1-11

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