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Suzuki V Storm Owner's Manual

Other manuals for V Storm: Owner's Manual
Manual is about: Motorcycle

Summary of V Storm

  • Page 1

    Top 1st cover 4th cover top 1st cover 4th cover dl650a owner’s manual 99011-27g62-03a dl650a part no. 99011-27g62-03a july, 2008 en tk 5 mm 5 mm no.646 dl650a 99011-27g62-03a 2/1 no.646 dl650a 99011-27g62-03a 2/1 dic184(tdp006) dic157 this owner’s manual contains important safety information. Please...

  • Page 2: Warning

    Top 3rd cover 2nd cover 5 mm no.646 dl650a 99011-27g62-03a 2/1 black california proposition 65 warning warning engine exhaust, some of its constituents, and certain product com- ponents contain or emit chemicals known to the state of california to cause cancer and birth defects or other reproductive...

  • Page 3: Warning/caution/note

    Important warning/caution/note please read this manual and fol- low its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay spe- cial attention to the messages highlighted by these signal words: note: indicates speci...

  • Page 4

    All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication. Due to improvements or other changes, there may be some discrepan- cies between information in this manual and your motorcycle. Suzuki reserves...

  • Page 5: Table of Contents

    Table of contents 1 2 3 4 5 6 7 8 9 10 the sport of motorcycling fuel, engine oil and coolant recommendations controls, equipment and adjustments break-in and inspection before riding riding tips accessory use and motorcycle loading inspection and maintenance troubleshooting storage procedure and mo...

  • Page 7: The Sport of Motorcycling

    1-1 1 the sport of motorcycling most accidents can be avoided ............................................................. 1-2 if you don’t have a helmet - buy a helmet, and wear it every time you ride ..................................................................... 1-2 if a collision is immin...

  • Page 8: Most Accidents Can Be

    1-2 the sport of motorcycling your motorcycle and this owner’s manual have been designed by people like you who enjoy motor- cycling. People become motorcy- clists for many reasons. For starters, street riding is fun and invigorating. But no matter why you became a motorcyclist, or how experienced y...

  • Page 9: If A Collision Is Imminent,

    1-3 if a collision is imminent, do something! Many riders fear locking up their brakes or haven’t learned to swerve to avoid an accident. Many inexperienced riders (and too many seasoned riders) use only their rear brake in an emer- gency, resulting in unnecessary impacts in some cases and unnecessa...

  • Page 10: Know Your Limits

    1-4 know your limits always ride within the boundaries of your own skills. Knowing these limits and staying within them will help you avoid accidents. A major cause of accidents involv- ing only a motorcycle (and no cars) is going too fast through a turn. Before entering a turn, select an appropriat...

  • Page 11: Inspection Before Riding

    1-5 inspection before riding review the instructions in the “inspection before riding” section of this manual. Perform an entire pre-ride inspection before you head out on the road. Spend- ing a few minutes preparing your machine for a ride can help pre- vent accidents due to mechanical failure or c...

  • Page 12: Motorcycle Safety

    1-6 motorcycle safety foundation’s “riding tips and practice guide” handbook (for owners in usa) this special handbook, supplied with your owner’s manual, con- tains a variety of safety tips, help- ful hints, and practice exercises. This manual can increase your riding enjoyment and safety. You shou...

  • Page 13: Fuel, Engine Oil and Coolant

    2-1 2 fuel, engine oil and coolant recommendations fuel .................................................................................................................... 2-2 engine oil ......................................................................................................... 2-3 en...

  • Page 14: Fuel

    2-2 fuel, engine oil and coolant recommendations fuel your motorcycle requires regular unleaded gasoline with a mini- mum pump octane rating of 87 ((r+m)/2 method). In some areas, the only fuels that are available are oxygenated fuels. Oxygenated fuels which meet the minimum octane requirement and t...

  • Page 15: Engine Oil

    2-3 note: • to help minimize air pollution, suzuki recommends that you use oxygenated fuels. • be sure that any oxygenated fuel you use has octane rat- ings of at least 87 pump octane ((r+m)/2 method). • if you are not satisfied with the driveability or fuel economy of your motorcycle when you are u...

  • Page 16: Jaso T903

    2-4 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 perfor- mance requirements for motorcy- cle and atv clutches and transmissions. The...

  • Page 17: Engine Coolant Solution

    2-5 engine coolant solution use engine coolant that is com- patible with an aluminum radiator, mixed with distilled water at a 50:50 mixture ratio for engine coolant solution. An engine cool- ant mixture other than 50:50 can affect cooling efficiency or rust inhibiting performance. Engine coolant en...

  • Page 19: Controls, Equipment and

    3-1 3 controls, equipment and adjustments location of parts ....................................................................................... 3-2 key ...................................................................................................................... 3-5 ignition switch ........

  • Page 20: Location of Parts

    3-2 controls, equipment and adjustments location of parts 1 clutch lever 2 left handlebar switches 3 ignition switch 4 speedometer 5 indicator lights 6 tachometer 7 front brake fluid reservoir 8 right handlebar switches 9 throttle grip 0 front brake lever a fuel tank cap.

  • Page 21

    3-3 b tools c gearshift lever d side stand e seat lock.

  • Page 22

    3-4 f rear brake pedal.

  • Page 23: Key

    3-5 key two keys come with this motorcy- cle. Keep the spare key in a safe place. An identifying number is stamped on the plate. Use this number when making a replace- ment key. Please write down your key num- ber in the box provided for your future reference. Ignition switch the ignition switch has...

  • Page 24: “P” (Parking) Position

    3-6 “p” (parking) position the taillight will come on to increase visibility for temporary road side parking at night. The key can be removed and the steering will be locked. The key hole can be covered by turning the lid. Align the lid hole position with the key hole position when inserting the key...

  • Page 25: Instrument Panel

    3-7 instrument panel when the ignition switch is turned to the “on” position, the speed- ometer and tachometer needles moves to the full scale position and return to the home position. Lcd displays all segments for 3 seconds when the ignition switch is turned to the “on” position to confirm display ...

  • Page 26: “Fi”/clock

    3-8 fuel injection system indicator “fi”/clock 6 if the fuel injection system fails, the red indicator light 7 comes on and the display 6 indicates “fi” in following two modes; a. The display 6 indicates “fi” and the clock alternately, and the red indicator light 7 comes on and remains lit. B. The d...

  • Page 27: Clock

    3-9 when the display 6 indicates “chec”, check following items; • make sure that the engine stop switch is in the “ ” position. • make sure that the transmis- sion is in neutral or the side stand is fully up. If the display still indicates “chec” after checking the above items, inspect the ignition ...

  • Page 28: Oil Pressure Indicator Light

    3-10 oil pressure indicator light “ ” 7 with the ignition switch in the “on” position but the engine is not started, the symbol “ ” in the display and the indicator light 7 comes on. As soon as the engine is started, the symbol “ ” and the indicator light should go out. When the engine oil pressure ...

  • Page 29: Fuel Meter “

    3-11 note: if the abs indicator light goes off before starting the motor- cycle, check the abs indicator light function by turning off and on the ignition switch. The abs indi- cator light can go off if the engine is revved at high speed before starting the motorcycle. If the abs indicator light doe...

  • Page 30: Odometer/trip Meter

    3-12 odometer/trip meter a this display has 3 functions; odometer and two trip meters. When the ignition switch is turned to the “on” position, the display indicates the test pattern shown below for 3 seconds. Then the display changes to odometer or trip meter, according to what was selected before ...

  • Page 31: Coolant Temperature Meter

    3-13 to reset the trip meter to zero, push the “adj” button b for two seconds while the display indi- cates the trip meter 1 or 2 you want to reset. Coolant temperature meter “ ” c the coolant temperature meter indicates engine coolant tempera- ture. When the coolant tempera- ture becomes high, the ...

  • Page 32: Left Handlebar

    3-14 left handlebar clutch lever 1 the clutch lever is used for disen- gaging the drive to the rear wheel when starting the engine or shift- ing transmission gears. Squeez- ing the lever disengages the clutch. Headlight flasher switch 2 press the switch to flash the headlight. The headlight high bea...

  • Page 33: Turn Signal Switch “

    3-15 turn signal switch “ ” 5 moving the switch to the “ ” position will flash the left turn sig- nals. Moving the switch to the “ ” position will flash the right turn signals. The indicator light will also flash intermittently. To cancel turn signal operation, push the switch in. Horn button “ ” 6 ...

  • Page 34: Electric Starter Button “

    3-16 electric starter button “ ” 3 use this button to operate the starter motor. With the ignition switch in the “on” position, the engine stop switch in the “ ” position, and the transmission in neutral, pull in the clutch lever and push the electric starter button to start the engine. Note: this m...

  • Page 35: Front Brake Lever Adjustment

    3-17 front brake lever adjustment the distance between the throttle grip and the front brake lever is adjustable to 5 positions. To change the position, push the brake lever forward and turn the adjuster to the desired position. Be sure the adjuster stops in the proper position; a projection of the ...

  • Page 36: Fuel Tank Cap

    3-18 fuel tank cap to open the fuel tank cap, insert the ignition key into the lock and turn it clockwise. With the key inserted, lift up the cap. To close the cap, push the cap down firmly with the key in the cap lock. 1 fuel level 2 filler neck warning overfilling the fuel tank can cause the fuel ...

  • Page 37: Gearshift Lever

    3-19 gearshift lever this motorcycle has a 6-speed transmission which operates as shown. To shift properly, squeeze the clutch lever and close the throttle at the same time you operate the gearshift lever. Lift the gearshift lever to upshift and depress the lever to downshift. Neutral is located bet...

  • Page 38: Seat Lock

    3-20 seat lock to remove the seat, insert the ignition key into the lock and turn it clockwise. Raise the rear end of the seat and slide it backward. To reinstall the seat, slide the seat hooks into the seat hook retainers and push down firmly until the seat snaps into the locked posi- tion. A small...

  • Page 39: Side Stand

    3-21 side stand an interlock system is provided to cut off the ignition circuit when the side stand is down and the trans- mission is in any gear other than neutral. The side stand/ignition interlock system works as follows: • if the side stand is down and the transmission is in gear, the engine can...

  • Page 40: Suspension Adjustment

    3-22 suspension adjustment the standard settings for both front and rear suspensions are selected to meet various riding conditions such as low to high motorcycle speed and light to heavy load on the motorcycle. The suspension settings can be adjusted to fine-tune then accord- ing your preference. F...

  • Page 41: Rear Suspension

    3-23 rear suspension spring pre-load adjustment to adjust the rear suspension spring pre-load, turn the adjuster 1 . Turning the adjuster clockwise will stiffen the spring pre-load and turning it counterclockwise will soften the spring pre-load. Posi- tion 0 provides the softest spring pre-load and ...

  • Page 42: Windshield Height

    3-24 windshield height adjustment the windshield height can be adjusted in 3 positions. To change windshield height, follow the pro- cedure below. 1. Remove the screws and plates. 2. Remove the screws and wind- shield. 3. Remove the 4 bolts. 4. Move the windshield up and down to desired windshield h...

  • Page 43: Break-In and Inspection

    4-1 4 break-in and inspection before riding inspection before riding .......................................................................... 4-3.

  • Page 44: Maximum Engine Speed

    4-2 break-in and inspection before riding the first 800 km (500 miles) is the most important in the life of your motorcycle. Proper operation dur- ing this break-in period will help assure maximum life and perfor- mance from your new motorcycle. The following guidelines explain proper break-in proce...

  • Page 45: Critical Service

    4-3 observe your initial and most critical service the initial service (break-in main- tenance) is the most important service your motorcycle will receive. During break-in opera- tion, all of the engine components will have mated together and seated. Maintenance required as part of the initial servi...

  • Page 46: Warning

    4-4 check the condition of the motor- cycle to help make sure that you do not have mechanical problems or get stranded somewhere when you ride. Before riding the motor- cycle, be sure to check the follow- ing items. Be sure your motorcycle is in good condition for the personal safety of the rider, p...

  • Page 47: Riding Tips

    5 5-1 riding tips starting the engine .................................................................................... 5-2 starting off and shifting ........................................................................ 5-3 using the transmission ..................................................

  • Page 48: Starting The Engine

    5-2 riding tips starting the engine before attempting to start the engine, make sure: 1. The transmission is in neutral. 2. The engine stop switch is in the “ ” position. Note: this motorcycle has inter- lock switches for the ignition cir- cuit and the starter circuit. The engine can only be started...

  • Page 49: Starting Off and Shifting

    5-3 starting off and shifting make sure that the side stand is in the fully up position. Squeeze the clutch lever and pause momen- tarily. Engage first gear by depressing the gearshift lever downward. Turn the throttle grip toward you and at the same time release the clutch lever gently and smoothly...

  • Page 50: Using The Transmission

    5-4 using the transmission the transmission is provided to keep the engine operating smoothly in its normal operating speed range. The gear ratios have been carefully chosen to meet the characteristics of the engine. The rider should always select the most suitable gear for the prevailing conditions...

  • Page 51: Riding On Hills

    5-5 riding on hills • when climbing steep hills, the motorcycle may begin to slow down and show lack of power. At this point you should shift to a lower gear so that the engine will again be operating in its normal power range. Shift rap- idly to prevent the motorcycle from losing momentum. • when r...

  • Page 52: Warning

    5-6 you must still ride sensibly and alertly. On regular paved roads, some riders may be able to obtain slightly shorter stopping distances with conventional brake systems than with abs. Note: in some situations, a motorcycle with abs may require a longer stopping distance to stop on loose or uneven...

  • Page 53: How The Abs Works

    5-7 how the abs works abs works by electronically con- trolling braking pressure. A com- puter monitors wheel rotation speed. If the computer detects that a braked wheel has slowed suddenly, indicating a skidding sit- uation, the computer will reduce braking pressure to prevent that wheel from locki...

  • Page 54: Carrying A Passenger

    5-8 5. Park the motorcycle on a firm, flat surface where it will not fall over. 6. Turn the ignition switch to the “off” position. 7. Turn the handlebars all the way to the left and lock the steering for security. 8. Remove the ignition key. Note: if an optional anti-theft lock such as u-shape lock,...

  • Page 55: Accessory Use and

    6-1 6 accessory use and motorcycle loading accessory use .............................................................................................. 6-2 accessory installation guideline ....................................................... 6-2 loading limit ........................................

  • Page 56: Accessory Use

    6-2 accessory use and motorcycle loading accessory use the addition of unsuitable acces- sories can lead to unsafe operat- ing conditions. It is not possible for suzuki to test each accessory on the market or combinations of all the available accessories; how- ever, your dealer can assist you in sel...

  • Page 57: Loading Limit

    6-3 • additional electrical accesso- ries may overload the existing electrical system. Severe over- loads may damage the wiring harness or create a hazardous situation due to the loss of electrical power during the operation of the motorcycle. • do not pull a trailer or sidecar. This motorcycle is n...

  • Page 58: Loading Guidelines

    6-4 loading guidelines this motorcycle is primarily intended to carry small items when you are not riding with a passenger. Follow the guidelines below to carry a passenger or cargo: • balance the load between the left and right side of the motor- cycle and fasten it securely. • keep cargo weight lo...

  • Page 59: Inspection and Maintenance

    7-1 7 inspection and maintenance notice ................................................................................................................ 7-2 maintenance schedule .............................................................................. 7-2 tools ....................................

  • Page 60: Notice

    7-2 inspection and maintenance notice maintenance schedule it is very important to inspect and maintain your motorcycle regu- larly. Follow the guidelines in the chart. The intervals between peri- odic services in kilometers, miles and months are shown. At the end of each interval, be sure to perfor...

  • Page 61: Warning

    7-3 note: the maintenance chart specifies the minimum requirements for maintenance. If you use your motorcycle under severe conditions, perform main- tenance more often than shown in the chart. If you have any ques- tions regarding maintenance intervals, consult your suzuki dealer or a qualified mec...

  • Page 62: Maintenance Chart

    7-4 maintenance chart interval: this interval should be judged by odometer reading or number of months, whichever comes first. Note: i= inspect and clean, adjust, replace or lubricate as necessary, r= replace, t= tighten note: (california model only) and (ca. Only) means that the items or the mainte...

  • Page 63: Tools

    7-5 tools a tool kit is provided with your motorcycle. It is located under the seat. Fuel tank lift 1. Place the motorcycle on the side stand. 2. Remove the seat. 3. Remove the bolt 1 and hooks 2 . Remove the covers. 4. Remove the fasteners 3 and bolts 4 ..

  • Page 64

    7-6 5. Remove the bolts 5 . 6. Remove the bolt 6 . Remove the prop 7 . 7. Raise the covers with hand to separate the covers. 8. Support the fuel tank with the prop 7 ..

  • Page 65: Lubrication Points

    7-7 lubrication points proper lubrication is important for safe, smooth operation and a long life for your motorcycle. Be sure that all lubrication is performed during periodic maintenance on the motorcycle. Increase fre- quency when you use your motor- cycle in severe conditions. .... Motor oil ......

  • Page 66: Battery

    7-8 battery the battery is located under the seat. This battery is a sealed type battery and requires no mainte- nance. Have your dealer check the battery’s state of charge peri- odically. The standard charging rate in 1.2a × 5 – 10 hours and the maximum rate is 5a × 1 hour. Warning battery posts, t...

  • Page 67: Air Cleaner

    7-9 air cleaner the air cleaner element must be kept clean to provide good engine power and gas mileage. If you use your motorcycle under normal low-stress conditions, you should service the air cleaner at the inter- vals specified. If you ride in dusty, wet, or muddy conditions, you will need to in...

  • Page 68: Air Cleaner Element Removal

    7-10 air cleaner element removal 1. Lift the fuel tank by referring to the fuel tank lift section. 2. Disconnect the fuel hose 1 and coupler 2 . 3. Disconnect the hose 3 . 4. Remove the nut 4 and bolt. 5. Remove the fuel tank. 6. Remove the screws. 7. Pull up the air cleaner cover 5 . 8. Remove the ...

  • Page 69: Air Cleaner Element Cleaning

    7-11 air cleaner element cleaning carefully use an air hose to blow the dust from the air cleaner ele- ment. Note: always apply air pressure to the mesh side of the air cleaner element only. If you apply air pres- sure to the fabric side, dirt will be forced into the pores of the ele- ment, restrict...

  • Page 70: Spark Plug

    7-12 spark plug your motorcycle comes equipped with ngk cr8e or denso u24esr-n spark plugs. To deter- mine if the standard spark plug is right for your usage, check the color of the plug’s porcelain cen- ter electrode insulator after motor- cycle operation. A light brown color indicates that the plu...

  • Page 71: Spark Plug Removal

    7-13 spark plug removal to remove the spark plugs, follow the procedure below: front side 1. Remove the bolts 1 . 2. Remove the fasteners. 3. Remove the screws 2 . 4. Remove the radiator mounting bolt 3 and 4 . 5. Release the hook 5 and slide the radiator forward..

  • Page 72: Rear Side

    7-14 6. Pull off the spark plug cap. 7. Remove the spark plugs with a spark plug wrench. Note: be careful not to damage the radiator fins. Rear side 1. Lift the fuel tank by referring to the fuel tank lift section. 2. Remove the spark plugs with a spark plug wrench. Note: pry up the spark plug cap w...

  • Page 73: Spark Plug Cleaning

    7-15 spark plug cleaning to maintain a hot, strong spark, keep the plugs free from carbon. Adjust the gap to 0.7 – 0.8 mm (0.028 – 0.031 in) for good igni- tion. Use a thickness (feeler) gauge to check the gap. Installation to install a spark plug, turn it in as far as possible with your fingers, th...

  • Page 74: Engine Oil

    7-16 engine oil engine life depends on oil amount and quality. Daily oil level checks and periodic changes are two of the most important maintenance items to be performed. Engine oil level check check the engine oil level as fol- lows: 1. Place the motorcycle on level ground on the side stand. 2. St...

  • Page 75: Engine Oil and Filter Change

    7-17 engine oil and filter change change the engine oil and oil filter at the scheduled times. The engine should always be warm when the oil is changed so the oil will drain easily. The procedure is as follows: 1. Place the motorcycle on the side stand. 2. Remove the oil filler cap 1 . 3. Remove the...

  • Page 76

    7-18 4. Reinstall the drain plug and gasket. Tighten the plug securely with a wrench. Oil filter wrench (part no. 09915-40620) 5. Turn the oil filter 3 counter- clockwise with a suzuki “cap type” oil filter wrench or a “strap type” filter wrench of the proper size. 6. Wipe off the mounting surface 4...

  • Page 77: Caution

    7-19 note: to tighten the oil filter properly, it is important to accu- rately identify the position at which the filter gasket first con- tacts the mounting surface. 9. Mark the top dead center posi- tion on the “cap type” filter wrench or on the oil filter. Use an oil filter wrench to tighten the ...

  • Page 78: Engine Idle Speed

    7-20 10.Reinstall the drain plug and tighten it securely. Pour about 2700 ml (2.9 us qt) of the specified engine oil in the filler hole. (see fuel, engine oil and coolant recom- mendations section.) note: about 2300 ml (2.4 us qt) of oil will be required when chang- ing oil only. 11.Reinstall the oi...

  • Page 79: Throttle Cable Play

    7-21 throttle cable play this motorcycle has a twin throttle cable system. Cable a is for pull- ing and cable b is for returning. To adjust the cable play: 1. Loosen the lock nut 1 . 2. Turn in the adjuster 2 fully. 3. Loosen the lock nut 3 . 4. Turn the adjuster 4 so that the throttle grip has 2.0 ...

  • Page 80: Fuel Hoses

    7-22 fuel hoses inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced. Engine coolant coolant level remove the seat to check the coolant level. The engine coolant solution should be between the “f” (full) and the “l” (low) level lines on the engi...

  • Page 81: Warning

    7-23 to add mixed coolant: 1. Lift the fuel tank by referring to the fuel tank lift section. 2. Remove the filler cap and add mixed coolant through the filler hole. Note: adding only water will dilute the engine coolant and reduce its effectiveness. Add a 50:50 mixture of engine coolant and water. W...

  • Page 82: Drive Chain

    7-24 drive chain this motorcycle has an endless drive chain constructed from spe- cial materials. It does not use a master link. The drive chain has special “o” rings that permanently keep grease inside. We recom- mend that you take your motorcy- cle to an authorized suzuki dealer if the drive chain...

  • Page 83: Drive Chain Cleaning and

    7-25 drive chain cleaning and oiling clean and oil the chain as follows: 1. Wash the chain with kerosene. Kerosene will lubricate and clean the chain. Warning improperly installing a replace- ment chain, or using a joint-clip type chain, can be hazardous. An incompletely riveted master link, or a jo...

  • Page 84: Drive Chain Adjustment

    7-26 2. Allow the chain to dry, then lubricate the links with suzuki chain lube or an equivalent chain lubricant. Drive chain adjustment inspect the drive chain slack before each use of the motorcy- cle. Place the motorcycle on the side stand. The drive chain should be adjusted for 20 – 30 mm (0.8 –...

  • Page 85: Warning

    7-27 to adjust the drive chain, follow the procedure below: 1. Place the motorcycle on the side stand. 2. Loosen the axle nut 1 . 3. Turn the right and left adjuster bolts 2 until the chain has 20 – 30 mm (0.8 – 1.2 in) of slack halfway between the engine sprocket and rear sprocket. 4. At the same t...

  • Page 86: Clutch

    7-28 clutch at each maintenance interval, adjust the clutch cable play with the clutch cable adjuster. The cable play should be 10 – 15 mm (0.4 – 0.6 in) as measured at the clutch lever end before the clutch begins to disengage. If you find the play of clutch incorrect, adjust it in the following wa...

  • Page 87: Brakes

    7-29 brakes this motorcycle has front and rear disk brakes. Note: operating in mud, water, sand or other extreme conditions can cause accelerated brake wear. If you operate your motorcy- cle under these conditions, the brakes must be inspected more often than recommended in the maintenance schedule....

  • Page 88: Warning

    7-30 warning brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with skin or eyes. If swallowed, do not induce vomiting. Immediately contact a poison control center or a physician. If brake fluid gets in eyes, flush eyes with water and seek medical attention. Wash thoro...

  • Page 89: Brake Pads

    7-31 brake pads front rear inspect the front and rear brake pads to see if they are worn down to the grooved wear limit line 1 . If a front or rear pad is worn to the grooved limit line both front or both rear pads must be replaced with new ones by your authorized suzuki dealer or qualified service ...

  • Page 90: Rear Brake Adjustment

    7-32 rear brake adjustment the rear brake pedal must be adjusted to set the clearance between the pedal and the foot- rest. Adjust the brake pedal as fol- lows: 1. Loosen the lock nut 1 , and turn the push rod 2 to locate the pedal 15 – 25 mm (0.6 – 1.0 in) below the top face of the foot rest. 2. Re...

  • Page 91: Tires

    7-33 tires warning failure to follow these warn- ings may result in an accident due to tire failure. The tires on your motorcycle form the cru- cial link between your motorcy- cle and the road. Follow these instructions: • check tire condition and pressure, and adjust pres- sure before each ride. • ...

  • Page 92: Tire Pressure and Loading

    7-34 tire pressure and loading proper tire pressure and proper tire loading are important factors. Overloading your tires can lead to tire failure and loss of motorcycle control. Check tire pressure each day before you ride, and adjust tire pressure according to the table below. Tire pressure should...

  • Page 93: Warning

    7-35 note: the “ ” mark indicates the place where the wear bars are molded into the tire. When the wear bars contact the road, it indi- cates that the tire wear limit has been reached. Whenever you replace a tire, use a tire of the size and type listed below. If you use a different size or type of t...

  • Page 94: Side Stand/ignition

    7-36 side stand/ignition interlock system check the side stand/ignition interlock system for proper opera- tion as follows: 1. Sit on the motorcycle in the normal riding position, with the side stand up. 2. Shift into first gear, hold the clutch in, and start the engine. 3. While continuing to hold ...

  • Page 95: Front Wheel Removal

    7-37 front wheel removal 1. Place the motorcycle on the side stand. 2. Remove both brake calipers from the front forks by remov- ing two mounting bolts 1 on each of the caliper. Note: never squeeze the front brake lever with the caliper removed. It is very difficult to force the pads back into the c...

  • Page 96: Caution

    7-38 3. Remove the front wheel speed sensor by removing the mounting bolt 2 . 4. Loosen the axle holder bolt 3 on the right front fork. 5. Loosen the axle 4 tempo- rarily. Note: a special tool is necessary to loosen the shaft 4 . The special tool is available at suzuki dealer. 6. Place an accessory ...

  • Page 97: Warning

    7-39 front axle tightening torque: 65 n·m (6.5 kgf-m, 47.0 lbf-ft) front axle holder bolt tightening torque: 23 n·m (2.3 kgf-m, 16.5 lbf-ft) front brake caliper mounting bolt tightening torque: 39 n·m (3.9 kgf-m, 28.0 lbf-ft) note: be careful not to damage the oil seal when installing the front whee...

  • Page 98: Rear Wheel Removal

    7-40 rear wheel removal 1. Place the motorcycle on the side stand. 2. Remove the axle nut 1 . 3. Place an accessory service stand or equivalent under the swingarm to lift the rear wheel slightly off the ground. 4. Loosen the right and left chain adjusting bolts 2 . 5. Remove the rear wheel speed sen...

  • Page 99: Warning

    7-41 note: never depress the rear brake pedal with the rear wheel removed. It is very difficult to force the pads back into the caliper assembly. 9. To replace the wheel, reverse the complete sequence listed. 10.After installing the wheel, apply the brake several times and then check that the wheel ...

  • Page 100: Light Bulb Replacement

    7-42 light bulb replacement the wattage rating of each bulb is shown in the following chart. When replacing a burned out bulb, always use the same watt- age rating. Headlight 1. Disconnect the socket 1 from the headlight and remove the rubber cap 2 . 2. Unhook the bulb holder spring 3 and pull out t...

  • Page 101: Headlight Beam Adjustment

    7-43 headlight beam adjustment the headlight beam can be adjusted both horizontally and vertically if necessary. To adjust the beam horizontally: turn the adjuster 1 clockwise or counterclockwise. To adjust the beam vertically: turn the adjuster 2 clockwise or counterclockwise. Note: to adjust the h...

  • Page 102: Brake Light/taillight

    7-44 brake light/taillight to change the brake light/taillight bulb, perform the following steps: 1. Turn the socket 1 counter- clockwise and remove it. 2. Push in the bulb, turn it to the left and pull it off. Fuses the main fuse is located under the seat. One 30a spare fuse is located in the fuse ...

  • Page 103: Fuse List

    7-45 the abs fuse is located under the seat. Two spare fuses (one 40a and one 25a) are provided in the fuse box. The fuses are designed to open when an overload exists in indi- vidual electrical system circuits. If any electrical system fails to oper- ate, then the fuses must be checked. Fuse list •...

  • Page 105: Troubleshooting

    8-1 8 troubleshooting fuel system check ...................................................................................... 8-2 ignition system check ................................................................................ 8-3.

  • Page 106: Fuel System Check

    8-2 troubleshooting this troubleshooting guide is pro- vided to help you find the cause of some common complaints. Complaint: engine is hard to start or does not start at all. Fuel system check if the meter indicates “fi”, show- ing signs of trouble in the fuel injection system, take your machine to...

  • Page 107: Ignition System Check

    8-3 ignition system check 1. Remove the spark plugs and reattach them to the spark plug leads. 2. Put the engine stop switch in the “ ” position and the igni- tion switch in the “on” posi- tion. While holding a spark plug with its base firmly against the engine, push the electric starter button. If ...

  • Page 109: Storage Procedure and

    9-1 9 storage procedure and motorcycle cleaning storage procedure .................................................................................... 9-2 procedure for returning to service ................................................. 9-3 corrosion prevention ......................................

  • Page 110: Storage Procedure

    9-2 storage procedure and motorcycle cleaning storage procedure if your motorcycle is to be left unused for an extended period of time, it needs special servicing requiring appropriate materials, equipment and skill. For this rea- son, suzuki recommends that you trust this maintenance work to your s...

  • Page 111: Maintenance During

    9-3 maintenance during storage once a month, recharge the bat- tery. The standard charging rate is 1.2a × 5 – 10 hours. Procedure for returning to service 1. Clean the entire motorcycle. 2. Remove the oily rags from the air cleaner intake and muffler outlet. 3. Drain all the engine oil. Install a ne...

  • Page 112: Motorcycle Cleaning

    9-4 • repair finish damage as soon as possible. Carefully exam- ine your motorcycle for dam- age to the painted surfaces. Should you find any chips or scratches in the paint, touch them up immediately to pre- vent corrosion from starting. If the chips or scratches have gone through to the bare metal...

  • Page 113: Windshield Cleaning

    9-5 3. Once the dirt has been com- pletely removed, rinse off the detergent with running water. 4. After rinsing, wipe off the motorcycle with a wet chamois or cloth and allow it to dry in the shade. 5. Check carefully for damage to painted surfaces. If there is any damage, obtain “touch-up” paint a...

  • Page 114: Waxing The Motorcycle

    9-6 waxing the motorcycle after washing the motorcycle, waxing is recommended to further protect and beautify the paint. Observe the precautions speci- fied by the wax manufacturer. Special care for matte finish paint • do not use polishing com- pounds or waxes that contain polishing compounds on su...

  • Page 115: Consumer Information

    10 10-1 consumer information emission control warranty ................................................................. 10-2 reporting safety defects ..................................................................... 10-2 tampering with noise control system prohibited ...................... 10-3...

  • Page 116: Emission Control

    10-2 consumer information emission control warranty suzuki motor corporation war- rants to the ultimate purchaser and each subsequent purchaser that this vehicle is designed, built, and equipped so as to conform at the time of sale with all u.S. Emis- sion standards applicable at the time of manufac...

  • Page 117: Tampering With Noise

    10-3 to contact american suzuki, own- ers in the continental united states can call toll-free 1-800- 444-5077, or write to: american suzuki motor corporation motor- cycle customer service p.O. Box 1100, brea, ca 92822-1100. For owners outside the continen- tal united states, please refer to the dist...

  • Page 118: On-Board Motorcycle

    10-4 among those acts presumed to constitute tampering are the acts listed below: • removing or puncturing the muffler, baffles, header pipes, screen type spark arrester (if equipped) or any other compo- nent which conducts exhaust gases. • replacing the exhaust system or muffler with a system or mu...

  • Page 119: Serial Number Location

    10-5 some information may be stored by the on-board computer when malfunctions occur. This stored information can assist techni- cians in repairing the motorcycle. To read the stored information, special equipment is needed and access to the motorcycle or stor- age device is required. In addi- tion,...

  • Page 120: Location of Labels

    10-6 location of labels read and follow all of the warn- ings labeled on your motorcycle. Make sure you understand all of the labels. Keep the labels on your motorcycle. Do not remove them for any reason. 1 2 3 warning do not carry any objects in the space behind the fairing or on the fairing suppor...

  • Page 121: Warning

    10-7 4 5 6 7 warning never make any modifications to the aluminum alloy frame, such as drilling or welding. Such modifications will weaken the frame and may lead to an accident. The owner’s manual contains important safety information and instructions which should be read carefully before operating ...

  • Page 122: Specifications

    Specifications dimensions and curb mass overall length ..................................................2290 mm (90.2 in) overall width.................................................... 840 mm (33.1 in) overall height ..................................................1390 mm (54.7 in) ... Low win...

  • Page 123

    Electrical ignition type .....................................................Electronic ignition (transistorized) spark plug .......................................................Ngk cr8e or denso u24esr-n battery .............................................................12v 36.0 kc(10 ah)/10 h...

  • Page 124: Index

    Index a accessories and loading ............................... 1-5 accessory installation guideline ............................ 6-2 accessory use ................ 6-2 air cleaner ....................... 7-9 b battery............................... 7-8 be extra safety- conscious on bad weather days...

  • Page 125

    I if a collision is imminent, do something! .................. 1-3 if you don’t have a helmet - buy a helmet, and wear it every time you ride ....... 1-2 ignition switch ................ 3-5 ignition system check................................... 8-3 inspection after cleaning .........................

  • Page 126

    R rear brake pedal ......... 3-19 rear wheel removal............................ 7-40 reporting safety defects............................. 10-2 riding on hills ................. 5-5 right handlebar ........... 3-15 s seat lock ......................... 3-20 serial number location .....................

  • Page 127: Dl650A

    Top 1st cover 4th cover top 1st cover 4th cover dl650a owner’s manual 99011-27g62-03a dl650a part no. 99011-27g62-03a july, 2008 en tk 5 mm 5 mm no.646 dl650a 99011-27g62-03a 2/1 no.646 dl650a 99011-27g62-03a 2/1 dic184(tdp006) dic157 this owner’s manual contains important safety information. Please...