dl650k5

GROUPINDEXGENERALINFORMATION1PERIODICMAINTENANCE2ENGINE3FISYSTEMDIAGNOSIS4FUELSYSTEMANDTHROTTLEBODY5COOLINGANDLUBRICATIONSYSTEM6CHASSIS7ELECTRICALSYSTEM8SERVICINGINFORMATION910FOREWORDThismanualcontainsanintroductorydescriptionontheSUZUKIDL650andproceduresforitsinspec-tion/serviceandoverhaulofitsmaincomponents.Otherinformationconsideredasgenerallyknownisnotincluded.ReadtheGENERALINFORMATIONsectiontofamiliarizeyourselfwiththemotorcycleanditsmain-tenance.Usethissectionaswellasothersectionstouseasaguideforproperinspectionandservice.Thismanualwillhelpyouknowthemotorcyclebet-tersothatyoucanassureyourcustomersoffastandreliableservice.©COPYRIGHTSUZUKIMOTORCORPORATION2003*Thismanualhasbeenpreparedonthebasisofthelatestspecificationsatthetimeofpubli-cation.Ifmodificationshavebeenmadesincethen,differencesmayexistbetweenthecon-tentofthismanualandtheactualmotorcycle.*Illustrationsinthismanualareusedtoshowthebasicprinciplesofoperationandworkprocedures.Theymaynotrepresenttheactualmotorcycleexactlyindetail.*Thismanualiswrittenforpersonswhohaveenoughknowledge,skillsandtools,includingspecialtools,forservicingSUZUKImotorcy-cles.Ifyoudonothavetheproperknowledgeandtools,askyourauthorizedSUZUKImotorcycledealertohelpyou.Inexperiencedmechanicsormechanicswithoutthepropertoolsandequipmentmaynotbeabletoproperlyperformtheservicesdescribedinthismanual.Improperrepairmayresultininjurytothemechanicandmayrenderthemotorcycleunsafefortheriderandpassenger.EMISSIONCONTROLINFORMATION99500-36135-03EPartShark.com877-999-568603ENGINE.bookPage105Tuesday,February28,20063:03PMPartShark.com877-999-5686111213SUPPLEMENTSDL650K5('05-MODEL)DL650K6('06-MODEL)DL650/AK7('07-MODEL)1415DL650/AK9(’09-MODEL)DL650/AK8('08-MODEL)16WIRINGDIAGRAMPartShark.com877-999-5686HOWTOUSETHISMANUALTOLOCATEWHATYOUARELOOKINGFOR:1.Thetextofthismanualisdividedintosections.2.ThesectiontitlesarelistedintheGROUPINDEX.3.Holdingthemanualasshownattherightwillallowyoutofindthefirstpageofthesectioneasily.4.Thecontentsarelistedonthefirstpageofeachsectiontohelpyoufindtheitemandpageyouneed.COMPONENTPARTSANDWORKTOBEDONEUnderthenameofeachsystemorunit,isitsexplodedview.Workinstructionsandotherserviceinformationsuchasthetighteningtorque,lubricatingpointsandlockingagentpoints,areprovided.Example:Frontwheel1Brakedisc2Dustseal3Bearing4Centerspacer5Frontwheel6TirevalveAFrontaxleBBrakediscboltITEMN·mkgf-mlb-ftA656.547.0B232.316.5PartShark.com877-999-5686SYMBOLListedinthetablebelowarethesymbolsindicatinginstructionsandotherinformationnecessaryforservic-ing.Themeaningofeachsymbolisalsoincludedinthetable.SYMBOLDEFINITIONSYMBOLDEFINITIONTorquecontrolrequired.Databesideitindicatesspecifiedtorque.ApplyTHREADLOCKSUPER“1360”.99000-32130Applyoil.Useengineoilunlessother-wisespecified.Useenginecoolant.Applymolybdenumoilsolution.(MixtureofengineoilandSUZUKIMOLYPASTEinaratioof1:1)Useforkoil.99000-99001-SS8ApplySUZUKISUPERGREASE“A”.99000-25030(USA)99000-25010(Others)Applyorusebrakefluid.ApplySUZUKIMOLYPASTE.99000-25140Measureinvoltagerange.ApplySUZUKISILICONEGREASE.99000-25100Measureincurrentrange.ApplySUZUKIBOND“1215”.99000-31110(ExceptUSA)Measureinresistancerange.ApplySUZUKIBOND“1207B”.99104-31140(USA)99000-31140(Others)Measureindiodetestrange.ApplyTHREADLOCKSUPER“1303”.99000-32030Measureincontinuitytestrange.ApplyTHREADLOCKSUPER“1322”.99000-32110(ExceptUSA)Usespecialtool.ApplyTHREADLOCK“1342”.99000-32050Indicationofservicedata.PartShark.com877-999-5686ABBREVIATIONSUSEDINTHISMANUALAABDC:AfterBottomDeadCenterAC:AlternatingCurrentACL:AirCleaner,AirCleanerBoxAPI:AmericanPetroleumInstituteATDC:AfterTopDeadCenterATMPressure:AtmosphericPressureAtmosphericPressureSensor(APS)A/F:AirFuelMixtureBBBDC:BeforeBottomDeadCenterBTDC:BeforeTopDeadCenterB+:BatteryPositiveVoltageCCKPSensor:CrankshaftPositionSensor(CKPS)CKT:CircuitCLPSwitch:ClutchLeverPositionSwitch(ClutchSwitch)CMPSensor:CamshaftPositionSensor(CMPS)CO:CarbonMonoxideCPU:CentralProcessingUnitDDC:DirectCurrentDMC:DealerModeCouplerDOHC:DoubleOverHeadCamshaftDRL:DaytimeRunningLightEECM:EngineControlModuleEngineControlUnit(ECU)(FIControlUnit)ECTSensor:EngineCoolantTemperatureSensor(ECTS),WaterTemp.Sensor(WTS)EVAP:EvaporativeEmissionEVAPCanister:EvaporativeEmissionCanister(Canister)FFI:FuelInjection,FuelInjectorFP:FuelPumpFPR:FuelPressureRegulatorFPRelay:FuelPumpRelayGGEN:GeneratorGND:GroundGPSwitch:GearPositionSwitchHHC:HydrocarbonsIIAPSensor:IntakeAirPressureSensor(IAPS)IATSensor:IntakeAirTemperatureSensor(IATS)IG:IgnitionLLCD:LiquidCrystalDisplayLED:LightEmittingDiode(MalfunctionIndicatorLamp)LH:LeftHandPartShark.com877-999-5686MMAL-Code:MalfunctionCode(DiagnosticCode)Max:MaximumMIL:MalfunctionIndicatorLamp(LED)Min:MinimumNNOx:NitrogenOxidesOOHC:OverHeadCamshaftOPS:OilPressureSwitchPPCV:PositiveCrankcaseVentilation(CrankcaseBreather)RRH:RightHandROM:ReadOnlyMemorySSAE:SocietyofAutomotiveEngineersSTCSystem:SecondaryThrottleControlSystem(STCS)STPSensor:SecondaryThrottlePositionSensor(STPS)STValve:SecondaryThrottleValve(STV)STVActuator:SecondaryThrottleValveActuator(STV