Introduction to repair manual motorcycle Suzuki DL650 V-Strom (2004-2011)

Component parts and work to be done
Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided. Example: Front wheel 1 Brake disc 2 Dust seal 3...

Symbols indicating instructions for servicing
Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. SYMBOL DEFINITION SYMBOL DEFINITION Torque control required. Data beside it...

Abbreviations used in this manual
A ABDC : After Bottom Dead Center AC : Alternating Current ACL : Air Cleaner, Air Cleaner Box API : American Petroleum Institute ATDC : After Top Dead Center ATM Pressure : Atmospheric Pressure Atmospheric Pressure Sensor (APS) A/F : Air Fuel...

SAE-to-former Suzuki term
This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION A...

Wire color codes
В Black Gr Gray R Red Bl Blue Lbl Light blue W White Br Brown Lg Light green Y Yellow Dg Dark green О Orange G Green P Pink B/Bl Black with Blue tracer B/Br Black with Brown tracer B/G Black with Green tracer B/O Black with Orange tracer B/R Black...

Warning/caution/note
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words....

Serial number location
Right side Left side Difference between photographs and actual motorcycles depends on the markets. The frame serial number or V.I.N. (Vehicle Identification Number) (1) is stamped on the right side of the steering head. The engine serial number (2)...

Fuel, oil and engine coolant recommendation
Fuel (for USA and Canada) Use only unleaded gasoline of at least 87 pump octane (R+M)/2 or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol with...

Break-in procedures
During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to "BREAK-IN" before subjecting the engine to maximum stresses. The future...

Cylinder identification
The two cylinders of this engine are identified as NO.1 and NO.2 cylinder, as viewed from front to rear.

Information labels
DL650 DL650UE 1 Noise label A (For E-03, 24, 33) 2 Information label A (For E-03, 28, 33) 3 Vacuum hose routing label A (For E-33) 4 Fuel caution label A (For E-02, 24) 5 Manual notice label A (For E-03, 33) 6 Frame caution plate A A 7 Screen...

Specifications of motorcycle
DIMENSIONS AND DRY MASS Overall length 2 290 mm (90.2 in) Overall width 840 mm (33.1 in) Overall height 1 390 mm (54.7 in) Low windshield position (STD) 1 420 mm (55.9 in) Middle windshield position 1 450 mm (57.1 in) High windshield position...

Country and area codes
The following codes stand for the applicable country (-ies) and area (-s). MODEL CODE COUNTRY or AREA DL650 E-02 U.K. E-03 U.S.A. (Except for California) E-19 EU E-24 Australia E-28 Canada E-33 California (U.S.A.) DL650-UE E-19 EU

Special tools for motorcycle repair
09900-18710 Hexagon bit 12 mm 09900-20101, 09900-20102 Vernier calipers 09900-20202 Micrometer (25-50 mm) 09900-20204 Micrometer (75-100 mm) 09900-20205 Micrometer (0-25 mm) 09900-20508 Cylinder gauge set 09900-20602 Dial gauge (1/1000 mm, 1 mm)...

Tightening torques of fastening elements
Engine ITEM N·m kgf·m lb·ft Cylinder head cover bolt 14 1.4 10.0 Spark plug 11 1.1 8.0 Camshaft journal holder bolt 10 1.0 7.0 Cam chain tension adjuster cap bolt 8 0.8 5.7 Cam chain tension adjuster mounting bolt 10 1.0 7.0 Cylinder head bolt...

Service data of motorcycle
Valve + guide Unit: mm (in) ITEM STANDARD LIMIT Valve diam. IN. 31 (1-2) — EX. 25.5 (1.0) — Valve clearance (when cold) IN. 0.10-0.20 (0.004 - 0.008) — EX. 0.20 - 0.30 (0.008-0.012) — Valve guide to valve stem clearance IN. 0.020 - 0.047...