SuzukiDL650K4ServiceManual

ISERVICEMANUALIFOREWORDThismanualcontainsanintroductorydescriptionontheSUZUKIDL650andproceduresforitsinspec-tion/serviceandoverhaulofitsmaincomponents.Otherinformationconsideredasgenerallyknownisnotincluded.ReadtheGENERALINFORMATIONsectiontofamiliarizeyourselfwiththemotorcycleanditsmain-tenance.Usethissectionaswellasothersectionstouseasaguideforproperinspectionandservice.Thismanualwillhelpyouknowthemotorcyclebet-tersothatyoucanassureyourcustomersoffastandreliableservice.Thismanualhasbeenpreparedonthebasisofthelatestspecificationsatthetimeofpubli-cation.Ifmodificationshavebeenmadesincethen,differencesmayexistbetweenthecon-tentofthismanualandtheactualmotorcycle.illustrationsinthismanualareusedtoshowthebasicprinciplesofoperationandworkprocedures.Theymaynotrepresenttheactualmotorcycleexactlyindetail.Thismanualiswrittenforpersonswhohaveenoughknowledge,skillsandtools,includingspecialtools,forservicingSUZUKImotorcy-cles.Ifyoudonothavetheproperknowledgeandtools,askyourauthorizedSUZUKImotorcycledealertohelpyou.Inexperiencedmechanicsormechanicswithoutthepropertoolsandequipmentmaynotbeabletoproperlyperformtheservicesdescribedinthismanual.Improperrepairmayresultininjurytothemechanicandmayrenderthemotorcycleunsafefortheriderandpassenger.GENERALINFORMATIONPERIODICMAINTENANCEENGINEFISYSTEMDIAGNOSISFUELSYSTEMANDTHROTTLEBODYCOOLINGANDLUBRICATIONSYSTEMCHASSISELECTRICALSYSTEMSERVICINGINFORMATIONEMISSIONCONTROLINFORMATIONWIRINGDIAGRAMSUZUKlMOTORCORPORATIONOCOPYRIGHTSUZUKlMOTORCORPORATION2003HOWTOUSETHISMANUALTOLOCATEWHATYOUARELOOKINGFOR:1.Thetextofthismanualisdividedintosections.2.ThesectiontitlesarelistedintheGROUPINDEX.3.Holdingthemanualasshownattherightwillallowyoutofindthefirstpageofthesectioneasily.4.Thecontentsarelistedonthefirstpageofeachsectiontohelpyoufindtheitemandpageyouneed.COMPONENTPARTSANDWORKTOBEDONEUnderthenameofeachsystemorunit,isitsexplodedview.Workinstructionsandotherserviceinformationsuchasthetighteningtorque,lubricatingpointsandlockingagentpoints,areprovided.Example:Frontwheel@1BrakediscOI~ustsealI@IBearingI@(CenterspacerI@IFrontwheel@IBrakediscboltI@@TirevalveFrontaxleSYMBOLListedinthetablebelowarethesymbolsindicatinginstructionsandotherinformationnecessaryforservic--ing.Themeaningofeachsymbolisalsoincludedinthetable.SYMBOLPIDEFINITIONTorquecontrolrequired.Databesideitindicatesspecifiedtorque.Applyoil.Useengineoilunlessother-wisespecified.Applymolybdenumoilsolution.(MixtureofengineoilandSUZUKlMOLYPASTEinaratioof1:1)ApplySUZUKlSUPERGREASEA.99000-25030(USA)99000-25010(Others)ApplySUZUKlMOLYPASTE.99000-25140ApplySUZUKlSILICONEGREASE.99000-25100ApplySUZUKlBOND121599000-31110(ExceptUSA)ApplySUZUKlBOND12078.99104-31140(USA)99000-31140(Others)ApplyTHREADLOCKSUPER1303.99000-32030ApplyTHREADLOCKSUPER1322.99000-32110(ExceptUSA)ApplyTHREADLOCK134299000-32050SYMBOLDEFINITIONApplyTHREADLOCKSUPER1360.99000-32130Useenginecoolant.Useforkoil.99000-99001-SS8Applyorusebrakefluid.Measureinvoltagerange.Measureincurrentrange.Measureinresistancerange.Measureindiodetestrange.Measureincontinuitytestrange.Usespecialtool.Indicationofservicedata.ABBREVIATIONSUSEDINTHISMANUALABDC:AfterBottomDeadCenterAC:AlternatingCurrentACL:AirCleaner,AirCleanerBoxAPI:AmericanPetroleumInstituteATDC:AfterTopDeadCenterATMPressure:AtmosphericPressureAtmosphericPressureSensor(APS):AirFuelMixtureBBBDCBTDCB+:BeforeBottomDeadCenter:BeforeTopDeadCenter:BatteryPositiveVoltageCCKPSensor:CrankshaftPositionSensor(CKPS)CKT:CircuitCLPSwitch:ClutchLeverPositionSwitch(ClutchSwitch)CMPSensor:CamshaftPositionSensor(CMPS)CO:CarbonMonoxideCPU:CentralProcessingUnitDDCDMCDOHCDRL:DirectCurrent:DealerModeCoupler:DoubleOverHeadCamshaft:DaytimeRunningLightEECM:EngineControlModuleEngineControlUnit(ECU)(FIControlUnit)-ECTSensor:EngineCoolantTemperatureSensor(ECTS),WaterTemp.Sensor(WTS)EVAP:EvaporativeEmissionEVAPCanister:EvaporativeEmissionFFIFPFPRFPRelayGGENGNDGPSwitchHHCIIAPSensIATSensorLLCDLEDCanister(Canister):FuelInjection,FuelInjector:FuelPump:FuelPressureRegulator:FuelPumpRelay:Generator:Ground:GearPositionSwitch:Hydrocarbons:IntakeAirPressureSensor(IAPS):IntakeAirTemperatureSensor(IATS):Ignition:LiquidCrystalDisplay:LightEmittingDiode(MalfunctionIndicatorLamp):LeftHandMaxMILMinNNOx0OHCOPSPPCVRRHROMSSAESTCSystemSTPSensorSTValve:MalfunctionCode(DiagnosticCode):Maximum:MalfunctionIndicatorLamp(LED):Minimum:NitrogenOxides:OverHeadCamshaft:OilPressureSwitch:PositiveCrankcaseVentilation(CrankcaseBreather):RightHand:ReadOnlyMemory:SocietyofAutomotiveEngineers:SecondaryThrottleControlSystem(STCS):SecondaryThrottlePositionSensor(STPS):SecondaryThrottleValve(STV)STVActuator:SecondaryThrottleValveActuator(STVA)TTOSensor:TipOverSensor(TOS)TPSensor:ThrottlePositionSensor(TPS)vVD:VacuumDamperSAE-TO-FORMERSUZUKlTERMThistablelistsSAE(SocietyofAutomotiveEngineers)J1930termsandabbreviationswhichmaybeusedinthismanualincompliancewithSAErecommendations,aswellastheirformerSUZUKlnames.SAETERMFULLTERM4AirCleanerBBarometricPressureBatteryPositiveVoltageCCamshaftPositionSensorCrankshaftPosition