Suzuki v strom dl 650 мануал

This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.

California Proposition 65 Warning

Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves or wash your hands frequently when servicing your vehicle. For more information go to www.P65Warnings.ca.gov/ passenger-vehicle.

WARNING

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3rd cover2nd cover

Black4/1 6 mmDL650A/XA (99011-28K53-03A)

2020 V-Strom 650 / 650XT

IMPORTANT

WARNING/CAUTION/ NOTICE/NOTE Please read this manual and fol- low its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION, NOTICE and NOTE have special mean- ings. Pay particular attention to messages highlighted by these signal words:

NOTE: Indicates special informa- tion to make maintenance easier or instructions clearer.

FOREWORD

Motorcycling is one of the most exhilarating sports and to ensure your riding enjoyment, you should become thoroughly familiar with the information presented in this Owners Manual before riding the motorcycle.

The proper care and maintenance that your motorcycle requires is outlined in this manual. By follow- ing these instructions explicitly, you will ensure a long trouble-free operating life for your motorcycle. This motorcycle also conforms to the U.S. Environmental Protection Agency (EPA) and California Air Resource Board (CARB) emis- sion regulations which apply to new motorcycles. The proper adjustment of engine components is necessary for this motorcycle to comply with the EPA and CARB regulations. Therefore, please fol- low the maintenance instructions closely to ensure emission com- pliance. Your Suzuki dealer has experienced technicians that are trained to provide your machine with the best possible service with the right tools and equipment.

WARNING Indicates a potential hazard that could result in death or serious injury.

CAUTION Indicates a potential hazard that could result in minor or moderate injury.

NOTICE Indicates a potential hazard that could result in vehicle or equipment damage.

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 the right to make production changes at any time, without notice and without incur- ring any obligation to make the same or similar changes to vehi- cles previously built or sold.

Suzuki Motor Corporation believes in conservation and pro- tection of Earths natural resources. To that end, we encourage every vehicle owner to recycle, trade in, or properly dis- pose of, as appropriate, used motor oil, coolant, and other flu- ids, batteries and tires.

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 MOTORCYCLE CLEANING

CONSUMER INFORMATION

SPECIFICATIONS

INDEX

1-1

1

THE SPORT OF MOTORCYCLING

MOST ACCIDENTS CAN BE AVOIDED ……………………………………………………. 1-2 IF YOU DONT HAVE A HELMET, BUY A HELMET AND WEAR IT EVERY TIME YOU RIDE …………………………………………………………… 1-2 IF A COLLISION IS IMMINENT, DO SOMETHING! ……………………………………. 1-3 SPECIAL SITUATIONS REQUIRE SPECIAL CARE …………………………………… 1-4 KNOW YOUR LIMITS ……………………………………………………………………………… 1-4 BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYS …………………… 1-4 PRACTICE AWAY FROM TRAFFIC …………………………………………………………. 1-5 INSPECTION BEFORE RIDING ……………………………………………………………….. 1-5 ACCESSORIES AND LOADING ………………………………………………………………. 1-5 CARRYING A PASSENGER ……………………………………………………………………. 1-5 MOTORCYCLE SAFETY FOUNDATIONS RIDING TIPS AND PRACTICE GUIDE HANDBOOK (FOR OWNERS IN USA) …………………………………………………………………………. 1-5 BE STREET SMART ………………………………………………………………………………. 1-6 LABELS ………………………………………………………………………………………………… 1-6 CONCLUSION ……………………………………………………………………………………….. 1-6

1-2

THE SPORT OF MOTORCYCLING

Your motorcycle and this owners 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 you are, you will eventually face some challenging situations.

In preparing for these challenges, you will be fine-tuning your coordi- nation, concentration, and atti- tude. Learning the skills and strategies associated with motor- cycling is the basis for safely par- ticipating in this sport. Many motorcyclists find that as they become better riders, they also get more enjoyment from the free- dom unique to motorcycling.

Please remember:

MOST ACCIDENTS CAN BE AVOIDED The most common type of motor- cycle accident in the U.S. occurs when a car traveling towards a motorcycle turns left in front of the motorcycle. Is that because other drivers are out to get motorcy- clists? No. Other drivers simply dont always notice motorcyclists.

Ride defensively. Wise motorcy- clists use a strategy of assuming they are invisible to other drivers, even in broad daylight. Pay care- ful attention to other motorists, especially at intersections, because they may not be paying attention to you. Select a lane position that gives you the best view of others, and other motor- ists the best view of you. Wear bright, reflective clothing. Put reflective strips on your helmet.

IF YOU DONT HAVE A HELMET, BUY A HELMET AND WEAR IT EVERY TIME YOU RIDE Most accidents occur within a few miles of home, and almost half occur at speeds of less than 30 mph. So even if youre just going on a quick errand, be prepared strap on your helmet before you take off.

Helmets do not reduce essential vision or hearing. Generally, hel- mets do not cause or intensify injury if you crash. Helmets simply help your skull protect your intelli- gence, your memory, your per- sonality, and your life.

Your eyesight is equally valuable. Wearing suitable eye protection can help keep your vision unblurred by the wind and save your eyes from airborne hazards like bugs, dirt, or pebbles kicked up by tires.

1-3

IF A COLLISION IS IMMINENT, DO SOMETHING! Many riders fear locking up their brakes or havent 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 unnecessarily high impact speeds in other cases. Your rear brake can only provide about 30% of your motorcycles potential stop- ping power. The front and rear brakes can and should be used together to maximize braking effectiveness.

Experienced motorcyclists learn to cover the front brake lever by lightly resting a couple of fingers over the lever when riding in traffic and near intersections to give their reaction time a head start.

Emergency stopping and swerv- ing are techniques that you should practice and master before you find yourself in an emergency situation. The best place to prac- tice such techniques is in a con- trolled environment such as the Motorcycle Safety Foundations (MSF) rider training courses. The MSFs Motorcycle Rider Courses (fundamental techniques) and Experienced Rider Courses (advanced strategies) present hands-on instruction of the basic principles of motorcycling and a variety of accident-avoidance maneuvers. Even a seasoned motorcyclist can improve his or her riding skills, and pick up a few new skills, through these courses. Some insurance companies even offer discounts to course gradu- ates.

1-4

SPECIAL SITUATIONS REQUIRE SPECIAL CARE Of course, there are some times when full-force braking is not the correct technique. When the road surface is wet, loose, or rough, you should brake with care. When youre leaned over in a corner, avoid braking. Straighten up before braking. Better yet, slow down before entering the corner.

In these situations, the traction available between your tires and the road surface is limited. Over- braking when traction is limited will cause your tires to skid, possi- bly resulting in loss of directional control or causing you and your motorcycle to fall over.

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 appropriately low cornering speed. Even on straight roads, ride at a speed that is appropriate for the traffic, visibility and road conditions, your motorcycle, and your experience.

Riding a motorcycle safely requires that your mental and physical skills are fully part of the experience. You should not attempt to operate a motor vehi- cle, especially one with two wheels, if you are tired or under the influence of alcohol or other drugs. Alcohol, illegal drugs, and even some prescription and over- the-counter drugs can cause drowsiness, loss of coordination, loss of balance, and especially the loss of good judgment. If you are tired or under the influence of alcohol or other drugs, PLEASE DO NOT RIDE your motorcycle.

BE EXTRA SAFETY-CONSCIOUS ON BAD WEATHER DAYS Riding on bad weather days, especially wet ones, requires extra caution. Braking distances increase on a rainy day. Stay off the painted surface marks, man- hole covers, and greasy-appear- ing areas, as they can be especially slippery. Use extra cau- tion at railway crossings and on metal gratings and bridges. When it starts to rain, any oil or grease on the road rises to the surface of the water. Pull over and wait a few minutes until this oil film is washed away before riding. Whenever in doubt about road conditions, slow down !

1-5

PRACTICE AWAY FROM TRAFFIC Your riding skill and your mechan- ical knowledge form the founda- tion for safe riding practices. We suggest that you practice riding your motorcycle in a non-traffic situation until you are thoroughly familiar with your machine and its controls. Again, consider taking one of the MSFs Rider Courses. Even experts will be pleased with the caliber of the information pre- sented in these courses. As the MSF says: The more you know, the better it gets !

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 costly, inconvenient breakdowns far from home.

ACCESSORIES AND LOADING The accessories you use with your motorcycle and the manner in which you load your gear onto the bike might create hazards. Aerodynamics, handling, balance, and cornering clearance can suf- fer, and the suspension and tires can be overloaded. Read the ACCESSORY USE AND MOTORCYCLE LOADING sec- tion.

CARRYING A PASSENGER Carrying a passenger, when done correctly, is a great way to share the joy of motorcycling. You will have to alter your riding style somewhat since the extra weight of a passenger will affect handling and braking. You may also need to adjust tire pressures and sus- pension; please refer to the Tire Pressure and Loading section and the Suspension section for more details.

A passenger needs the same pro- tection that you do, including a helmet and proper clothing. The passenger should not wear long shoe laces or loose pants that could get caught in the wheel or the chain. Passengers must be tall enough that their feet reach the footrests.

MOTORCYCLE SAFETY FOUNDATIONS RIDING TIPS AND PRACTICE GUIDE HANDBOOK (FOR OWNERS IN USA) This special handbook, supplied with your owners manual, con- tains a variety of safety tips, help- ful hints, and practice exercises. This manual can increase your riding enjoyment and safety. You should read it thoroughly.

1-6

BE STREET SMART Always heed speed limits, local laws, and the basic rules of the road. Set a good example for oth- ers by demonstrating a courteous attitude and a responsible riding style.

LABELS Read and follow all the labels on the motorcycle. Make sure you understand all of the labels. Do not remove any labels from the motorcycle.

CONCLUSION Traffic, road and weather condi- tions vary. Other motorists actions are unpredictable. Your motorcycles condition can change. These factors can best be dealt with by giving every ride your full attention.

Circumstances beyond your con- trol could lead to an accident. You need to prepare for the unex- pected by wearing a helmet and other protective gear, and learn- ing emergency braking and swerving techniques to minimize the damage to you and your machine.

The best way to learn basic riding skills and evasive maneuvers or refresh your own riding skills is to take one of the courses offered by the Motorcycle Safety Foundation. Your Suzuki dealer can help you locate the fundamental or advanced riding skills course nearest you, or owners in the USA can call toll-free 1-800-446-9227.

Good riding on your new Suzuki !

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2

FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS

FUEL …………………………………………………………………………………………………….. 2-2 ENGINE OIL …………………………………………………………………………………………… 2-4 ENGINE COOLANT SOLUTION ………………………………………………………………. 2-5

2-2

FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS

FUEL Your motorcycle requires 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.

NOTE: If the engine develops some

trouble like lack of acceleration or insufficient power, the cause may be due to the fuel the motorcycle uses. In such case, try changing to a different gas station. If the situation is not improved by changing, consult your Suzuki dealer.

If pinking or knocking is experi- enced, substitute higher octane grade gasoline or another brand, because there are differences between brands.

Oxygenated fuels which meet the minimum octane requirement and the requirements described below may be used in your motorcycle without jeopardizing the New Vehicle Limited Warranty or the Emission Control System War- ranty.

NOTE: Oxygenated fuels are fuels which contain oxygen-carry- ing additives such as alcohol.

Gasoline/Ethanol Blends Blends of unleaded gasoline and ethanol (grain alcohol), also known as GASOHOL, are com- mercially available in some areas. Blends of this type may be used in your motorcycle if they are no more than 10% ethanol. Make sure this gasoline-ethanol blend has octane ratings no lower than those recommended for gasoline.

Use the recommended gasoline.

or

2-3

Fuel Pump Labeling In some states, pumps that dis- pense oxygenated fuels are required to be labeled for the type and percentage of oxygenate, and whether important additives are present. Such labels may provide enough information for you to determine if a particular blend of fuel meets the requirements listed above. In other states, pumps may not be clearly labeled as to the content or type of oxygen and additives. If you are not sure that the fuel you intend to use meets these requirements, check with the service station operator or the fuel supplier.

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 drivability or fuel economy of your motorcycle when you are using an oxygenated fuel, or if engine pinging is experi- enced, substitute another brand as there are differences between brands.

NOTICE Spilled gasoline containing alcohol can damage the painted surfaces of your motorcycle.

Be careful not to spill any fuel when filling the fuel tank. Wipe spilled gasoline up immedi- ately.

2-4

ENGINE OIL Suzuki recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or equivalent engine oil. If SUZUKI PERFORMANCE 4 MOTOR OIL is not available, select a proper engine oil accord- ing to the following guideline. Oil quality is a major contributor to your engines performance and life. Always select good quality engine oil. Use oil with an API (American Petroleum Institute) classification of SG, SH, SJ, SL, SM or SN with a JASO classifica- tion of MA.

API: American Petroleum Institute JASO: Japanese Automobile Standards Organization

NOTE: SUZUKI highly recom- mends the use of ECSTAR brand engine oil. ECSTAR has been specially formulated for your SUZUKI product and contributes to the desired motorcycle perfor- mance and ideal riding experi- ence.

SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the following chart.

* USE ONLY SG, SH, SJ or SL.

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.

There are two classes, MA and MB. The oil container shows the classification as follows.

1 Code number of oil sales company 2 Oil classification

SAE API JASO

10W-40 SG, SH, SJ, SL,

SM or SN MA

ENGINE OIL

TEMP.

2-5

Energy Conserving Suzuki does not recommend the use of ENERGY CONSERVING or RESOURCE CONSERVING oils. Some engine oils which have an API classification of SH, SJ, SL, SM or SN have an ENERGY CONSERVING or RESOURCE CONSERVING indication in the API classification donut mark. These oils can affect engine life and clutch performance.

API SG, SH, SJ, SL, SM or SN

Recommended

API SH, SJ, SL or SM API SN

Not recommended

ENGINE COOLANT SOLUTION Use SUZUKI SUPER LONG LIFE COOLANT or SUZUKI LONG LIFE COOLANT. If SUZUKI SUPER LONG LIFE COOLANT and SUZUKI LONG LIFE COOLANT are not avail- able, use a glycol-based anti- freeze compatible with an aluminum radiator mixed with dis- tilled water only at the ratio of 50:50.

AP I SERVICE SJ

SAE 10W-40

E N

E RGY CONSERVIN

G

AP I SERVICE SJ

SAE 10W-40

R E

SOURCE CONSERVI N

G

AP

I SERVICE SN

SAE 10W-40

WARNING Engine coolant is harmful or fatal if swallowed or inhaled. Solution can be poisonous to animals.

Do not drink antifreeze or cool- ant solution. If swallowed, do not induce vomiting. Immedi- ately contact a poison control center or a physician. Avoid inhaling mist or hot vapors; if inhaled, remove to fresh air. If coolant gets in eyes, flush eyes with water and seek medical attention. Wash thoroughly after handling. Keep out of the reach of children and animals.

2-6

NOTE: SUZUKI highly recom- mends the use of ECSTAR brand coolant. ECSTAR has been spe- cially formulated for your SUZUKI product and contributes to the desired motorcycle performance and ideal riding experience.

ENGINE COOLANT Engine coolant performs as a rust inhibitor and water pump lubricant as well as an anti-freeze solution. Therefore Engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to the freezing point.

SUZUKI SUPER LONG LIFE COOLANT (Blue) SUZUKI SUPER LONG LIFE COOLANT is pre-mixed to the proper ratio. Add only SUZUKI SUPER LONG LIFE COOLANT if coolant level drops. It is not nec- essary to dilute SUZUKI SUPER LONG LIFE COOLANT when replacing coolant.

SUZUKI LONG LIFE COOLANT (Green)

Water for Mixing Use distilled water only. Water other than distilled water can cor- rode and clog the aluminum radia- tor.

Required amount of engine cool- ant/water solution capacity (total): 1950 ml (2.1 US qt)

NOTE: This 50% mixture will protect the cooling system from freezing at temperatures above 31C (24F). If the motorcycle is to be exposed to temperature below 31C (24F), this mix- ing ratio should be increased up to 55% (40C/40F) or 60% (55C/67F) coolant. The mix- ing ratio should not exceed 60% coolant.

NOTICE Spilled engine coolant can damage the painted surfaces of your motorcycle.

Be careful not to spill any fluid when filling the radiator. Wipe spilled engine coolant up immediately.

Engine coolant 975 ml

(1.0 US qt)

Water 975 ml

(1.0 US qt)

3-1

3

CONTROLS, EQUIPMENT AND ADJUSTMENTS

LOCATION OF PARTS …………………………………………………………………………… 3-2 KEY ………………………………………………………………………………………………………. 3-5 IGNITION SWITCH …………………………………………………………………………………. 3-5 INSTRUMENT PANEL …………………………………………………………………………….. 3-8 LEFT HANDLEBAR ………………………………………………………………………………. 3-22 RIGHT HANDLEBAR ……………………………………………………………………………. 3-27 FUEL TANK CAP …………………………………………………………………………………. 3-30 GEARSHIFT LEVER ……………………………………………………………………………… 3-31 REAR BRAKE PEDAL ………………………………………………………………………….. 3-31 SEAT LOCK …………………………………………………………………………………………. 3-32 SIDE STAND ………………………………………………………………………………………… 3-32 REAR SUSPENSION …………………………………………………………………………….. 3-33 WINDSHIELD ……………………………………………………………………………………….. 3-35 OUTPUT TERMINAL …………………………………………………………………………….. 3-36

3-2

CONTROLS, EQUIPMENT AND ADJUSTMENTS

LOCATION OF PARTS

DL650A

1Clutch lever 2Left handlebar switches 3 Instrument panel 4Front brake fluid reservoir 5Right handlebar switches 6Throttle grip 7Front brake lever 8Output terminal 9Fuel tank cap 0 Ignition switch

DL650XA

3-3

DL650A

AAir cleaner BSpark plugs CFuses DBattery ETools FEngine oil drain plug GGearshift lever HSide stand IFootrests JSeat lock KPassenger footrests DL650XA

3-4

DL650A

LRear brake fluid reservoir MEngine oil filler cap NRear brake light switch ORear brake pedal PEngine oil inspection window QEngine oil filter

DL650XA

3-5

KEY

Two keys come with this motorcy- cle. Keep the spare key in a safe place.

IGNITION SWITCH

The ignition switch has 4 posi- tions:

OFF Position All electrical circuits are off. The engine will not start. The key can be removed.

ON Position The ignition circuit is completed and the engine can run. The headlight, position light, taillight and license plate light will auto- matically turn on. The key cannot be removed in this position.

NOTE: Start the engine promptly after turning the key to the ON position, or the battery will lose power due to consumption by the headlight and taillight.

3-6

LOCK position All electrical circuits are off. The key can be removed and the steering will be locked. Turn the steering all the way to the left and push down the key and turn it to the LOCK position.

NOTE: Move the handlebar to the

right and left, to make sure that the steering has been locked securely.

When it cannot be locked eas- ily, turn the key to the LOCK position, moving the handlebar slightly to the right.

P (Parking) Position The taillight will come on to increase visibility for temporary roadside parking at night. The key can be removed and the steering will be locked.

WARNING Turning the ignition switch to the P (PARKING) or LOCK position while the motorcycle is moving can be hazardous. Moving the motorcycle while the steering is locked can be hazardous. You could lose your balance and fall, or you could drop the motorcycle.

Stop the motorcycle and place it on the side stand before lock- ing the steering. Never attempt to move the motorcycle when the steering is locked.

3-7

A lid 2 is provided for the key cyl- inder 1 to prevent tampering. Turning the lid position covers the keyhole 3, to prevent any alien substance entering the keyhole. To turn the lid, insert the tip of the key slightly into the lid and turn it.

In order to align the lid with the keyhole, the same procedure is used.

WARNING If the motorcycle falls down due to a slip or collision, unex- pected damage to the motorcy- cle could cause the engine to keep running, which could result in a fire, or could result in injury from moving parts such as the rear wheel.

If the motorcycle falls down, turn the ignition switch off immediately. Ask your autho- rized Suzuki dealer to inspect the motorcycle for unseen damage.

ON

IGNITION

OFF

P

L O

C

K

P U

S H

ON

IGNITION

OFF

P

L O

C K

P U

S H

3-8

INSTRUMENT PANEL

The malfunction indicator light 6, freeze indicator light B, coolant temperature indicator/oil pres- sure indicator light 4, ABS indi- cator light D, traction control system indicator light 5, LCDs and tachometer needle work as follows to confirm their function when the ignition switch is turned to the ON position.

The malfunction indicator light 6 and freeze indicator light B come on for 2 seconds.

The tachometer needle moves to the full scale position and returns to the home position.

All LCD segments appear and then show the normal display.

Turn Signal Indicator Light 2 When the turn signals are being operated either to the right or to the left, the indicator light will blink intermittently.

NOTE: If a turn signal light is not operating properly due to bulb fila- ment or circuit failure, the indica- tor light blinks more quickly to notify the rider of the existence of a problem.

H

GEAR

C

E F

mph

TRIP

RANGE

ADJ

MPG km/L/100km V

AVG

AIR

1 2

1 OFF TC

2

12

km/h

2

11

1000 r/min

1210

0 3

4 5 6 7

8 9

1

WARNING Changing the display while riding can be hazardous. Removing a hand from the han- dlebars can reduce your ability to control the motorcycle.

Never change the display while riding. Keep both hands on the handlebars.

3-9

Tachometer 3 The tachometer indicates the engine speed in revolutions per minute (r/min).

If the tachometer needle does not point to zero, follow the procedure below to reset the tachometer.

1. Press and hold the ADJUST button 1 and turn on the igni- tion switch.

2. Hold the ADJUST button 1 for 4 seconds.

Oil Pressure Indicator Light 4 When the ignition switch is in the ON position but the engine has not been started, the symbol 7 in the display and the indicator light 4 comes on. As soon as the engine is started, the symbol 7 and the indicator light should go out.

When the engine oil pressure drops under the normal operating range, the symbol 7 in the display appears and the indicator light 4 comes on.

NOTICE After starting the engine, open- ing the throttle or running the motorcycle with the oil pres- sure indicator light turned on, may adversely affect the engine.

Make sure that the oil pressure indicator light has turned off before operating the throttle or running the motorcycle.

NOTICE Riding the motorcycle with the oil pressure indicator light lit can damage the engine and transmission.

If the oil pressure indicator light comes on, indicating low oil pressure, stop the engine immediately. Check the oil level and add oil if necessary. If there is a proper amount of oil and the light still does not go out, have your authorized Suzuki dealer or a qualified mechanic inspect your motor- cycle.

3-10

Traction Control System Indicator Light TC 5 When the traction control system is turned off, the traction control system indicator light remains lit.

When the traction control system is set to Mode 1 or Mode 2, the traction control system indicator light indicates as follows.

The indicator comes on when the ignition switch is turned ON and goes off after the motorcycle speed exceeds 5 km/h (3 mph).

The indicator comes on and remains on when the traction control system is not working due to a system malfunction.

The indicator blinks when the traction control system senses rear wheel spin and is control- ling engine power output.

The indicator remains off when the traction control system is monitoring the traction of the rear wheel during acceleration.

NOTE: For more detailed informa- tion on the traction control sys- tem, see page 3-24.

H

GEAR

C

E F

mph

TRIP

RANGE

ADJ

MPG km/L/100km V

AVG

AIR

1 2

1 OFF TC

2

12

km/h

2

11

1000 r/min

1210

0 3

4 5 6 7

8 9

1

WARNING Riding the motorcycle with the traction control system turned on and the traction control sys- tem indicator light lit can be hazardous.

If the traction control system indicator light comes on while riding, stop the motorcycle in a safe place and turn off the igni- tion switch. Turn the ignition switch ON after a while and check whether the indicator light comes on. If the indicator light goes off

after starting to ride, the trac- tion control system will be functioning.

If it does not go off after starting to ride, the traction control system is not func- tioning. You should have the system checked by an autho- rized Suzuki dealer as soon as possible.

3-11

Malfunction Indicator Light 6

If the fuel injection system fails, the malfunction indicator light 6 comes on and the display indi- cates FI in the odometer display area in the following two modes;

A. The display J in the odometer display area alternately indi- cates FI and the odometer/ trip meter reading, and the malfunction indicator light 6 comes on and remains lit.

B. The display J in the odometer display area indicates FI con- tinuously and the malfunction indicator light 6 blinks while cranking the engine.

The engine may continue to run in mode A, but the engine will not run in mode B.

NOTE: If the display indicates FI

continuously and the malfunc- tion indicator light blinks, the engine will not start.

If the malfunction indicator light comes on and fast blinks 3 times, the battery voltage is lower. Ask your authorized Suzuki dealer to inspect the motorcycle.

When the display indicates CHEC in the odometer display area, check the 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 fuse and the connection of the lead wire couplers.NOTICE

The malfunction indicator light comes on to indicate a problem with the fuel injection system.

If the display indicates FI and the malfunction indicator light comes on, have your autho- rized Suzuki dealer or a quali- fied mechanic inspect the fuel injection system as soon as possible.

3-12

Gear Position Indicator 8 The gear position indicator indi- cates gear position. This indica- tor displays N when the transmission is in neutral.

NOTE: When the display indi- cates CHEC in the odometer display area, the gear position indicator does not indicate a num- ber but indicates .

Speedometer 9 The speedometer indicates the road speed in kilometers per hour or miles per hour.

NOTE: Set the meter J to odometer,

then press and hold the ADJUST button 1 for 2 sec- onds to switch between km/h and mph. At the same time, the odometer will be changed between km and mile.

Select km/h or mph, as appro- priate, to comply with traffic regulations.

Check the km/h and mph dis- play after adjusting the instru- ment panel display.

H

GEAR

C

E F

mph

TRIP

RANGE

ADJ

MPG km/L/100km V

AVG

AIR

1 2

1 OFF TC

2

12

km/h

2

11

1000 r/min

1210

0 3

4 5 6 7

8 9

1

3-13

Thermometer 0

The thermometer shows the ambient air temperature, when the ignition switch is in the ON position.

The thermometer display will be changed between C and F according to the speedometer setting when the ADJUST button 1 is pressed and held for 2 sec- onds.

NOTE: The thermometer will not indi-

cate the actual ambient air temperature when riding at low speed or when stopped.

The thermometer displays Lo when the ambient air tempera- ture is below 10C (14F). The thermometer displays HI when the ambient air tempera- ture is above 50C (122F).

Neutral Indicator Light N A The green light will come on when the transmission is in neutral. The light will go out when you shift into any gear other than neutral.

Freeze Indicator Light B The freeze indicator light B starts blinking when the ambient tem- perature falls below 3C (38F). The freeze indicator light keeps flashing for 30 seconds and then remains lit until the ambient tem- perature rises above 5C (41F).

Display 0 shows the thermome- ter reading and blinks for 30 sec- onds when the ambient temperature falls below 3C (38F).

High Beam Indicator Light C This blue indicator light will be lit when the headlight high beam is turned on.

Speedometer Thermometer

mph F

km/h C

AIR

3-14

ABS Indicator Light D This indicator normally comes on when the ignition switch is turned ON and goes off after the motor- cycle speed exceeds 5 km/h (3 mph).

If there is a problem with the ABS (Anti-lock Brake System), this indicator light blinks or comes on. The ABS does not operate when the ABS indicator light is on or blinking.

NOTE: If the ABS indicator light goes off after you start the motor- cycle but before you begin riding, check the ABS indicator light function by turning off and on the ignition switch. The ABS indicator light can go off if the engine is revved at high speed before you begin riding. If the ABS indicator light does not come on when the ignition switch is turned on, you should have the system checked by an authorized Suzuki dealer as soon as possible.

H

GEAR

C

E F

mph

TRIP

RANGE

ADJ

MPG km/L/100km V

AVG

AIR

1 2

1 OFF TC

2

12

km/h

2

11

1000 r/min

1210

0 3

4 5 6 7

8 9

1

WARNING Riding the motorcycle with the ABS indicator light on can be hazardous.

If the ABS indicator light blinks or comes on while riding, stop the motorcycle in a safe place and turn off the ignition switch. Turn the ignition switch ON after a while and check if the indicator light comes on. If the indicator light goes off

after starting to ride, the ABS will be functioning.

If it does not go off after starting to ride, ABS is not functioning. You should have the system checked by an authorized Suzuki dealer as soon as possible.

3-15

Coolant Temperature Meter E The coolant temperature is dis- played by an LCD segment tem- perature meter E, water temperature mark 7, and indica- tor light 4.

When the coolant temperature exceeds 116C (241F), all six LCD segments turn on. When the coolant temperature comes to 120C (248F), the indicator light 4 turns on. If all six LCD seg- ments for the temperature meter E turn on, stop the engine, wait until the engine is cooled, and check the coolant level.

Fuel Meter F The fuel meter indicates the amount of fuel remaining in the fuel tank. The fuel meter displays all 6 segments when the fuel tank is full. The mark blinks when the fuel level drops below 5.0 L (5.3 US qt). The mark and segment blink when the fuel drops below 2.0 L (2.1 US qt).

NOTE: The fuel meter will not indicate

correctly when the motorcycle is placed on the side stand. Turn the ignition switch to the ON position when the motor- cycle is held upright.

If the fuel mark blinks, fill the fuel tank immediately. Also, the last segment of the fuel meter blinks when the fuel tank is almost empty.

NOTICE Riding the motorcycle with the coolant temperature indicator lit can cause serious engine damage due to overheating.

If the engine coolant tempera- ture indicator light comes on, stop the engine to let it cool. Do not run the engine until the coolant temperature indicator light goes off.

Fuel tank Approxi- mately 2.0 L

Approxi- mately 5.0 L

Full

Fuel gauge Blink

mark

Blink Blink

3-16

Instantaneous Fuel Consumption Meter/Average Fuel Consumption Meter/ Driving Range Meter/Voltmeter G The display has 4 functions; instantaneous fuel consumption meter, average fuel consumption meter, driving range meter and voltmeter. When the ignition switch is turned to the ON posi- tion, the test pattern shown below is displayed for 2 seconds.

After the test pattern is displayed, the display will show the function that was displayed the last time that the ignition switch was turned off.

To change the display, push the left handlebar MODE switch (Down). The display changes in the order below.

H

GEAR

C

E F

mph

TRIP

RANGE

ADJ

MPG km/L/100km V

AVG

AIR

1 2

1 OFF TC

2

12

km/h

2

11

1000 r/min

1210

0 3

4 5 6 7

8 9

1

km/L

km/L1

RANGE km

AVG

V

Instantaneous fuel consumption

Trip meter 1 or 2 average fuel consumption

Driving range

Volt

3-17

Instantaneous fuel consumption meter and average fuel consumption meter To change between MPG and km/L (L/100 km), set the meter J to odometer, then press and hold the ADJUST button 1 for 2 seconds. At the same time, the odometer will be change between mile and km.

To change between km/L and L/ 100 km, set the meter G to either instantaneous fuel consumption meter or average fuel consump- tion meter and hold the MODE switch (Down) for 2 seconds.

Instantaneous fuel consumption meter The instantaneous fuel consump- tion meter displays the fuel con- sumption value only when the motorcycle is moving. However, when the motorcycle is stopping, the fuel consumption meter dis- plays —.-. This meter ranges from 0.1 to 50.0 (km/L, L/100 km) or from 0.1 to 99.9 (MPG US).

NOTE: The display shows esti- mated values. Indications may not be the same as actual values.

3-18

Average fuel consumption meter The average fuel consumption meter displays average fuel con- sumption ratio or trip 1 and trip 2. The average fuel consumption meter ranges from 0.1 to 99.9 (km/L, MPG US) or from 2.0 to 99.9 (L/100km). The average fuel consumption meter indicates —.- when the trip meter indicates 0.0. For resetting the fuel consumption meter, reset the trip meter.

NOTE: The display shows esti- mated values. Indications may not be the same as actual values.

Driving range meter The driving range meter displays estimated driving range (distance) based on the remaining fuel within the range from 0 to 999 km (mile). The driving range is recal- culated when you refuel, but the indication may not change when only a small amount of fuel is added.

The driving range will not be recalculated when the motorcycle is placed on the side stand. Check the estimated driving range (distance) when the side stand is retracted. When the bat- tery is disconnected, the driving range meter will be reset. when this happens, the meter indicates — until the motorcycle is ridden for a certain distance.

NOTE: The driving range (distance) is

an estimated value. The indi- cation may not be the same as the actual driving distance.

The meter does not use the average fuel consumption value to calculate driving range (distance) and the cal- culation result may not be the same as indicated by the aver- age fuel consumption meter.

To avoid running out of gaso- line, you should not continue ride the motorcycle until the estimated driving range becomes 0.

H

GEAR

C

E F

mph

TRIP

RANGE

ADJ

MPG km/L/100km V

AVG

AIR

1 2

1 OFF TC

2

12

km/h

2

11

1000 r/min

1210

0 3

4 5 6 7

8 9

1

3-19

Voltmeter The voltmeter displays the battery voltage within the range of 10.0 to 16.0 V.

Traction Control System Display H The setting of the traction control system is indicated by OFF, 1 or 2.

NOTE: For more detailed informa- tion on the traction control sys- tem, see page 3-24.

Clock I

Time is shown when the ignition switch is in the ON position. The clock has a 12-hour display. Fol- low the procedure below to adjust the clock.

To adjust the clock, press and hold the left handlebar MODE switch (Up or Down) and the ADJUST button 1 simultaneously for 2 seconds until the clock dis- play blinks. Push the left handle- bar MODE switch (Up or Down) to adjust the hour display. Push the ADJUST button 1 to adjust the minute display. Press and hold the left handlebar MODE switch (Up or Down) and the ADJUST button 1 simultaneously for 2 seconds to return to the clock mode.

NOTE: When the switch or button is

pressed and held, the display will increase continuously.

The clock can be adjusted when the ignition switch is in the ON position.

This clock is powered by the battery of the motorcycle. If your motorcycle is to be left unused for more than two months, remove the battery from the motorcycle.

1 OFF TC

2

3-20

Odometer/Trip Meter/Instrument Panel Light Brightness J The display has 4 functions; odometer, two trip meters and instrument panel light brightness. When the ignition switch is turned to the ON position, the test pat- tern shown below is displayed for 2 seconds. After the test pattern is displayed, the display will show the function that was displayed the last time that the ignition switch was turned off.

NOTE: Set the meter to odometer,

then press and hold the ADJUST button 1 for 2 sec- onds to switch between km and mile. At this time, speedometer will be changed between km/h and mph and the instantaneous fuel consumption meter will be changed between km/L (L/100 km) and MPG.

Select km/h or mph, as appro- priate, to comply with traffic regulations.

Check the km/h and mph dis- play after adjusting the instru- ment panel display.

To change the display, push the left handlebar MODE switch (Up). The display changes in the order below.

H

GEAR

C

E F

mph

TRIP

RANGE

ADJ

MPG km/L/100km V

AVG

AIR

1 2

1 OFF TC

2

12

km/h

2

11

1000 r/min

1210

0 3

4 5 6 7

8 9

1

TRIP 1

TRIP 2

Odometer

Trip meter 1

Trip meter 2

Instrument panel light brightness

3-21

Odometer The odometer registers the total distance that the motorcycle has been ridden. The odometer ranges from 0 to 999999 km or from 0 to 624999 miles.

NOTE: The odometer display locks at 999999 km or 624999 miles when the total distance exceeds 999999 km or 624999 miles.

Trip meters The two trip meters are resettable odometers. They can register two kinds of distances at the same time. For instance, trip meter 1 can register the trip distance and trip meter 2 can register the dis- tance between fuel stops.

To reset a meter to zero, push the ADJUST button 1 or MODE switch (Up) for 2 seconds while the display indicates the trip meter 1, or 2, you want to reset. When you reset the trip meter 1 or 2, the fuel consumption meter will also be reset.

NOTE: When the trip meter exceeds 9999.9, the trip meter will return to 0.0 and start counting again.

Instrument panel light brightness Set the meter to instrument panel light brightness. Pushing the ADJUST button 1 will change the instrument panel light brightness in 6 steps. The brightness indica- tor indicates brightness from (min) to (max).

WARNING Changing the display while riding can be hazardous. Removing a hand from the han- dlebars can reduce your ability to control the motorcycle.

Never change the display while riding. Keep both hands on the handlebars.

3-22

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.

Dimmer Switch 2 position The headlight low beam turns on.

position Push the dimmer switch forward, the headlight low beam, high beam turn on. The high beam indicator light also comes on.

Headlight flasher switch Press the switch to flash the headlight.

MODE

PASS

SEL

NOTICE Sticking tape or placing objects in front of the headlight can obstruct headlight heat radiation. This can result in headlight damage.

Do not stick tape on the head- light or place objects in front of the headlight.

NOTICE Do not put objects in front of the headlight or taillight when they are on, and do not cover with clothes when the motorcy- cle is stopped.

This may cause melting of the lens or damage to the object by the heat from the lens.

3-23

Mode Switch 3 Use the MODE SWITCH to change the speedometer display setting and traction control sys- tem setting. Refer to the INSTRUMENT PANEL and TRACTION CON- TROL SYSTEM sections for details.

NOTE: For more detailed informa- tion on the traction control sys- tem, see page 3-24.

Horn Switch 4 Press the switch to sound the horn.

Turn Signal Light Switch 5 Moving the switch to the posi- tion will flash the left turn signals. Moving the switch to the posi- tion will flash the right turn sig- nals. The indicator light will also flash intermittently. To cancel turn signal operation, push the switch in.

WARNING Failure to use the turn signals, and failure to turn off the turn signals can be hazardous. Other drivers may misjudge your course and this may result in an accident.

Always use the turn signals when you intend to change lanes or make a turn. Be sure to turn off the turn signals after completing the turn or lane change.

3-24

Traction Control System Switch 6

Traction Control System When the traction control system senses rear wheel spin during acceleration, it automatically con- trols engine power output to restore the gripping power of the rear tire. The traction control sys- tem indicator light blinks when the traction control system is control- ling engine power output.

MODE

PASS

SEL

WARNING Relying too much on the trac- tion control system can be haz- ardous.

The traction control system cannot provide control to limit rear wheel spin under certain conditions. The system cannot control rear wheel spin result- ing from high speed cornering, excessive bank angle, braking operation or engine braking effect. Be sure to operate the motorcycle at an appropriate speed according to your riding skill, and weather and road conditions.

WARNING Replacing the tires with other than the specified tires can be hazardous.

When replacing tires, be sure to mount the specified tires. If tires other than the specified size or type are mounted on the motorcycle, the traction control system will not be able to control engine power output properly.

3-25

NOTE: When the traction control sys-

tem is controlling engine power output, the engine sound and exhaust sound will change.

When the front tire is not in full contact with the road surface due to sudden acceleration or other reasons, the traction control system will control engine power output.

When the front or rear tires do not stay in full contact with the road surface, such as when riding on a bumpy road, the traction control system will control engine power output.

When the traction control sys- tem is controlling engine power output, the engine speed will not increase even if the throttle grip is operated to increase engine power. If this happens, close the throttle completely to restore the nor- mal condition.

The traction control system can be set to OFF, Mode 1 or Mode 2.

The traction control system does not control engine power output even if the rear tire spins.

The sensitivity level of the traction control system is set low in this mode, so the traction control sys- tem allows a certain degree of wheel spin before controlling engine power output.

The sensitivity level of the traction control system is set high in this mode, so the traction control sys- tem allows a lesser degree of wheel spin than when set in Mode 1 before controlling engine power output.

WARNING Failure to confirm that the trac- tion control system is in the in the intended mode before oper- ating the motorcycle can be hazardous.

Confirm that the traction con- trol system is in the intended mode before operating the motorcycle.

3-26

Mode setting 1. Press the traction control sys-

tem switch 6 for mode selec- tion.

2. Press the Mode switch (UP, DOWN) 3 and change the indication on the traction con- trol system display in the meter cluster to the desired mode. The display changes in the order below.

3. Press the traction control sys- tem switch 6 to cancel the mode selection. The traction control system display in the meter cluster returns to the normal display mode.

NOTE: Be sure to keep the throttle

fully closed when changing the mode. If the change of mode is not possible because the throt- tle is not fully closed, a seg- ment of the selected mode on the traction control system dis- play blinks.

The setting is retained in the memory even when the igni- tion switch is turned off.

The setting of the traction con- trol system is retained in the memory even when the bat- tery becomes fully discharged or is disconnected and removed from the motorcycle.

MODE

PASS

SEL

1 OFF TC

2 1

OFF TC

2

1 OFF TC

2

1 OFF TC

2

1 OFF TC

2

3-27

RIGHT HANDLEBAR

Engine Stop Switch 1 position The ignition circuit is off. The engine cannot start or run.

position The ignition circuit is on and the engine can run.

Front Brake Lever 2 The front brake is applied by squeezing the brake lever gently toward the throttle grip. This motorcycle is equipped with a disk brake system and excessive pressure is not required to slow the machine down properly. The brake light will be lit when the lever is squeezed inward.

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. When changing the brake lever position, always be sure the adjuster stops in the proper posi- tion; a projection of the brake lever pivot should fit into the depression of the adjuster. This motorcycle is delivered from the factory with its adjuster set on position 3.

NOTICE Changing the engine stop switch from to or from to to while riding may damage to the engine or the catalytic converter (if equipped).

Do not use the engine stop switch except for an emer- gency.

3-28

Electric Starter Switch 3 This switch is used for operating the starter motor. With the ignition switch in the ON position, the engine stop switch in and the transmission in neutral and push the electric starter switch to start the engine.

NOTE: This motorcycle is equipped with an interlock system for the ignition circuit and the starter circuit. The engine can only be started if: The transmission is in neutral,

or The transmission is in gear,

the side stand is fully up and the clutch is disengaged.

NOTE: The headlight will go off when the electric starter switch is pushed.

WARNING Adjusting the front brake lever position while riding can be hazardous. Removing a hand from the handlebars can reduce your ability to control the motorcycle.

Never adjust the front brake lever position while riding. Keep both hands on the han- dlebars.

3-29

Suzuki Easy Start System Suzuki Easy Start System permits engine start by simple one-push action on the electric starter switch. When the transmission is in neutral, the engine can be started without squeezing the clutch lever. When the transmis- sion is in a position other than neutral, the engine can be started by squeezing the clutch lever.

NOTE: When the electric starter

switch is pushed, the starter motor will continue turning for a few seconds even when you release your hand from the switch. After a few seconds, or when the engine is started, the starter motor will stop auto- matically.

Depending on the condition of the battery, the engine might not start easily by Suzuki Easy Start System. If the engine is difficult to start, squeeze the clutch lever and continue pressing the electric starter switch to start up the engine. If the engine fails to start up, the battery will most likely lose power. In this case, charge or change the battery.

Throttle Grip 4 Engine speed is controlled by the position of the throttle grip. Twist it toward you to increase engine speed. Turn it away from you to decrease engine speed.

NOTICE Engaging the starter motor for more than five seconds at a time can damage the starter motor and wiring harness from overheating.

Do not engage the starter motor for more than five sec- onds at a time. If the engine does not start after several attempts, check the fuel supply and ignition system. Refer to the TROUBLESHOOTING sec- tion in this manual.

NOTICE If the neutral indicator light and the gear position indicator are not giving proper indications, starting the engine can cause serious engine damage.

Before starting the engine, make sure of the followings: When the neutral indicator

light comes on, the gear position indicator should indicate N (Neutral).

When the neutral indicator light goes off, the gear posi- tion indicator should indicate either 1, 2, 3, 4, 5 or 6.

If the neutral indicator light and the gear position indica- tor are not working properly, consult your Suzuki dealer.

3-30

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 with the key and open the fuel tank cap. To close the fuel tank cap, push the cap down firmly with the key in the cap lock.

Use fresh gasoline when filling up the fuel tank. Do not use bad gas- oline which is contaminated with dirt, dust, water or other liquid. Be careful that dirt, dust or water do not enter the fuel tank when refu- eling.

Fuel tank capacity: 20.0 L (5.3 US gal)

1Fuel level 2Filler neck

WARNING If you overfill the fuel tank, fuel may overflow when it expands due to engine heat or heating by the sun. Fuel that overflows can catch fire.

Stop adding fuel when the fuel level reaches the bottom of the filler neck.

WARNING Failure to follow safety precau- tions when refueling could result in a fire or cause you to breathe toxic fumes.

Refuel in a well ventilated area. Make sure the engine is off and avoid spilling fuel on a hot engine. Do not smoke, and make sure there are no open flames or sparks in the area. Avoid breath- ing gasoline vapors. Keep chil- dren and pets away when you refuel the motorcycle.

3-31

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 between 1st and 2nd gear. When neutral is desired, depress or lift the lever halfway between 1st and 2nd gear.

NOTE: When the transmission is in neutral, the green indicator light on the instrument panel will be lit. However, even though the light is illuminated, cautiously and slowly release the clutch lever to make sure that the transmission is posi- tively in neutral.

Reduce the motorcycle speed before down-shifting. When down- shifting, the engine speed should be increased before the clutch is engaged. This will prevent unnec- essary wear on the drive train components and the rear tire.

REAR BRAKE PEDAL

Depressing the rear brake pedal will apply the rear disk brake. The brake light will be illuminated when the rear brake is operated.

5 4 3 2

3-32

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.

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 not be started.

If the engine is running and the transmission is shifted into gear with the side stand down, the engine will stop running.

If the engine is running and the side stand is put down with the transmission in gear, the engine will stop running.

WARNING Failure to install the seat prop- erly could allow the seat to move and cause loss of rider control.

Latch the seat securely in its proper position.

3-33

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 position 5 provides the stiffest. This motorcycle is delivered from the factory with its adjuster set on position 2.

WARNING Riding with the side stand incompletely retracted can result in an accident when you turn left.

Check operation of the side stand/ignition interlock sys- tem before riding. Always retract the side stand com- pletely before starting off.

NOTICE If you do not take proper pre- cautions when parking, the motorcycle can fall over.

Park the motorcycle on firm, level ground whenever possi- ble. If you must park on an incline, aim the front of the motorcycle uphill and put the transmission into 1st gear to reduce the possibility of rolling off the side stand.

NOTICE Turning adjusters by force can damage the suspensions.

Do not turn adjusters beyond their natural limits.

0 12 34 5

3-34

Damping Force Adjustment

The rebound damping force adjuster 2 is located at the bot- tom of the rear suspension damper unit. To adjust the damp- ing force, set the adjuster to the standard setting first and then adjust it to the desired position. To set the damping force adjuster to the standard position:

1. Turn the adjuster clockwise until it stops.

2. Turn the adjuster counterclock- wise 2 turns until the two punch marks align.

Turn the adjuster clockwise to stiffen the damping force and turn it counterclockwise to soften the damping force.

Rear Suspension Label

NOTE: Ask your Suzuki dealer to dispose of the rear suspension unit.

TEN H S

WARNING

This unit contains high-pres- sure nitrogen gas. Mishandling can cause explo- sion.

Keep away from fire and heat. Read owners manual for

more information.

3-35

WINDSHIELD The windshield height can be adjusted to 3 positions. To change the windshield height, follow the procedure below.

1. Remove the caps 1 and bolts 2 and then remove the wind- shield 3.

2. Move the windshield up or down to the desired windshield position.

3. Reinstall the windshield in the reverse order of removal.

WARNING Moving the motorcycle with its windshield interfering with the rear view mirror can be hazard- ous. You could lose your bal- ance and fall.

After adjusting the windshield height and the rear view mirror position, turn the handlebar right and left to check that the windshield does not interfere with the rear view mirror. If the rear view mirror touches the windshield, adjust the rear view mirror position. Also check if the windshield is firmly and securely fixed.

3-36

OUTPUT TERMINAL

DL650A/XA has an output termi- nal for attaching 12V electrical accessories. Total electrical accessory wattage should be less than 36W. Check electrical charg- ing voltage and wattage before attaching accessories to the out- put terminal.

NOTE: Using the output terminal during the idling operation or in the engine stop condition, may cause dead battery. Use the out- put terminal under the engine operating condition.

POWER

OUTLET

WARNING If you insert a long socket into the output terminal, it may interfere with the handlebars and disturb safe riding or mov- ing the motorcycle, and you could lose your balance and fall.

After inserting the socket into the output terminal, turn the handlebars right and left to check that the inserted socket does not interfere with the han- dlebars.

WARNING When using the output termi- nal, if its electrical devices are not properly installed and con- nected, they may interfere with movement of the handlebars, causing loss of control or causing the devices to fall off.

Before riding, turn the handle- bars to the right and to the left to make it sure that there is no interference with handlebar movement or secure installa- tion of the devices.

3-37

NOTICE Using improper electrical accessories can damage your motorcycle. Exceeding 36W or using other than 12V acces- sory can seriously damage the electrical system and acces- sory.

Check voltage and wattage before connecting electrical accessories.

NOTICE When water enters the output terminal, it may cause short- circuit.

Do not use the output terminal during the motorcycle washing operation, or in case of rain. In such cases, remove the attach- ment plug and close the cap.

4-1

4

BREAK-IN AND INSPECTION BEFORE RIDING

BREAK-IN ……………………………………………………………………………………………… 4-2 INSPECTION BEFORE RIDING ……………………………………………………………….. 4-3

4-2

BREAK-IN AND INSPECTION BEFORE RIDING

BREAK-IN 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 procedures.

Maximum Engine Speed Recommendation This table shows the maximum engine speed recommendation during the break-in period.

Vary the Engine Speed Vary the engine speed during the break-in period. This allows the parts to load (aiding the mating process) and then unload (allowing the parts to cool). Although it is essential to place some stress on the engine com- ponents during break-in, you must be careful not to load the engine too much.

Breaking in the New Tires New tires need proper break-in to assure maximum performance, just as the engine does. Wear in the tread surface by gradually increasing your cornering lean angles over the first 160 km (100 miles) before attempting maxi- mum performance. Avoid hard acceleration, hard cornering, and hard braking for the first 160 km (100 miles).

Initial 800 km (500 miles) Below 5000 r/min

Up to 1600 km (1000 miles) Below 7500 r/min

Over 1600 km (1000 miles) Below 10000 r/min

WARNING Failure to perform break-in of the tires could cause tire slip and loss of control.

Use extra care when riding on new tires. Perform proper break-in of the tires as described in this section and avoid hard acceleration, hard cornering, and hard braking for the first 160 km (100 miles).

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 service includes correction of all adjustments, tightening of all fasteners and replacement of dirty oil. Timely performance of this service will help make sure you get a longer service life and the best perfor- mance from the engine.

NOTE: The 1000 km (600 miles) service should be performed as outlined in the INSPECTION AND MAINTENANCE section of this Owners Manual. Pay particular attention to the CAUTION and WARNING messages in that sec- tion.

INSPECTION BEFORE RIDING

WARNING Failure to inspect your motor- cycle before riding and to prop- erly maintain your motorcycle increases the chances of an accident or equipment dam- age.

Always inspect your motorcy- cle each time you use it to make sure it is in safe operat- ing condition. Refer to the INSPECTION AND MAINTE- NANCE section in this owners manual.

WARNING If you operate this motorcycle with improper tires or improper or uneven tire pressure, you may lose control of the motor- cycle. This will increase your risk of an accident.

Always use tires of the size and type specified in this owners manual. Always maintain proper tire pressure as described in the INSPECTION AND MAINTENANCE section.

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, passenger and protection of the motorcycle.

NOTE: Check switch operation before riding when ambient tem- perature is below zero.

WARNING Checking maintenance items when the engine is running can be hazardous. You could be severely injured if your hands or clothing get caught in mov- ing engine parts.

Shut the engine off when per- forming maintenance checks, except when checking the lights, engine stop switch, and throttle.

WHAT TO CHECK CHECK FOR:

Steering Smoothness No restriction of movement No play or looseness

Throttle ( 7-26)

Correct play in the throttle cable

Smooth operation and positive return of the throttle grip to the closed position

Clutch ( 7-32)

Correct lever play Smooth and progressive

action

Brakes ( 3-27, 3-31, 7-32)

Proper pedal and lever operation

Fluid level in the reservoir to be above LOWER line

Correct pedal play No sponginess No fluid leakage Brake pads not worn down

to the limit line

Suspension ( 3-33)

Smooth movement

Fuel ( 3-15)

Enough fuel for the planned distance of operation

Drive chain ( 7-28)

Correct tension or slack Adequate lubrication No excessive wear or

damage

Tires ( 7-37)

Correct pressure Adequate tread depth No cracks or cuts

Engine oil ( 7-20)

Correct level

Cooling system ( 7-27)

Proper coolant level No coolant leakage

Lighting ( 3-5, 3-8, 3-22)

Operation of all lights and indicators

Horn ( 3-23)

Correct function

Engine stop switch ( 3-27)

Correct function

Side stand/ Ignition interlock switch ( 7-41)

Proper operation

Windshield ( 3-35, 9-6)

Good visibility

Spoke wheels (DL650XA) ( 7-40)

Spoke tension Check for damage

5

5-1

RIDING TIPS

STARTING THE ENGINE ………………………………………………………………………… 5-2 STARTING OFF AND SHIFTING ……………………………………………………………… 5-4 USING THE TRANSMISSION ………………………………………………………………….. 5-5 RIDING ON HILLS ………………………………………………………………………………….. 5-6 STOPPING AND PARKING …………………………………………………………………….. 5-7 CARRYING A PASSENGER ………………………………………………………………….. 5-10

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 an interlock system for the ignition circuit and the starter circuit. The engine can only be started if: The transmission is in neutral,

or The transmission is in gear,

the side stand is fully up and the clutch is disengaged.

3. Close the throttle completely and push the electric starter switch.

NOTE: Open the throttle 1/8 and push the electric starter switch when the engine is hard to start.

NOTE: The fuel supply system stops the engine when the motor- cycle is overturned. Turn off the ignition switch before restarting the engine.

NOTICE If the neutral indicator light and the gear position indicator are not giving proper indications, starting the engine can cause serious engine damage.

Before starting the engine, make sure of the followings: When the neutral indicator

light comes on, the gear position indicator should indicate N (Neutral).

When the neutral indicator light goes off, the gear posi- tion indicator should indicate either 1, 2, 3, 4, 5 or 6.

If the neutral indicator light and the gear position indica- tor are not working properly, consult your Suzuki dealer.

WARNING Exhaust gas contains carbon monoxide, a dangerous gas that is difficult to detect because it is colorless and odorless. Breathing carbon monoxide can cause death or severe injury.

Never start the engine or let it run indoors or where there is little or no ventilation.

5-3

Suzuki Easy Start System Suzuki Easy Start System permits engine start by simple one-push action on the electric starter switch. When the transmission is in neutral, the engine can be started without squeezing the clutch lever. When the transmis- sion is in a position other than neutral, the engine can be started by squeezing the clutch lever.

NOTE: When the electric starter

switch is pushed, the starter motor will continue turning for a few seconds even when you release your hand from the switch. After a few seconds, or when the engine is started, the starter motor will stop auto- matically.

Depending on the condition of the battery, the engine might not start easily by Suzuki Easy Start System. If the engine is difficult to start, squeeze the clutch lever and continue pressing the electric starter switch to start up the engine. If the engine fails to start up, the battery will most likely lose power. In this case, charge or change the battery.

NOTICE After starting the engine, open- ing the throttle or running the motorcycle with the oil pres- sure indicator light turned on, may adversely affect the engine.

Make sure that the oil pressure indicator light has turned off before operating the throttle or running the motorcycle.

NOTICE Running the engine too long without riding may cause the engine to overheat. Overheat- ing can result in damage to internal engine components and discoloration of exhaust pipes.

Shut the engine off if you can- not begin your ride promptly.

5-4

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 gear shift lever downward. Turn the throttle grip toward you and at the same time release the clutch lever gently and smoothly. As the clutch engages, the motorcycle will start moving forward. To shift to the next higher gear, accelerate gently, then close the throttle and squeeze the clutch lever simultaneously. Lift the gear shift lever upward to select the next gear and, release the clutch lever as you open the throttle again. Select higher gears in this manner until top gear is reached.

NOTE: This motorcycle has a side stand/ignition interlock system. If you shift the transmission into gear when the side stand is down, the engine will stop running.

WARNING Riding at excessive speeds increases your chances of los- ing control of the motorcycle, which can result in an acci- dent.

Always ride at a speed that is proper for the terrain, visibility and operating conditions, and your skills and experience.

WARNING If you remove even one hand or foot from the motorcycle, you can reduce your ability to con- trol the motorcycle. This could cause you to lose your balance and fall off the motorcycle. If you remove a foot from a foot- rest, your foot or leg may come in contact with the rear wheel. This could injure you or cause an accident.

Always keep both hands on the handlebars and both feet on the footrests of your motorcy- cle during operation.

WARNING Sudden side winds, which can occur when being passed by larger vehicles, at tunnel exits or in hilly areas, can cause you to lose control of the motorcy- cle.

Reduce your speed and be alert to the possibility of sud- den side winds.

5-5

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. Never slip the clutch to control road speed, but rather downshift to allow the engine to run within its normal operational range. The table below shows the approxi- mate speed range for each gear.

Shifting up schedule

Shifting down schedule

Disengage the clutch when the motorcycle speed drops below 15 km/h (9 mph).

Gear position km/h mph

1st 2nd 19 12

2nd 3rd 34 21

3rd 4th 46 29

4th 5th 59 37

5th 6th 72 45

Gear position km/h mph

6th 5th 69 43

5th 4th 56 35

4th 3rd 44 28

3rd 2nd 26 16

WARNING Downshifting when engine speed is too high can: cause the rear wheel to skid

and lose traction due to increased engine braking, resulting in an accident; or

force the engine to overrev in the lower gear, resulting in engine damage.

Reduce speed before down- shifting.

WARNING Downshifting while the motor- cycle is leaned over in a corner may cause rear wheel skid and loss of control.

Reduce your speed and down- shift before entering a corner.

NOTICE Revving the engine into the red zone can cause severe engine damage.

Never allow the engine to rev into the red zone in any gear.

5-6

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 rapidly to prevent the motorcycle from losing momentum.

When descending a long, steep slope, use the engine compression to assist the brakes by shifting to a lower gear. Continuous brake appli- cation can overheat the brakes and reduce their effectiveness.

Be careful, however, not to allow the engine to overrev.

NOTICE Improper gearshift lever opera- tion can damage the transmis- sion.

Do not rest your foot on the gearshift lever.

Do not use force to shift gears.

5-7

STOPPING AND PARKING

Anti-lock Brake System (ABS) This model is equipped with an Anti-lock Brake System (ABS) designed to help prevent wheel lock up during hard braking or during braking on slippery sur- faces while riding in a straight line.

The ABS will operate whenever it senses that the wheels are lock- ing up. You may feel the brake lever and/or the brake pedal pul- sate lightly while the ABS is oper- ating.

Even though ABS helps prevent wheel lock-up, you must still be careful when braking in curves. Hard braking while turning could cause wheel skidding and loss of control, whether or not your motorcycle is equipped with ABS. Having ABS does not mean you can take unnecessary risks. ABS will not compensate for poor judg- ment, incorrect braking tech- niques, or not slowing down over bad roads or in poor weather con- ditions.

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 surfaces than an equivalent motorcycle without ABS.

WARNING Inexperienced riders tend to underutilize the front brake. This can cause excessive stop- ping distance and lead to a col- lision. Using only the front or rear brake can cause skidding and loss of control.

Apply both brakes evenly and at the same time.

WARNING Braking while turning the motorcycle can be hazardous, whether or not your motorcycle is equipped with ABS. ABS can not control wheel side-slips that occur when you brake hard while turning and the side-slips could cause loss of control.

Slow down sufficiently in a straight line before you begin to turn and avoid other than slight braking while turning.

5-8

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 locking up. ABS works automatically, so you do not need any special braking technique. Just apply the front and rear brakes, as forcefully as necessary for the situation, without pumping either one. It is normal for the brake lever/pedal to pulsate while the ABS is operating.

Non-recommended tires can affect wheel speed and may con- fuse the computer.

ABS does not work at very low speed, less than 5 km/h (3 mph), and does not work with a dis- charged battery.

WARNING Failure to use good judgment with ABS can be hazardous. ABS cannot make up for bad road conditions, bad judge- ment, or improper operation of the brakes.

Remember that ABS will not compensate for poor judg- ment, incorrect braking tech- niques, or the need to slow down over bad roads or in poor weather conditions. Use good judgment and do not ride faster than conditions will safely allow.

5-9

STOPPING AND PARKING 1. Turn the throttle grip away from

you to close the throttle com- pletely.

2. Apply the front and rear brakes evenly and at the same time.

3. Downshift through the gears as motorcycle speed decreases.

4. Select neutral with the clutch lever squeezed toward the grip (disengaged position) when the motorcycle is almost com- pletely stopped. The neutral position can be confirmed by observing the neutral indicator light.

WARNING Inexperienced riders tend to underutilize the front brake. This can cause excessive stop- ping distance and lead to a col- lision. Using only the front or rear brake can cause skidding and loss of control.

Apply both brakes evenly and at the same time.

WARNING Hard braking while turning may cause wheel skid and loss of control.

Brake before you begin to turn.

WARNING Hard braking on wet, loose, rough, or other slippery sur- faces can cause wheel skid and loss of control.

Brake lightly and with care on slippery or irregular surfaces.

WARNING Following another vehicle too closely can lead to a collision. As vehicle speeds increase, stopping distance increases progressively.

Always maintain a safe stop- ping distance between you and the vehicle in front of you.

NOTICE Holding the motorcycle stopped with throttle and clutch lever operation on inclines can damage the motor- cycles clutch.

Use the brakes when stopping the motorcycle on inclines.

5-10

5. Park the motorcycle on a firm, flat surface where it will not fall over.

NOTE: If the motorcycle is to be parked on the side stand on a slight slope, the front end of the motorcycle should face up the incline to avoid rolling forward off the side stand. You may leave the motorcycle in 1st gear to help pre- vent it from rolling off the side stand. Shift to neutral before start- ing the engine.

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 a U-shape lock, brake disk lock or chain is used to avoid theft, be sure to remove the anti-theft lock before moving the motorcycle.

CARRYING A PASSENGER Before you invite someone to be a passenger on your motorcycle, you need to be thoroughly familiar with motorcycle operation. Adjust tire pressures and suspension according to the Tire Pressure and Loading section and the Sus- pension section of this manual.

The passenger should always hold onto your waist or hips, or onto the seat strap or grab bar, as equipped. Ask your passenger not to make any sudden move- ments. When you lean going around a corner, the passenger should lean with you. The passen- ger should always keep his or her feet on the footrests, even when you are stopped at a light.

To help prevent burn injuries, warn your passenger not to con- tact the muffler when mounting or dismounting your motorcycle.

CAUTION A hot muffler can cause severe burns. The muffler will be hot enough to cause burns for some time after stopping the engine.

Park the motorcycle where pedestrians or children are not likely to touch the muffler.

6-1

6

ACCESSORY USE AND MOTORCYCLE LOADING

ACCESSORY USE …………………………………………………………………………………. 6-2 ACCESSORY INSTALLATION GUIDELINES ……………………………………………. 6-2 LOADING LIMIT …………………………………………………………………………………….. 6-3 LOADING GUIDELINES ………………………………………………………………………….. 6-4 MODIFICATION ……………………………………………………………………………………… 6-5

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 selecting quality accessories and installing them correctly. Use extreme caution when selecting and installing the accessories on your motorcycle and consult your Suzuki dealer if you have any questions.

ACCESSORY INSTALLATION GUIDELINES Install aerodynamic-affecting

accessories, such as a fairing, windshield, backrests, saddle- bags, and travel trunks, as low as possible, as close to the motorcycle and as near the center of gravity as is feasible. Check that the mounting brack- ets and other attachment hard- ware are rigidly mounted.

Inspect for proper ground clear- ance and bank angle. Inspect that the accessory does not interfere with the operation of the suspension, steering or other control operations.

Accessories fitted to the han- dlebars or the front fork area can create serious stability problems. This extra weight will cause the motorcycle to be less responsive to your steering control. The weight may also cause oscillations in the front end and lead to instability prob- lems. Accessories added to the handlebars or front fork of the machine should be as light as possible and kept to a mini- mum.

WARNING Improper installation of acces- sories or modification of the motorcycle may cause changes in handling which could lead to an accident.

Never use improper accesso- ries, and make sure that any accessories that are used are properly installed. All parts and accessories added to the motorcycle should be genuine Suzuki parts or their equivalent designed for use on this motor- cycle. Install and use them according to their instructions. If you have any questions, con- tact your Suzuki dealer.

6-3

Certain accessories displace the rider from his or her normal riding position. This limits the freedom of movement of the rider and may limit control abil- ity.

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 elec- trical power during the opera- tion of the motorcycle.

Do not pull a trailer or sidecar. This motorcycle is not designed to pull a trailer or sidecar.

LOADING LIMIT

Never exceed the GVWR (Gross Vehicle Weight Rating) of this motorcycle. The GVWR is the combined weight of the machine, accessories, payload, rider and passenger. When selecting your accessories, keep in mind the weight of the rider as well as the weight of the accessories. The addi- tional weight of the accessories may not only create an unsafe riding condition but may also affect the steering ease.

GVWR: 415 kg (915 lbs) at the tire pressure (cold) Front: 250 kPa

(2.50 kgf/cm2, 36 psi) Rear: 290 kPa

(2.90 kgf/cm2, 42 psi)

WARNING Overloading or improper load- ing can cause loss of motorcy- cle control and an accident.

Follow loading limits and load- ing guidelines in this manual.

6-4

LOADING GUIDELINES This motorcycle is primarily intended to carry small items when you are not riding with a passenger. Follow the loading guidelines below: Balance the load between the

left and right side of the motor- cycle and fasten it securely.

Keep cargo weight low and as close to the center of the motorcycle as possible.

Do not attach large or heavy items to the handlebars, front forks or rear fender.

Do not install a luggage carrier or a luggage box protruding over the tail end of the motor- cycle.

Do not carry any items that protrude over the tail end of the motorcycle.

Check that both tires are prop- erly inflated to the specified tire pressure for your loading conditions. Refer to page 7-38.

Improperly loading your motor- cycle can reduce your ability to balance and steer the motor- cycle. You should ride at reduced speeds, less than 130 km/h (80 mph), when you are carrying cargo or have added accessories.

Adjust suspension setting as necessary.

WARNING Placing objects in the space behind the fairing can interfere with steering and can cause loss of control.

Do not carry any objects in the space behind the fairing.

6-5

MODIFICATION Modification of the vehicle or removal of original equipment may render the vehicle unsafe or illegal. Obey all applicable regula- tions in your area including federal and state regulations regarding environmental protection. Suzukis limited warranties may not cover damage caused by modifications that would change the original vehicle specifications including, without limitation, modi- fications of any emission-related parts such as the carburetor(s), fuel injection system components, the engine control module, air suction system components, the catalytic converter (if equipped), evaporative emission control sys- tem components (such as the car- bon canister, fuel tank, fuel hoses and vapor hoses), etc. It is strictly prohibited to mod- ify a vehicle by installing parts that can affect emissions con- trol, except in accordance with very specific U.S. Environmen- tal Protection Agency and Cali- fornia Air Resources Board regulations.

The frame of this motorcycle is made of an aluminum alloy. Therefore, never make any modi- fications such as drilling or weld- ing to the frame as it weakens the frame significantly. This could result in an unsafe vehicle operat- ing condition and subsequent accident. Suzuki will not be responsible in any way for per- sonal injury or damage to the motorcycle caused by frame mod- ifications.

Bolt-on-accessories that do not modify the frame in any way may be installed, provided that you do not exceed the loading limit described in this section.

WARNING Modification to an aluminum alloy frame, such as drilling or welding, weakens the frame. This could result in an unsafe operating condition and may lead to an accident.

Never make any modifications to the frame.

7-1

7

INSPECTION AND MAINTENANCE

MAINTENANCE SCHEDULE …………………………………………………………………… 7-2 TOOLS ………………………………………………………………………………………………….. 7-5 FUEL TANK LIFT …………………………………………………………………………………… 7-5 FUEL TANK REMOVAL ………………………………………………………………………….. 7-7 LUBRICATION POINTS ………………………………………………………………………….. 7-8 BATTERY ……………………………………………………………………………………………… 7-9 AIR CLEANER ……………………………………………………………………………………… 7-11 SPARK PLUGS ……………………………………………………………………………………. 7-14 FUEL HOSE …………………………………………………………………………………………. 7-19 ENGINE OIL …………………………………………………………………………………………. 7-20 ENGINE IDLE SPEED INSPECTION ………………………………………………………. 7-25 THROTTLE CABLE PLAY …………………………………………………………………….. 7-26 ENGINE COOLANT ………………………………………………………………………………. 7-27 DRIVE CHAIN ………………………………………………………………………………………. 7-28 CLUTCH ………………………………………………………………………………………………. 7-32 BRAKES ……………………………………………………………………………………………… 7-32 TIRES ………………………………………………………………………………………………….. 7-37 SPOKE WHEELS (DL650XA) ………………………………………………………………… 7-40 SIDE STAND/IGNITION INTERLOCK SYSTEM ……………………………………….. 7-41 FRONT WHEEL REMOVAL …………………………………………………………………… 7-42 REAR WHEEL REMOVAL …………………………………………………………………….. 7-45 LIGHT BULB REPLACEMENT ………………………………………………………………. 7-48 FUSES ………………………………………………………………………………………………… 7-53 FRONT BRAKE LEVER FITTING …………………………………………………………… 7-55 CLUTCH LEVER FITTING ……………………………………………………………………… 7-55 CATALYTIC CONVERTER ……………………………………………………………………. 7-56

7-2

INSPECTION AND MAINTENANCE

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 perform the maintenance listed.

MAINTENANCE, REPLACE- MENT OR REPAIR OF THE EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY MOTORCYCLE REPAIR ESTABLISHMENT OR INDI- VIDUAL USING ANY MOTOR- CYCLE PART WHICH HAS BEEN CERTIFIED UNDER THE PROVISIONS IN THE CLEAN AIR ACT Sec. 207 (a)(2).

WARNING Improper maintenance or fail- ure to perform recommended maintenance can lead to an accident.

Keep your motorcycle in good condition. Ask your Suzuki dealer or a qualified mechanic to perform the maintenance items marked with an asterisk (*). You may perform the unmarked maintenance items by referring to the instructions in this section, if you have mechanical experience. If you are not sure how to do any of the jobs, ask your Suzuki dealer to do the maintenance.

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 mechanic.

WARNING Exhaust gas contains carbon monoxide, a dangerous gas that is difficult to detect because it is colorless and odorless. Breathing carbon monoxide can cause death or severe injury.

Never start the engine or let it run indoors or where there is little or no ventilation.

NOTICE Servicing electric parts with the ignition switch in the ON position can damage the elec- tric parts when the electric cir- cuit is shorted.

Turn off the ignition switch before servicing the electric parts to avoid short-circuit damage.

NOTICE Poorly-made replacement parts can cause your motorcycle to wear more quickly and may shorten its useful life.

When replacing parts on your motorcycle, use only genuine Suzuki replacement parts or their equivalent.

7-4

MAINTENANCE CHART Interval: This interval should be judged by number of months or odom- eter reading, 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 maintenance interval is to be applied only for the California model.

Interval months 2 12 24 36 48

km 1000 6000 12000 18000 24000

Element miles 600 4000 7500 11000 14500

Air cleaner element ( 7-11) I I R I

* Exhaust pipe bolts and muffler bolts T T T

* Valve clearance Inspect every 24000 km (15000 miles)

Spark plug ( 7-14) I R I R

Fuel hose ( 7-19) I I I I

* Evaporative emission control system (California model only)

I I

Engine oil ( 7-20) R R R R R

Engine oil filter ( 7-20) R R

Throttle cable play ( 7-26) I I I I I

* Throttle valve synchronization I (CA. only) I I

* Engine coolant ( 7-27)

SUZUKI SUPER LONG LIFE COOLANT (Blue)

Replace every 4 years or 48000 km (29000 miles)

SUZUKI LONG LIFE COOLANT (Green) or an engine coolant other than SUZUKI SUPER LONG LIFE COOLANT (Blue)

R R

Radiator hose ( 7-28) I I I I

Clutch cable play ( 7-32) I I I I

Drive chain ( 7-28) I I I I I

Clean and lubricate every 1000 km (600 miles)

* Brakes ( 7-32) I I I I I

Brake hose ( 7-32) I I I I

*Replace every 4 years

Brake fluid ( 7-33) I I I I

*Replace every 2 years

Tires ( 7-37) I I I I

* Steering I I I

* Front forks I I

* Rear suspension ( 3-33) I I

* Chassis bolts and nuts T T T T T

Lubrication Lubricate every 1000 km (600 miles)

Spoke wheel ( 7-40) I I I I I

7-5

TOOLS

A tool kit is supplied and located under the seat.

FUEL TANK LIFT 1. Place the motorcycle on the

side stand. 2. Remove the seat by referring

to the SEAT LOCK section.

3. Remove the fasteners.

4. Remove the bolts.

5. Unhook the end of the front side covers 1.

7-6

6. Slide and unhook the front side covers.

7. Remove the fasteners and bolts. Remove the front fuel tank cover 2.

8. Remove the screws and bolts.

9. Slide the fuel tank side covers 3 forward to slip off the hooks.

10.Disconnect the connector and the hook.

11.Remove the wiring harness. 12.Remove the fuel tank side cov-

ers 3.

7-7

13.Remove the bolts.

14.Remove the hooks and remove the bolt. Remove the prop 4 and rubber cushion.

15.Remove the rubber cushion from the prop 4.

16.Support the fuel tank with the prop 4.

FUEL TANK REMOVAL Lift the fuel tank by referring to the FUEL TANK LIFT section.

1. Disconnect the hoses and coupler.

2. Pull the retainer 1. 3. Disconnect the fuel feed hose

joint 2 from fuel pipe.

7-8

LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of your motor- cycle and also for safe riding. It is a good practice to lubricate the motorcycle after a long rough ride and after getting it wet it in the rain or after washing it. Major lubrication points are indicated below.

….Grease ….Drive chain lubricant

1….Clutch lever pivot 2….Gearshift lever pivot and

footrest pivot 3….Side stand pivot and spring

hook 4….Drive chain 5….Brake lever pivot 6….Brake pedal pivot and

footrest pivot

NOTICE Lubricating electrical switches can damage the switches.

Do not apply grease or oil to electrical switches.

D

7-9

BATTERY The battery is a sealed type battery and requires no maintenance of fluid level and gravity. But have your dealer check the charging condition of the battery periodically.

NOTE: For charging a sealed type

battery, use a battery charger applicable to a sealed type battery.

If you cannot charge the bat- tery, consult your authorized Suzuki dealer.

WARNING Battery posts, terminals, and related accessories contain lead and lead compounds. Lead is harmful to your health if it gets into your blood stream.

Wash hands after handling any parts containing lead.

WARNING Diluted sulfuric acid from the battery can cause blindness or severe burns.

When working near the battery, use proper eye protection and gloves. Flush eyes or body with ample water and get medi- cal care immediately if you suf- fer injury. Keep batteries out of reach of children.

WARNING Batteries produce flammable hydrogen gas which can explode if exposed to flames or sparks.

Keep flames and sparks away from the battery. Never smoke when working near the battery.

WARNING Wiping the battery with a dry cloth can cause a static elec- tricity spark, which can start a fire.

Wipe the battery with a damp cloth to avoid static electricity build up.

NOTICE Exceeding the maximum charging rate for the battery can shorten its life.

Never exceed the maximum charging rate for the battery.

7-10

Battery Removal To remove the battery, follow the procedure below: 1. Place the motorcycle on the

side stand. 2. Remove the seat by referring

to the SEAT LOCK section. 3. Remove the rubber band 1.

4. Disconnect the negative () terminal 2.

5. Remove the cap. Disconnect the positive (+) terminal 3.

6. Remove the battery 4.

To install the battery: 1. Install the battery in the

reverse order of removal. 2. Connect the battery terminals

securely.

NOTE: Select the same type MF bat-

tery when replacing the battery. Recharge the battery once a

month if the motorcycle is not used for a long time.

WARNING Batteries contain toxic sub- stances including sulfuric acid and lead. They could cause injury to humans or could dam- age the environment.

A used battery must be dis- posed of or recycled according to local law and must not be discarded with ordinary house- hold waste. Make sure not to tip over the battery when you remove it from the vehicle. Oth- erwise, sulfuric acid could run out and you might be injured.

NOTICE Reversing the battery lead wires can damage the charging system and the battery.

Always attach the red lead to the (+) positive terminal and the black (or black with white tracer) lead to the () negative terminal.

7-11

The crossed-out wheeled bin symbol A located on the battery label indicates that a used battery should be collected separately from ordinary household waste. The chemical symbol of Pb B indicates the battery contains more than 0.004% lead.

By ensuring the used battery is disposed of or recycled correctly, you will help prevent potential negative consequences for the environment and human health, which could otherwise be caused by inappropriate waste handling of the battery. The recycling of materials will help to conserve natural resources. For more detailed information about dispos- ing or recycling of the used bat- tery, consult your Suzuki dealer.

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 inspect the air cleaner element much more frequently. Use the following procedure to remove the element and inspect it.

Pb

WARNING Operating the engine without the air cleaner element in place can be hazardous. A flame can spit back from the engine to the air intake box without the air cleaner element to stop it. Severe engine damage can also occur if dirt enters the engine due to running the engine without the air cleaner element.

Never run the engine without the air cleaner element in place.

7-12

Air Cleaner Element Removal 1. Lift the fuel tank by referring to

the FUEL TANK REMOVAL section.

2. Remove the screws. 3. Pull up the air cleaner cover

1.

4. Remove the air cleaner ele- ment 2.

NOTICE Failure to inspect the air cleaner element frequently if the vehicle is used in dusty, wet, or muddy conditions can damage your motorcycle. The air cleaner element can become clogged under these conditions, and engine damage may result.

Always inspect the air cleaner element after riding in severe conditions. Clean or replace the element as necessary. If water gets in the air cleaner case, immediately clean the element and the inside of the case.

7-13

5. Carefully use an air hose to blow the dust from the air cleaner element.

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, restricting the air flow through the element.

Installation Reinstall the cleaned element or new air cleaner element in reverse order of removal. Be absolutely sure that the element is securely in position and is seal- ing properly.

NOTE: Be careful not to spray water on the air cleaner box when cleaning the motorcycle.

Reinstall the fuel tank.

NOTE: Check that the fuel tank drain hose and breather hose are not bent before reinstalling the fuel tank.

NOTICE A torn air cleaner element will allow dirt to enter the engine and can damage the engine.

Replace the air cleaner element with a new one if it is torn. Carefully examine the air cleaner element for tears dur- ing cleaning.

NOTICE Failure to position the air cleaner element properly can allow dirt to bypass the air cleaner element. This will cause engine damage.

Be sure to properly install the air cleaner element.

7-14

Air Cleaner Drain Plug

1. Loosen the clamp bolts 1. Pull up the air cleaner box 2.

2. Remove the plug and drain water and oil at the periodic maintenance interval. The air cleaner drain plug is located beneath the air cleaner box.

SPARK PLUGS Your motorcycle comes equipped with NGK MR8E-9 spark plugs. To determine if the standard spark plug is right for your usage, check the color of the plugs porcelain center electrode insulator after motorcycle operation. A light brown color indicates that the plug is correct. A white or dark insula- tor indicates that the engine may need adjustment, or another plug type may be needed. Consult your Suzuki dealer or a qualified mechanic if your plug insulator is not a light brown color.

NOTICE An improper spark plug may have an incorrect fit or inappro- priate heat range for your engine. This may cause severe engine damage which may not be covered under warranty.

Use one of the spark plugs listed or their equivalent. Con- sult your Suzuki dealer if you are not sure which spark plug is correct for your type of usage.

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Plug Replacement Guide

NOTE: If the above-named plugs are not available, consult your Suzuki dealer.

NOTE: This motorcycle uses a resistor-type spark plug to avoid jamming electronic parts. Improper spark plug selection may cause electronic interfer- ence with your motorcycles igni- tion system, resulting in motorcycle performance prob- lems. Use only the recommended spark plugs.

SPARK PLUG REMOVAL To remove the spark plugs, follow the procedure below:NGK REMARKS

MR8E-9 Standard

CAUTION A hot radiator and hot engine can burn you.

Wait until the radiator and engine are cool enough to touch with bare hands before starting this work.

NOTICE Dirt can damage the moving engine parts of your motorcy- cle if it enters an open spark plug hole.

Cover the spark plug hole while the spark plug is out of the hole.

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Front Side 1. Remove the fuel tank side cov-

ers by referring to the FUEL TANK REMOVAL section.

2. Remove the radiator mounting bolt 1 and slide the radiator forward.

NOTE: Do not extract the radiator hose. 3. Pull off the spark plug cap.

4. Remove the spark plugs with a spark plug wrench.

NOTE: Be careful not to damage the radiator fins.

7-17

Rear Side 1. Remove the fuel tank by refer-

ring to the FUEL TANK REMOVAL section.

2. Pull off the spark plug caps. 3. Remove the spark plugs with a

spark plug wrench.

NOTE: Pry up the spark plug cap with a screwdriver or a bar if it is hard to remove by hand. Do not pull the spark plug cord.

NOTICE Dirt can damage the moving engine parts of your motorcy- cle if it enters an open spark plug hole.

Cover the spark plug hole while the spark plug is out of the hole.

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Spark Plug Inspection

0.8 0.9 mm (0.031 0.035 in)

Adjust the spark plug gap to 0.8 0.9 mm (0.031 0.035 in) by using a spark plug gap thickness gauge.

Installation To install a spark plug, turn it in as far as possible with your fingers, then tighten it with a wrench.

NOTICE Improper installation of the spark plug can damage your motorcycle. An overly-tight or cross-threaded spark plug will damage the aluminum threads of the cylinder head.

Carefully turn the spark plug by hand into the threads. If the spark plug is new, tighten it with a wrench about 1/2 turn past finger tight. If you are reusing the old spark plug, tighten it with a wrench about 1/8 turn past finger tight.

NOTICE Dirt can damage the moving engine parts of your motorcy- cle if it enters an open spark plug hole.

Cover the spark plug hole while the spark plug is out of the hole.

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NOTE: When installing the spark plug caps, point the arrow marks on the spark plug caps to the exhaust side.

NOTE: Push the spark plug caps all the way on so that there is a tight seal.

Remount the radiators and tighten the mounting bolts securely.

Reinstall the fuel tank.

NOTE: Check that the fuel tank drain hose and breather hose are not bent before reinstalling the fuel tank.

FUEL HOSE

Inspect the fuel hose for damage and fuel leakage. If any defects are found, the fuel hose must be replaced.

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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. Start the engine and allow it to

idle for three minutes. 3. Stop the engine and wait for

three minutes.

4. Hold the motorcycle vertically and check the oil level through the oil level inspection window on the right side of the engine. The engine oil level should be between L (low) and F (full) lines.

NOTICE Operating the motorcycle with too little or too much oil can damage the engine.

Place the motorcycle on level ground. Check the oil level with the engine oil inspection win- dow before each use of the vehicle. Be sure the engine oil level is always above the L (low) line and not higher than the F (full) line.

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Engine Oil and Filter Change Change the engine oil and oil filter at the scheduled time. The engine should always be warm when the oil is changed so the oil will drain easily. The procedure is as fol- lows:

1. Remove the bolts and the under cowling. (DL650XA)

2. Place the motorcycle on the side stand.

3. Remove the oil filler cap 1.

4. Remove the drain plug 2 and gasket 3 from the bottom of the engine and drain the engine oil into a drain pan.

CAUTION Hot engine oil and exhaust pipes can burn you.

Wait until the oil drain plug and exhaust pipes are cool enough to touch with bare hands before draining oil.

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NOTE: Recycle or properly dispose of

used oil. Before starting the work, check

that there is not any dust, mud, or foreign object inside the oil jug or on the oil filter mounting surface.

Available from Suzuki dealer Oil filter wrench (Part No. 09915-40620)

5. Turn the oil filter 4 counter- clockwise with a Suzuki cap type oil filter wrench or a strap type filter wrench of the proper size.

WARNING Children and pets may be harmed by swallowing new or used oil. Repeated, prolonged contact with used engine oil may cause skin cancer. Brief contact with oil may irritate skin.

Keep new and used oil and used oil filters away from chil- dren and pets. To minimize your exposure to used oil, wear a long-sleeve shirt and mois- ture-proof gloves (such as dishwashing gloves) when changing oil. If oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil. Recycle or properly dis- pose of used oil and filters.

NOTICE Turning the engine while drain- ing the engine oil will cause oil film shortage and adversely affect the engine.

Do not use the electric starter switch during engine oil replacement work.

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6. Wipe off the mounting surface 5 on the engine where the new filter will be seated with a clean rag.

7. Smear a little engine oil around the rubber gasket 6 of the new oil filter.

8. Screw the new filter by hand until the filter gasket contacts the mounting surface (a small resistance will be felt).

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.

NOTICE Failure to use an oil filter with the correct design and thread specifications can damage your motorcycles engine.

Be sure to use a genuine Suzuki oil filter or an equiva- lent one designed for your motorcycle.

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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 filter 2 turns or to specified torque.

Oil filter tightening torque: 20 Nm (2.0 kgf-m, 14.5 lbf-ft)

10.Replace the drain plug gasket with a new one. Reinstall the drain plug and gasket. Tighten the plug securely with a torque wrench. Pour about 2600 ml (2.7 US qt) of the specified engine oil in the filler hole. (See FUEL, ENGINE OIL AND COOLANT RECOMMENDA- TIONS section.)

Drain plug tightening torque: 23 Nm (2.3 kgf-m, 17 lbf-ft)

NOTE: About 2400 ml (2.5 US qt) of oil will be required when chang- ing oil only.

Mark top dead center

Oil filter wrench

Tighten the filter 2 turns or to specified torque.

In the position at which the filter gasket first contacts the mounting surface.

NOTICE Engine damage may occur if you use oil that does not meet Suzukis specifications.

Be sure to use the oil specified in the FUEL, ENGINE OIL AND COOLANT RECOMMENDA- TIONS section.

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11.Start the engine (while the motorcycle is outside on level ground) and allow it to idle for three minutes.

12.Turn the engine off and wait approximately three minutes. Recheck the oil level on the engine oil inspection window while holding the motorcycle vertically. If it is lower than the L line, add oil until the oil level is between the L line and the F line. Inspect the area around the drain plug and oil filter for leaks.

NOTE: If you do not have a proper oil filter wrench, have your Suzuki dealer perform this service.

ENGINE IDLE SPEED INSPECTION Inspect the engine idle speed. The engine idle speed should be 1200 1400 r/min when the engine is warm.

NOTE: If the engine idle speed is not within the specified range, ask your Suzuki dealer or a qualified mechanic to inspect and repair the motorcycle.

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THROTTLE CABLE PLAY

2.0 4.0 mm (0.08 0.16 in)

To adjust the cable play: 1. Remove the boot 1. 2. Loosen the lock nut 2. 3. Turn the adjuster 3 so that the

throttle grip has 2.0 4.0 mm (0.08 0.16 in) play.

4. Tighten the lock nut 2. 5. Reinstall the boot 1.

Throttle Cable Boots

The throttle cable has boots. Check that the boots are fit securely. Do not apply water directly to the boots when wash- ing. Wipe off dirt from the boots with a wet cloth when the boots are dirty.

WARNING Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handlebars. This can lead to loss of control and an accident.

Adjust the throttle cable play so that engine idle speed does not rise due to handlebar movement.

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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 engine coolant reser- voir. If the level is lower than the L level line, bring it up to the F level by adding specified engine coolant.

NOTE: Check the coolant level when

the engine is cold. If the engine coolant reservoir

is empty, check the radiator coolant level.

To add specified engine coolant: 1. Lift the fuel tank by referring to

the FUEL TANK LIFT section.

2. Remove the filler cap and add specified engine coolant through the filler hole until it reaches the F line. Refer to the FUEL, ENGINE OIL AND COOLANT RECOMMENDA- TIONS section.

WARNING Engine coolant is harmful or fatal if swallowed or inhaled. Solution can be poisonous to animals.

Do not drink antifreeze or cool- ant solution. If swallowed, do not induce vomiting. Immedi- ately contact a poison control center or a physician. Avoid inhaling mist or hot vapors; if inhaled, remove to fresh air. If coolant gets in eyes, flush eyes with water and seek medical attention. Wash thoroughly after handling. Keep out of the reach of children and animals.

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NOTE: Adding only water will dilute the engine coolant and reduce its effectiveness. Add specified engine coolant.

Changing The Coolant Change the coolant periodically.

NOTE: About 1950 ml (2.1 US qt) of coolant will required when fill- ing the radiator and reservoir tank.

Radiator Hose Inspection Inspect the radiator hoses for cracks, damage or engine coolant leakage. If any defects are found, ask your Suzuki dealer to replace the radiator hose with a new one.

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 needs to be replaced.

The condition and adjustment of the drive chain should be checked before each use of the motorcy- cle. Always follow the guidelines below for inspecting and servicing the chain.

WARNING Riding with the chain in poor condition or improperly adjusted can lead to an acci- dent.

Inspect, adjust, and maintain the chain properly before each ride, according to the instruc- tions in this section.

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Inspecting the Drive Chain When inspecting the chain, look for the following: Loose pins Damaged rollers Dry or rusted links Kinked or binding links Excessive wear Improper chain adjustment

If you find anything wrong with the drive chain condition or adjust- ment, correct the problem if you know how. If necessary, consult your authorized Suzuki dealer or a qualified mechanic.

Damage to the drive chain means that the sprockets may also be damaged. Inspect the sprockets for the following:

Good Worn

Excessively worn teeth Broken or damaged teeth Loose sprocket mounting nuts

If you find any of these problems with your sprocket, consult your Suzuki dealer or a qualified mechanic.

NOTE: The two sprockets should be inspected for wear when a new chain is installed and replace them if necessary.

WARNING Improperly installing a replace- ment chain, or using a joint-clip type chain, can be hazardous. An incompletely riveted master link, or a joint-clip type master link, may come apart and cause an accident or severe engine damage.

Do not use a joint-clip type chain. Chain replacement requires a special riveting tool and a high-quality, non-joint- clip type chain. Ask an autho- rized Suzuki dealer or a quali- fied mechanic to perform this work.

7-30

Drive Chain Cleaning and Oiling 1. Remove dirt and dust from the

drive chain. Be careful not to damage the seal ring.

2. Clean the drive chain with a sealed drive chain cleaner, or water and neutral detergent.

3. Use a soft brush to clean the drive chain. Be careful not to damage the seal ring even though using a soft brush.

4. Wipe off water and neutral detergent.

5. Lubricate with a motorcycle sealed drive chain lubricant or high viscosity oil (#80 90).

6. Lubricate both front and back plates of the drive chain.

7. Wipe off excess lubricant after lubricating all around the drive chain.

NOTICE Cleaning the drive chain improperly can damage seal rings and ruin the drive chain.

Do not use a volatile solvent such as paint thinner, kero- sene and gasoline.

Do not use a high pressure cleaner to clean the drive chain.

Do not use a wire brush to clean the drive chain.

NOTICE Some drive chain lubricant contains solvents and addi- tives which could damage the seal rings in the drive chain.

Use sealed drive chain lubri- cant which is specifically intended for use with sealed drive chains.

7-31

Drive Chain Adjustment

20 30 mm (0.8 1.2 in)

Inspect the drive chain slack before each use of the motorcycle.

Place the motorcycle on the side stand. The drive chain should be adjusted for 20 30 mm (0.8 1.2 in) of slack, as shown.

To adjust the drive chain, follow the procedure below:

1. Place the motorcycle on the side stand.

2. Loosen the axle nut 1. 3. Adjust the drive chain slack by

turning the right and left chain adjuster bolts 2. At the same time that the chain is being adjusted, the rear sprocket must be kept in perfect align- ment with the front sprocket. To assist you in performing this procedure, there are refer- ence marks 3 on the swing- arm and each chain adjuster which are to be aligned with each other and to be used as a reference from one side to the other.

4. Tighten the axle nut 1 securely.

5. Recheck the chain slack after tightening and readjust if nec- essary.

Rear axle nut tightening torque: 100 Nm (10.0 kgf-m, 72.5 lbf-ft)

WARNING Too much chain slack can cause the chain to come off the sprockets, resulting in an acci- dent or serious damage to the motorcycle.

Inspect and adjust the drive chain slack before each use.

CAUTION A hot muffler can burn you. The muffler will be hot enough to burn you for some time after stopping the engine.

Wait until the muffler cools before adjusting the drive chain.

7-32

CLUTCH

10 15 mm (0.4 0.6 in)

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 that the amount of clutch cable play is incorrect, adjust it in the following way:

1. Loosen the lock nut 1. 2. Turn the clutch lever adjuster

2 clockwise as far as it will go. 3. Loosen the cable adjuster lock

nut 3, and turn the cable adjuster 4 to obtain approxi- mately 10 15 mm (0.4 0.6 in) of free play at the clutch lever end as indicated.

4. Minor adjustment can now be made with the adjuster 2.

5. Tighten the lock nuts, 1 and 3, after finishing adjustment.

NOTE: Any maintenance of the clutch other than the clutch cable play should be performed by your Suzuki dealer.

BRAKES This motorcycle utilizes front and rear disk brakes. Proper operation of brake systems is vital to safe riding. Be sure to perform the brake inspection as scheduled.

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.

Brake Hose Inspection Inspect the brake hoses and hose joints for cracks, damage or brake fluid leakage. If any defects are found, ask your Suzuki dealer to replace the brake hose with a new one.

WARNING Failure to properly inspect and maintain your motorcycles brake systems can increase your chance of having an acci- dent.

Be sure to inspect the brakes before each use according to the INSPECTION BEFORE RIDING section. Always main- tain your brakes according to the MAINTENANCE SCHED- ULE.

7-33

Brake Fluid

FRONT

REAR

Check the brake fluid level in both the front and rear brake fluid res- ervoirs. If the level in either reser- voir is below the lower mark, inspect for brake pad wear and leaks.

WARNING Brake fluid will gradually absorb moisture through the brake hoses. Brake fluid with high water content lowers the boiling point and can cause brake system (including ABS) malfunction due to corrosion of brake components. Boiling brake fluid or brake system (including ABS) malfunction could result in an accident.

Replace the brake fluid every two years to maintain braking performance.

WARNING The use of any fluid except DOT4 brake fluid from a sealed container can damage the brake system and lead to an accident.

Clean filler cap before remov- ing. Use only DOT4 brake fluid from a sealed container. Never use or mix with different types of brake fluid.

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NOTE: SUZUKI highly recom- mends the use of ECSTAR brand brake fluid. ECSTAR has been specially formulated for your SUZUKI product and contributes to the desired motorcycle perfor- mance and ideal riding experi- ence.

Brake Pads

FRONT

REAR

WARNING Brake fluid is harmful or fatal if swallowed, and harmful if it comes in contact with skin or eyes. Solution can be poison- ous to animals.

If brake fluid is swallowed, do not induce vomiting. Immedi- ately contact a poison control center or a physician. If brake fluid gets in eyes, flush eyes with water and seek medical attention. Wash thoroughly after handling. Keep out of the reach of children and animals.

NOTICE Spilled brake fluid can damage painted surfaces and plastic parts.

Be careful not to spill any fluid when filling the brake fluid res- ervoir. Wipe spilled fluid up immediately.

7-35

Inspect the front and rear brake pads by noting whether or not the friction pads are worn down to the grooved wear limit line 1. If a front or rear pad is worn to the grooved wear limit line both front or both rear pads must be replaced with new ones by your authorized Suzuki dealer or quali- fied service mechanic.

NOTE: After replacing either the front or rear brake pads, the brake lever or pedal must be pumped several times. This will extend the pads to their proper position.

NOTE: Do not squeeze/depress the brake lever/pedal when the pads are not in their positions. It is difficult to push the pistons back and brake fluid leakage may result.

WARNING Failure to inspect and maintain the brake pads and replace them when recommended can increase your chance of having an accident.

If you need to replace brake pads, have your Suzuki dealer do this work. Inspect and main- tain the brake pads as recom- mended.

WARNING If you ride this motorcycle after brake system repair or brake pad replacement without pumping the brake lever/pedal, you may get poor braking per- formance which could result in an accident.

After brake system repair or brake pad replacement, pump the brake lever/pedal several times until brake pads are pressed against the brake disks and proper lever/pedal stroke and firm feel are restored.

WARNING Replacing only one of the two brake pads can result in uneven braking action and can increase your chance of having an accident.

Always replace both pads together.

7-36

Rear Brake Pedal Adjustment The rear brake pedal position must be properly adjusted at all times or the disk brake pads will rub against the disk causing dam- age to the pads and to the disk surface. Adjust the brake pedal position in the following manner:

15 25 mm (0.6 1.0 in)

1. Loosen the lock nut 1, and rotate the push rod 2 to locate the pedal 15 25 mm (0.6 1.0 in) below the top face of the footrest.

2. Retighten the lock nut 1 to secure the push rod 2 in the proper position.

3. Check the boot for deformation by torsion, and if deformed, correct the boot form by rotat- ing it back.

Rear Brake Light Switch

To adjust the brake light switch, hold the switch body and turn the adjuster so that the brake light will come on just before a pressure rise is felt when the brake pedal is depressed.

NOTICE An incorrectly adjusted brake pedal may force brake pads to continuously rub against the disk, causing damage to the pads and disk.

Follow the steps in this section to adjust the brake pedal prop- erly.

7-37

TIRES

WARNING The tires on your motorcycle form the crucial link between your motorcycle and the road. Failure to take the precautions below may result in an accident due to tire failure.

Check tire condition and pressure before each ride, and adjust pressure if neces- sary.

Avoid overloading your motorcycle.

Replace a tire when worn to the specified limit, or if you find damage such as cuts or cracks.

Always use the size and type of tires specified in this owners manual.

Balance the wheel after tire installation.

Read this section of the owners manual carefully.

WARNING Failure to perform break-in of the tires could cause tire slip and loss of control, which could result in an accident.

Use extra care when riding on new tires. Perform proper break-in of the tires referring to the BREAK-IN section of this manual and avoid hard acceler- ation, hard cornering, and hard braking for the first 100 miles (160 km).

7-38

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 and be sure the pres- sure according to the table below. Tire pressure should only be checked and adjusted before riding, since riding will heat up the tires and lead to higher inflation pressure readings.

Under-inflated tires make smooth cornering difficult, and can result in rapid tire wear. Over-inflated tires cause smaller amount of tire to be in contact with the road, which can contribute to skidding and loss of control.

NOTE: When you detect drops in tire pressure, check the tire for nails or other punctures, or a damaged wheel rim. Tubeless tires sometimes lose pressure gradually when punctured.

Tire Condition and Type Tire condition and tire type affect motorcycle performance. Cuts or cracks in the tires can lead to tire failure and loss of vehicle control. Worn tires are susceptible to puncture failures and subsequent loss of vehicle control. Tire wear also affects the tire profile, chang- ing vehicle handling characteris- tics.

Check the condition of your tires each day before you ride. Replace tires if tires show visual evidence of damage, such as cracks or cuts, or if tread depth is less than 1.6 mm (0.06 in) front, 2.0 mm (0.08 in) rear.

LOAD SOLO RIDING

DUAL RIDINGTIRE

FRONT 225 kPa

2.25 kgf/cm2

33 psi

225 kPa 2.25 kgf/cm2

33 psi

REAR 250 kPa

2.50 kgf/cm2

36 psi

290 kPa 2.90 kgf/cm2

42 psi

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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.

When you replace a tire, use a tire of the size and type listed below. If you use a different size or type of tire, motorcycle handling may be adversely affected, possibly resulting in loss of motorcycle control.

Always balance the wheel after repairing a puncture or replacing the tire. Proper wheel balance is important to avoid variable wheel- to-road contact, and to avoid uneven tire wear.

FRONT REAR

SIZE 110/80R19M/C 59V

150/70R17M/C 69V

TYPE BRIDGESTONE A40F F

BRIDGESTONE A40R F

WARNING An improperly repaired, installed, or balanced tire can cause loss of control and an accident, or can wear out sooner.

Ask your Suzuki dealer or a qualified mechanic to per- form tire repair, replacement, and balancing because proper tools and experience are required.

Install tires according to the rotation direction shown by arrows on the sidewall of each tire.

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SPOKE WHEELS (DL650XA)

Wheel Rim Inspection

Check to see if there is any dam- age like crack, distortion or bend in the wheel rim.

WARNING Failure to follow the instruc- tions below for tubeless tires may result in an accident due to tire failure. Tubeless tires require different service proce- dures than tube tires. Tubeless tires require an air-

tight seal between the tire bead and wheel rim. Special tire irons and rim protectors or a specialized tire mount- ing machine must be used for removing and installing tires to prevent tire or rim damage which could result in an air leak.

Repair punctures in tubeless tires by removing the tire and applying an internal patch.

Do not use an external repair plug to repair a puncture since the plug may work loose as a result of the cor- nering forces experienced by a motorcycle tire.

After repairing a tire, do not exceed 80 km/h (50 mph) for the first 24 hours, and do not exceed 130 km/h (80 mph) thereafter. This is to avoid excessive heat build-up which could result in a tire repair failure and tire deflation.

Replace the tire if it is punc- tured in the sidewall area, or if a puncture in the tread area is larger than 6 mm (3/16 in). These punctures cannot be repaired adequately.

WARNING Damaged rims can allow air to leak, resulting in reduced run- ning stability which can lead to accidents.

If any damage is found, replace the rim. Do not reuse the dam- aged rim by repairing or cor- recting it.

7-41

Spoke Inspection

Check the tension of spokes to verify the tightness of the spoke nipples. The tension can be checked by hitting the spokes with a small metal bar. If the spoke nip- ple is loose, its sound will be dull.

To tighten the spoke nipples prop- erly, tighten them equally to the specified torque. Loosened and overtightened spoke nipples may cause unequal tension of spokes and may result in distortion of the wheel rim. Contact your Suzuki dealer for this service to be per- formed.

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 the clutch in, move the side stand to the down position.

If the engine stops running when the side stand is moved to the down position, then the side stand/ignition interlock switch is working properly. If the engine continues to run with the side stand down and the transmission in gear, then the side stand/igni- tion interlock system is not work- ing properly. If the engine continues to run with the side stand down and the transmission in gear, then the side stand/igni- tion interlock system is not work- ing properly. Have your motorcycle inspected by an authorized Suzuki dealer or some other qualified service mechanic.

7-42

FRONT WHEEL REMOVAL 1. Place the motorcycle on the

side stand.

2. Remove the front wheel speed sensor by removing the mounting bolt.

3. Remove both brake calipers from the front forks by remov- ing two mounting bolts 1 on each of the calipers.

NOTE: Never squeeze the front brake lever with the caliper removed. It is very difficult to force the pads back into the caliper assembly and brake fluid leakage may result.

WARNING If the side stand/ignition inter- lock system is not working properly, it is possible to ride the motorcycle with the side stand in the down position. This may interfere with rider control during a left turn and could cause an accident.

Check the side stand/ignition interlock system for proper operation before riding. Check that the side stand is returned to its full up position before starting off.

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4. Loosen the axle holder bolt 2 on the left front fork.

5. Loosen the axle shaft 3 tem- porarily.

NOTE: A special tool is necessary to loosen the shaft 3. The special tool is available at a Suzuki dealer.

6. Place an accessory service stand or equivalent under the swingarm to help stabilize the rear end.

7. Carefully position a jack under the engine and raise the jack until the front wheel is slightly off the ground.

8. Turn the axle shaft 3 counter- clockwise and draw it out.

9. Slide the front wheel forward. 10.To reinstall the wheel assem-

bly, reverse the sequence described above.

11.After installing the wheel, apply the front brake several times to restore the proper lever stroke.NOTICE

Improper jacking may cause damage to the fairing or oil fil- ter.

Do not place the jack under the lower part of the fairing or the oil filter when jacking up the motorcycle.

7-44

Front axle tightening torque: 65 Nm (6.5 kgf-m, 47.0 lbf-ft)

Front axle holder bolt tightening torque: 23 Nm (2.3 kgf-m, 16.5 lbf-ft)

Front brake caliper mounting bolt tightening torque: 39 Nm (3.9 kgf-m, 28.0 lbf-ft)

NOTE: Be careful not to damage the oil seal when installing the front wheel.

WARNING Failure to extend brake pads after installing the wheel can cause poor braking perfor- mance and may result in an accident.

Before riding, pump the brake lever repeatedly until the brake pads are pressed against the brake disks and proper lever stroke and firm feel are restored. Also check that the wheel rotates freely.

WARNING Installing the front wheel in the reverse direction can be haz- ardous. The tire for this motor- cycle is directional. Therefore, the motorcycle may have unusual handling if the wheel is installed incorrectly.

Install the front wheel so that the tire rotates in the specified direction, as indicated by the arrow on the sidewall of the tire.