Suzuki DR650SE Shop Manual

Other manuals for DR650SE: Service Manual

Summary of DR650SE

  • Page 1

    General information periodic maintenance engine fuel and lubrication system chassis electrical system servicing information group index 1 foreword this manual contains an introductory description on suzuki dr650se and procedures for its in- spection/service and overhaul of its main compo- nents. Oth...

  • Page 3: Supplements

    Supplements dr650sev/w/x/y (’97/’98/’99/’00-models) dr650sek1 (’01-model) 9 10 11 dr650sek2/k3/k4/k5/k6/k7 (’02/’03/’04/’05/’06/’ 07/’08-models) dr650sek9 (’09-model) 12.

  • Page 241

    Dr650sev/w/x/y (’97/’98/’99/’00-models) contents specifications ................................................................................ 9- 1 service data .................................................................................... 9- 3 wiring diagram ...................................

  • Page 253: Dr650Sek1 (’01-Model)

    Dr650sek1 (’01-model) contents specifications .............................................................................. 10- 1 service data .................................................................................. 10- 2 liquid gasket ........................................................

  • Page 254: Specifications

    10-1 dr650sek1 (’01-model) specifications dimensions and dry mass overall length ........................................................................... 2 345 mm (92.3 in) ….. E-17, 28, 22 2 325 mm (91.5 in) ….. E-17, 28, 22 (low seat) 2 255 mm (88.8 in) ….. Others 2 235 mm (88.0 in) ….. Others ...

  • Page 255: Service Data

    Dr650sek1 (’01-model) 10-2 service data valve + guide unit: mm (in) item standard limit valve diam. In. 33 (1.3) ——— ex. 28 (1.1) ——— valve clearance in. 0.08 – 0.13 (when engine is cold) (0.003 – 0.005) ——— ex. 0.17 – 0.22 (0.0067 – 0.0087) ——— valve guide to valve stem in. 0.010 – 0.037 clearance ...

  • Page 256

    10-3 dr650sek1 (’01-model) camshaft + cylinder head unit: mm (in) item standard limit cam height in. 33.710 – 33.750 33.410 (1.3272 – 1.3287) (1.3154) ex. 33.700 – 33.740 33.400 (1.3268 – 1.3283) (1.3150) camshaft journal oil clearance right & 0.032 – 0.066 0.150 center (0.0013 – 0.0026) (0.0059) le...

  • Page 257

    Dr650sek1 (’01-model) 10-4 item standard limit piston ring to groove clearance 1st ——— 0.180 (0.0071) 2nd ——— 0.150 (0.0059) piston ring groove width 1st 1.230 – 1.250 (0.048 – 0.049) ——— 2nd 1.210 – 1.230 (0.047 – 0.048) ——— oil 2.810 – 2.830 (0.110 – 0.111) ——— piston ring thickness 1st 1.170 – 1....

  • Page 258

    10-5 dr650sek1 (’01-model) clutch unit: mm (in) item standard limit clutch lever play 10 – 15 (0.4 – 0.6) ——— drive plate thickness no.1 & 2.9 – 3.1 2.6 no.2 (0.11 – 0.12) (0.10) driven plate distortion ——— 0.10 (0.004) clutch spring free length ——— 33.0 (1.30) transmission + drive chain unit: mm (i...

  • Page 259

    Dr650sek1 (’01-model) 10-6 carburetor item specification e-03, 28 e-33 e-18 carburetor type mikuni bst40ss ← ← bore size 40 mm ← ← i.D. No. 32e1 32e6 32e2 idle r/min. 1 500 ± 100 r/min. 1 500 ± 50 r/min. Float height 14.7 ± 1.0 mm (0.58 ± 0.04in) ← ← main jet (m.J.) # ← #137.5 jet needle (j.N.) 6f23...

  • Page 260

    10-7 dr650sek1 (’01-model) electrical unit: mm (in) item specification note ignition timing 10° b.T.D.C. At 1 500 r/min. Spark plug type nd.: u31esr-n n.G.K.: cr10e gap 0.7 – 0.8 (0.028 – 0.031) spark performance over 8 (0.3) at 1 atm. Ignition coil resistance primary 0.07 – 0.12 Ω b – b/w secondary...

  • Page 261

    Dr650sek1 (’01-model) 10-8 item standard limit master cylinder bore front 12.700 – 12.743 (0.5000 – 0.5017) ——— rear 12.700 – 12.743 (0.5000 – 0.5017) ——— master cylinder piston diam. Front 12.657 – 12.684 (0.4983 – 0.4994) ——— rear 12.657 – 12.684 (0.4983 – 0.4994) ——— brake caliper cylinder bore f...

  • Page 262

    10-9 dr650sek1 (’01-model) item standard limit note rear shock absorber spring 247.5 ——— pre-set length (9.74) rear wheel travel 260 ——— (10.2) 220 ——— (8.7) low seat swingarm pivot shaft runout ——— 0.3 (0.01) tire pressure cold inflation solo riding dual riding tire pressure kpa kg/cm 2 psi kpa kg/...

  • Page 263: Liquid Gasket

    Dr650sek1 (’01-model) 10-10 liquid gasket cylinder head cover cylinder head note: suzuki bond no.1215 or no.1207b has to be applied to the cylinder head cover and cylinder head..

  • Page 265

    Contents specifications.............................................................................. 11- 2 service data .................................................................................. 11- 3 11 dr650sek2/k3/k4/k5/k6/k7 (’02/’03/’04/’05/’06/’07/’08-models) 11-1 dr650sek2/k3/k4/k5 /...

  • Page 266: Specifications

    Specifications dimensions and dry mass overall length ........................................................................... 2 345 mm (92.3 in) ….. E-17, 28 2 325 mm (91.5 in) ….. E-17, 28 (low seat) 2 255 mm (88.8 in) ….. Others 2 235 mm (88.0 in) ….. Others (low seat) overall width .............

  • Page 267: Service Data

    Service data valve + guide unit: mm (in) item standard limit valve diam. In. 33 (1.3) ——— ex. 28 (1.1) ——— valve clearance in. 0.08 – 0.13 (when engine is cold) (0.003 – 0.005) ——— ex. 0.17 – 0.22 (0.0067 – 0.0087) ——— valve guide to valve stem in. 0.010 – 0.037 clearance (0.0004 – 0.0015) ——— ex. 0...

  • Page 268

    Camshaft + cylinder head unit: mm (in) item standard limit cam height in. 33.710 – 33.750 33.410 (1.3272 – 1.3287) (1.3154) ex. 33.700 – 33.740 33.400 (1.3268 – 1.3283) (1.3150) camshaft journal oil clearance right & 0.032 – 0.066 0.150 center (0.0013 – 0.0026) (0.0059) left 0.028 – 0.059 0.150 (0.0...

  • Page 269

    Item standard limit piston ring to groove clearance 1st ——— 0.180 (0.0071) 2nd ——— 0.150 (0.0059) piston ring groove width 1st 1.230 – 1.250 (0.048 – 0.049) ——— 2nd 1.210 – 1.230 (0.047 – 0.048) ——— oil 2.810 – 2.830 (0.110 – 0.111) ——— piston ring thickness 1st 1.170 – 1.190 (0.0461 – 0.0469) ——— 2...

  • Page 270

    Clutch unit: mm (in) item standard limit clutch lever play 10 – 15 (0.4 – 0.6) ——— drive plate thickness no.1 & 2.9 – 3.1 2.6 no.2 (0.11 – 0.12) (0.10) driven plate distortion ——— 0.10 (0.004) clutch spring free length ——— 33.0 (1.30) drive train unit: mm (in) except ratio item standard limit primar...

  • Page 271

    Carburetor item specification e-03, 28 e-33 e-18 carburetor type mikuni bst40ss ← ← bore size 40 mm ← ← i.D. No. 32e1 32e6 32e2 idle r/min. 1 500 ± 100 r/min. 1 500 ± 50 r/min. Float height 14.7 ± 1.0 mm (0.58 ± 0.04in) ← ← main jet (m.J.) # ← #137.5 jet needle (j.N.) 6f23 ← 6h21-4th needle jet (n.J...

  • Page 272

    Electrical unit: mm (in) item specification note spark plug type nd.: u31esr-n n.G.K.: cr10e gap 0.7 – 0.8 (0.028 – 0.031) spark performance over 8 (0.3) at 1 atm. Ignition coil resistance primary 0.07 – 0.12 Ω b – b/w secondary 23 – 25 k Ω plug cap – plug cap generator coil resistance charging 0.5 ...

  • Page 273

    Item standard limit master cylinder bore front 12.700 – 12.743 (0.5000 – 0.5017) ——— rear 12.700 – 12.743 (0.5000 – 0.5017) ——— master cylinder piston diam. Front 12.657 – 12.684 (0.4983 – 0.4994) ——— rear 12.657 – 12.684 (0.4983 – 0.4994) ——— brake caliper cylinder bore front 27.000 – 27.050 (1.063...

  • Page 274

    Item standard limit note rear shock absorber spring 247.5 ——— pre-set length (9.74) rear wheel travel 260 ——— (10.2) 220 ——— (8.7) low seat swingarm pivot shaft runout ——— 0.3 (0.01) tire pressure cold inflation solo riding dual riding tire pressure kpa kg/cm 2 psi kpa kg/cm 2 psi front 150 1.50 22 ...

  • Page 275

    Contents page specifications....................................................................................... 12-2 note: * difference between k9-model and k8-model specification is indicated as an asterisk mark (*). * the service data is the same as the k8-model. 11 dr650sek9 (’09-models) 12-1...

  • Page 276: Specifications

    Specifications dimensions and curb mass overall length ...................................................................................... 2 255 mm (88.8 in) 2 235 mm (88.0 in).................... (low seat) overall width...............................................................................

  • Page 277

    Capacities fuel tank, including reserve .............................................................. 12.0 l (3.2/2.6 us/imp gal)..... E-33 13.0 l (3.4/2.9 us/imp gal)..... Others reserve ............................................................................. 3.0 l (0.8/0.7 us/imp gal) engine...