Suzuki DL650, DL1000 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Suzuki DL650, DL1000 Motorcycles, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Suzuki DL650, DL1000 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
“99500-36130-01E.pdf”
Suzuki DL650K4 V-strom 2004 Service Manual (English); 464 pages
“99500-36130-03E.pdf”
Suzuki DL650K4 V-strom 2004 Service Manual (English); 467 pages
“DL650K4 V-strom '04 (ES).pdf”
Suzuki DL650K4 V-strom 2004 Service Manual (Spanish); 467 pages
“99500-39230-03E.pdf”
Suzuki DL1000K2 V-strom 2002 Service Manual; 450 pages; 99500-39230-03E
“99500-39230-01E.pdf”
Suzuki DL1000K2 V-strom 2002 Service Manual; 444 pages; 99500-39230-01E
PRODUCT DETAILS:
Total Pages: 2,422 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
99500-36130-01E...2
99500-36130-01E DL650K4 SERVICE MANUAL...2
FORWORD_GROUP INDEX...3
HOW TO USE THIS MANUAL...4
TO LOCATE WHAT YOU ARE LOOKING FOR:...4
COMPONENT PARTS AND WORK TO BE DONE...4
SYMBOL...5
ABBREVIATIONS USED IN THIS MANUAL...6
01. GENERAL INFORMATION...9
WARNING/CAUTION/NOTE...10
GENERAL PRECAUTIONS...10
SUZUKI DL650K4 (’04-MODEL)...12
SERIAL NUMBER LOCATION...12
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION...12
BREAK-IN PROCEDURES...14
CYLINDER IDENTIFICATION...15
INFORMATION LABELS...16
SPECIFICATIONS...17
COUNTRY AND AREA CODES...19
02. PERIODIC MAINTENANCE...20
PERIODIC MAINTENANCE SCHEDULE...21
MAINTENANCE AND TUNE-UP PROCEDURES...23
COMPRESSION PRESSURE CHECK...48
OIL PRESSURE CHECK...49
03. ENGINE...50
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE...51
ENGINE REMOVAL AND INSTALLATION...52
ENGINE DISASSEMBLY...68
ENGINE COMPONENTS INSPECTION AND SERVICING...85
ENGINE REASSEMBLY...131
04. FI SYSTEM DIAGNOSIS...158
PRECAUTIONS IN SERVICING...160
FI SYSTEM TECHNICAL FEATURES...167
SELF-DIAGNOSIS FUNCTION...172
FAIL-SAFE FUNCTION...175
FI SYSTEM TROUBLESHOOTING...176
SENSORS...207
05. FUEL SYSTEM AND THROTTLE BODY...209
FUEL SYSTEM...210
FUEL SYSTEM...215
THROTTLE BODY AND STV ACTUATOR...222
06. COOLING AND LUBRICATION SYSTEM...243
ENGINE COOLANT...245
COOLING CIRCUIT...246
RADIATOR...247
RADIATOR CAP...250
WATER HOSE...250
COOLING FAN...251
COOLING FAN THERMO-SWITCH...252
ECT SENSOR...253
THERMOSTAT CASE ASSEMBLY...255
WATER PUMP...257
LUBRICATION SYSTEM...263
OIL COOLER...264
ENGINE LUBRICATION FLOW CHART...266
ENGINE LUBRICATION CIRCUIT...267
07. CHASSIS...269
EXTERIOR PARTS...271
FRONT WHEEL...278
FRONT FORK...285
STEERING AND HANDLEBAR...295
REAR WHEEL...304
REAR SHOCK ABSORBER...313
REAR SWINGARM...318
FRONT BRAKE...327
REAR BRAKE...337
TIRE AND WHEEL...348
DRIVE CHAIN...352
08. ELECTRICAL SYSTEM...356
CAUTIONS IN SERVICING...357
LOCATION OF ELECTRICAL COMPONENTS...360
CHARGING SYSTEM...362
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM...367
IGNITION SYSTEM...378
COMBINATION METER...384
LAMPS...391
RELAYS...392
BATTERY...395
09. SERVICING INFORMATION...398
TROUBLESHOOTING...399
WIRE HARNESS, CABLE AND HOSE ROUTING...413
TIGHTENING TORQUE...437
SERVICE DATA...441
10. EMISSION CONTROL INFORMATION...453
EMISSION CONTROL SYSTEMS...454
PAIR (AIR SUPPLY) SYSTEM INSPECTION...458
11. WIRING DIAGRAM...462
99500-36130-03E...466
99500-39230-01E...933
DL1000K2 SERVICE MANUAL...933
FORWORD_GROUP INDEX...934
HOW TO USE THIS MANUAL...935
TO LOCATE WHAT YOU ARE LOOKING FOR:...935
COMPONENT PARTS AND WORK TO BE DONE...935
SYMBOL...936
ABBREVIATIONS USED IN THIS MANUAL...937
01. GENERAL INFORMATION...939
WARNING/CAUTION/NOTE...940
GENERAL PRECAUTIONS...940
SUZUKI DL1000K2 (’02-MODEL)...942
SERIAL NUMBER LOCATION...942
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION...942
BREAK-lN PROCEDURES...944
CYLINDER IDENTIFICATION...944
INFORMATION LABELS...945
SPECIFICATIONS...946
COUNTRY AND AREA CODES...948
02. PERIODIC MAINTENANCE...949
PERIODIC MAINTENANCE SCHEDULE...950
MAINTENANCE AND TUNE-UP PROCEDURES...952
COMPRESSION PRESSURE CHECK...977
OIL PRESSURE CHECK...978
03. ENGINE...979
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE...980
ENGINE REMOVAL AND INSTALLATION...981
ENGINE DISASSEMBLY...997
ENGINE COMPONENTS INSPECTION AND SERVICING...1012
ENGINE REASSEMBLY...1056
04. FI SYSTEM...1091
PRECAUTIONS IN SERVICING...1093
FI SYSTEM TECHNICAL FEATURES...1100
FI SYSTEM PARTS LOCATION...1111
FI SYSTEM WIRING DIAGRAM...1113
SELF-DIAGNOSIS FUNCTION...1114
FAIL-SAFE FUNCTION...1117
FI SYSTEM TROUBLESHOOTING...1118
FUEL SYSTEM...1142
THROTTLE BODY AND STV ACTUATOR...1150
SENSOR...1165
05. COOLING AND LUBRICATION SYSTEM...1169
ENGINE COOLANT...1170
COOLING CIRCUIT...1171
RADIATOR...1172
RADIATOR RESERVOIR TANK...1174
RADIATOR CAP...1174
WATER HOSE...1175
COOLING FAN...1176
COOLING FAN THERMO-SWITCH...1177
ENGINE COOLANT TEMPERATURE SENSOR...1178
THERMOSTAT...1179
WATER PUMP...1181
LUBRICATION SYSTEM...1186
OIL COOLER...1186
ENGINE LUBRICATION FLOW CHART...1188
ENGINE LUBRICATION CIRCUIT...1189
06. CHASSIS...1190
EXTERIOR PARTS...1191
FRONT WHEEL...1197
FRONT FORK...1203
STEERING AND HANDLEBAR...1213
REAR WHEEL...1222
REAR SHOCK ABSORBER...1231
REAR SWINGARM...1236
FRONT BRAKE...1245
REAR BRAKE...1255
CLUTCH RELEASE CYLINDER AND MASTER CYLINDER...1266
TIRE AND WHEEL...1273
07. ELECTRICAL SYSTEM...1276
CAUTIONS IN SERVICING...1277
LOCATION OF ELECTRICAL COMPONENTS...1279
CHARGING SYSTEM...1281
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM...1285
IGNITION SYSTEM...1292
COMBINATION METER...1297
LAMPS...1304
RELAYS...1305
BATTERY...1308
08. SERVICING INFORMATION...1311
TROUBLESHOOTING...1312
WIRE HARNESS, CABLE AND HOSE ROUTING...1324
SPECIAL TOOLS...1342
TIGHTENING TORQUE...1345
SERVICE DATA...1349
09. EMISSION CONTROL INFORMATION...1359
EMISSION CONTROL SYSTEMS...1360
PAIR (AIR SUPPLY) SYSTEM INSPECTION...1364
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING...1366
HEATED OXGEN SENSOR (HO2S) INSPECTION...1367
HEATED OXGEN SENSOR WIRE ROUTING...1368
EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33)...1369
CANISTER HOSE ROUTING (Only for E-33)...1370
10. WIRING DIAGRAM...1371
99500-39230-03E...1377
0 Foreword...1377
1 General Info...1387
2 Periodic Maintenance...1397
3A Engine...1429
3B Engine...1491
4 Fuel Injection...1541
5 Cooling & Lubrication...1621
6A Chassis...1643
6B Chassis...1699
7 Electrical...1729
8 Servicing...1765
9 Emission Control...1813
10A Wiring...1823
10B Wiring...1825
10C Wiring...1826
DL650K4 V-strom '04 (ES)...1827
CAP II MANTENIMIENTO PERIODICO...1844
CAP III MOTOR...1876
CAP IV DIAGNOSTICO DEL SISTEMA FI...1986
CAP V SISTEMA DE COMBUSTIBLE...2039
CAP VI SISTEMA DE REFRIGERACION Y LUBRICACION...2075
CAP VII CHASIS...2101
CAP VIII SISTEMA ELECTRICO...2189
CAP IX INFORMACION DE SERVICIO...2231
CAP X CONTROL DE EMISIONES...2283
CAP XI DIAGRAMA DE CABLEADO...2292
Parts Catalog...2294
Gasket Set...2294
Front Cylinder Head...2296
Rear Cylinder Head...2298
Cylinder...2300
Crankcase...2302
Crankcase Cover...2304
Crankshaft...2306
Sharter Clutch...2308
Cam Shaft/Valve...2310
Cam Chain...2312
Throttle Body...2314
Fuel Delivery Pipe...2316
Air Cleaner...2318
Muffler...2320
Oil Pump...2322
Fuel Pump...2324
Oil Cooler...2326
Water Pump...2328
Radiator...2330
Radiator Hose...2332
2nd Air...2334
Clutch...2336
Transmission...2338
Gear Shifting...2340
Starting Motor...2342
Magneto...2344
Battery...2346
Electrical...2348
Speedometer...2350
Head Lamp...2352
Turnsignal Lamp...2354
Tail Lamp...2356
Wiring Harness...2358
Handle Switch...2360
Frame...2362
Stand...2364
Footrest...2366
Carrier...2368
Fuel Tank...2370
Front Bracket...2372
Evapo System...2374
Frame Cover...2376
Front Fender...2378
Handle Bar...2380
Handle Lever...2382
Rear Fender...2384
Cowling Body...2386
Cowl Installation Parts...2388
Side Cowling...2390
Side Cowling Installation Parts...2392
Label...2394
Seat...2396
Seat Tail Cover...2398
Front Damper...2400
Steering Stem...2402
Front Wheel...2404
Front Caliper...2406
Front Brake Hose...2408
Front Master Cylinder...2410
Rear Swinging Arm...2412
Rear Cushion Lever...2414
Rear Wheel...2416
Rear Caliper...2418
Rear Master Cylinder...2420
Optional...2422
Technical Information...2424
Suzuki DL650, DL1000 Repair Service Manual
