Suzuki DL650AK8 Service Bulletin

Summary of DL650AK8

  • Page 1

    Motorcycle date: jul. 27, 2007 page: 1 of 14 subject: notice of set-up manual applicable model: dl650ak8 effective engine or frame no.: reference: this bulletin is to inform you of set-up procedures of dl650ak8. Please inform your dealers of this notice. Dl650ak8 set-up manual will not be issued bec...

  • Page 2

    Motorcycle date: jul. 27, 2007 page: 2 of 14 right left [page: 5, 6 paragraph: 1] the photographs shown indicate the parts dismounted from the motorcycle in addition to the items shown in the preceding page. A: front brake master cylinder b: throttle assembly c: left switch d: clutch cable e: speedo...

  • Page 3

    Motorcycle date: jul. 27, 2007 page: 3 of 14 front brake master cylinder [page: 11, 12 paragraph: 1] install the front brake master cylinder onto the handle- bars. Align the dot mark on the handlebars with the master cylinder-to-holder fitting surface. Tighten the front brake master cylinder mountin...

  • Page 4

    Motorcycle date: jul. 27, 2007 page: 4 of 14 front wheel [page: 17, 18 paragraph: 3 through page: 21, 22 paragraph: 1] when installing the front wheel onto the axle, special attention must be paid to the arrow of the rotational direction on the tire sidewall. When the tire is properly installed, the...

  • Page 5

    Motorcycle date: jul. 27, 2007 page: 5 of 14 install the abs sensor bracket to the front wheel hub. A: abs sensor bracket b: oil seal (lip) align the abs sensor bracket stopper with stopper on the right fork leg. A: abs sensor bracket b: stopper (abs sensor bracket) c: stopper (right fork leg) inser...

  • Page 6

    Motorcycle date: jul. 27, 2007 page: 6 of 14 right left [page: 23, 24 paragraph: the next of 2] a: abs sensor lead wire b: speed sensor lead wire c: boss (fork leg) warning label [page: 27, 28 paragraph: 2] stick the label selected for your country. A: for e-19 cc selection b: for e-19 cd selection ...

  • Page 7

    Motorcycle date: jul. 27, 2007 page: 7 of 14 throttle cable [page: 37, 38 paragraph: 3, 4] this motorcycle has a twin throttle cable system. Cable a is for pulling cable and cable b is for return- ing. Check the throttle cable play at the throttle grip. Throttle cable play: 2.0–4.0 mm if adjustment ...

  • Page 8

    Motorcycle date: jul. 27, 2007 page: 8 of 14 rear suspension [page: 43, 44 paragraph: 3] rebound damping force adjustment (for canada) adjust the setting of the rebound damping force to the standard position. Standard setting: 1 turn back to adjust, turn the adjuster b clockwise until it stops and t...

  • Page 9

    Motorcycle date: jul. 27, 2007 page: 9 of 14 2. Remove the fastener to take off the fuel tank front cover. A: fuel tank front cover b: fastener c: boss 3. Remove the bolt. A: allen bolt b: meter panel c: side cowling 4. Unset the meter panel and side cowling from the boss. A: meter panel b: side cow...

  • Page 10

    Motorcycle date: jul. 27, 2007 page: 10 of 14 5. Remove the bolt to take off the prop stay. Lift the fuel tank and prop it up. A: prop stay b: bolt c: fuel tank d: boss e: hook 6. Remove the reservoir tank cap and add 50 : 50 mix- ture of engine coolant and distilled water to the “full” level line f...

  • Page 11

    Motorcycle date: jul. 27, 2007 page: 11 of 14 jaso t903 the jaso t903 standard is an index to select engine oils for 4-stroke motorcycle and atv engines. Motorcycle and atv engines lubricate clutch and transmission gears with engine oil. Jaso t903 specifies performance requirements for motorcycle an...

  • Page 12

    Motorcycle date: jul. 27, 2007 page: 12 of 14 5. Harness routing [page: 55, 56] wiring harness clamp clamp clamp starter motor lead wire wiring harness stop lamp lead wire abs sensor lead wire clamp rectifier lead wire breather hose isc valve coupler speed sensor lead wire clutch cable handlebar swi...

  • Page 13

    Motorcycle date: jul. 27, 2007 page: 13 of 14 clamp clamp clamp clamp clamp abs brake hose reserver hose turn signal light lead wire wiring harness pass the license light lead wire in front of the seat lock cable. Triangle mark of each spark plug cap must be brought to the exhaust side. Pass the pai...

  • Page 14

    Motorcycle date: jul. 27, 2007 page: 14 of 14 6. Safety check out [page: 57, 58, 59] engine and transmission chassis sp: spring setting r.Df: rebound damping force cold tire inflation pressure electricals road test inspection after completion of the setting-up the motor- cycle all the following item...