🏷️ Basic Information

Make:

Suzuki

Model:

DR650

Model Variant:

DR650 (often referred to as DR650S or DR650SE depending on specific features)

Years Covered:

1991, 1992, 1993

Generation Designation:

First Generation (DR650S)

Engine Code Prefix:

DR650SP (likely for the early models, specific codes may vary)

👋 Introduction

Segment:

Dual-sport motorcycle

Target Audience:

Mechanics and DIY enthusiasts

Competitors Early 90S:

Honda Transalp, Yamaha Tenere, Kawasaki KLR650

Vehicle Strengths:

Robust air-cooled engine, reliable chassis, versatile for on-road and off-road use, simplicity of maintenance

Manual Value Proposition:

Provides comprehensive, detailed, and easy-to-understand repair information to empower owners and technicians

📋 Manual Details

Primary Coverage:

Repair, Maintenance, Service, Troubleshooting

Diagnostic Coverage:

Troubleshooting, Diagnosis, Service Data, Specifications

Component Coverage:

All vehicle components, systems, and assemblies

Total Pages:

280+

Type:

Workshop Service Repair Manual

Purpose:

Guidance for repair interventions, maintenance, adjustments, removal, installation, disassembly, and assembly

Language:

English

Format:

PDF

Download Method:

Instant Download

📖 Manual Coverage

Engine:

Detailed coverage of engine operation, disassembly, assembly, adjustment, and troubleshooting

Fuel System:

Carburetor system, fuel tank, fuel lines, fuel pump (if applicable)

Ignition System:

Ignition timing, spark plugs, CDI unit, coils

Transmission:

Gearbox operation, disassembly, assembly, adjustment, maintenance

Clutch:

Clutch operation, adjustment, replacement, maintenance

Suspension:

Front forks (telescopic), rear shock absorber, linkages, adjustment, service, rebuild

Brakes:

Front and rear brake systems (likely disc brakes), hydraulic systems, pad replacement, fluid changes, caliper service

Wheels And Tires:

Wheel bearing maintenance, spoke tension adjustment (if applicable), tire pressure, tire replacement

Electrical System:

Wiring diagrams, lighting, battery, charging system (stator, regulator/rectifier), starter motor, fuses

Cooling System:

Air-cooled engine (no coolant specifications, focus on airflow and heat dissipation)

Exhaust System:

Muffler, header pipe, emissions controls (if applicable)

Frame And Bodywork:

Frame inspection, body panel removal/installation, seat, fuel tank, fenders

Controls:

Throttle, clutch, brake levers, footpegs, shifter linkage

Routine Maintenance:

Oil changes, filter replacement, chain adjustment, spark plug checks, air filter cleaning/replacement

Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon issues

Disassembly Assembly:

Comprehensive guides for taking apart and reassembling all major components

Adjustments:

Carburetor adjustments, clutch and brake lever adjustments, suspension adjustments

Rebuilds:

Engine rebuild procedures, carburetor rebuilds, suspension fork rebuilds

Component Replacement:

Instructions for replacing parts such as brake pads, cables, bearings, etc.

Depth:

Detailed, comprehensive step-by-step procedures from bumper to bumper

Diagrams Illustrations:

Pictorial diagrams, exploded diagrams, drawings, and photos for clear guidance

Special Tools:

Reference to and illustration of required special service tools

Specifications:

Service data, factory specifications, allowable limits, tightening torques

Wear Limits:

Information on wear limits for component replacement

📊 Manual Specifications

Format:

PDF

Requirement:

Adobe Reader

Compatibility:

Windows, Mac, Linux OS

Printability:

Yes, all pages are printable

Readability:

Designed for easy reading, simple explanation

Binding:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

Completeness Status:

100% complete and intact, no missing/corrupt pages/sections

⚙️ Engine Specifications

Engine Type:

4-stroke, SOHC, 4-valve, Air-cooled

Displacement:

644 cc (Cubic Centimeters)

Bore X Stroke:

Standard specification typically around 98.0 mm x 83.0 mm (requires specific manual lookup for exact figures)

Compression Ratio:

Typically around 9.0:1 to 9.5:1 (requires specific manual lookup for exact figures)

Engine Oil Capacity:

Approximately 2.6 liters (with filter change) - requires manual confirmation

Horsepower:

Typically in the range of 45-50 HP (Horsepower) at the crankshaft (requires specific manual lookup for exact figures)

Torque:

Typically in the range of 50-55 Nm (Newton-meters) at the crankshaft (requires specific manual lookup for exact figures)

Carburetor Type:

Single Mikuni carburetor, likely a VM36 or similar (requires specific manual lookup for exact model and jetting)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

Around 13-15 liters (requires specific manual lookup for exact figure)

🔧 Transmission

Type:

5-speed manual transmission

Transmission Options:

N/A (No automatic transmission offered)

Final Drive:

Chain drive

Clutch Type:

Wet, multi-plate, cable-operated

Transmission Oil Type:

API SG, SAE 20W-40 or 10W-40 motorcycle specific oil (requires manual confirmation)

📐 Dimensions

Length:

Varies slightly by year, typically around 2255 mm (requires specific manual lookup)

Width:

Varies slightly by year, typically around 800 mm (requires specific manual lookup)

Height:

Varies slightly by year, typically around 1200 mm (requires specific manual lookup)

Wheelbase:

Around 1475 mm (requires specific manual lookup)

Dry Weight:

Approximately 164 kg (requires specific manual lookup)

Wet Weight:

Approximately 180-185 kg (with fluids, requires specific manual lookup)

🛡️ Safety Features

Safety Certification:

Meets relevant motorcycle safety standards for its era

Braking System:

Hydraulic disc brakes front and rear for reliable stopping power

Suspension Stability:

Telescopic front forks and single rear shock absorber provide stable handling

Lighting:

Headlight, taillight, brake light, turn signals for visibility

💡 Technology Features

Infotainment System:

N/A (No electronic infotainment systems on this model)

Electronic Aids:

N/A (No electronic rider aids like ABS or traction control on these early models)

Connectivity Features:

N/A (No connectivity features)

🔧 Maintenance

Oil Change Interval:

Typically every 3,000-5,000 km or 6 months, whichever comes first (refer to manual for precise interval)

Chain Lubrication Cleaning:

Every 500-1000 km, or after riding in wet conditions

Air Filter Cleaning:

Every 3,000-5,000 km, or more frequently in dusty conditions

Spark Plug Check:

Every 3,000-5,000 km

Valve Clearance Check:

Typically around 6,000-12,000 km (requires specific manual lookup)

Engine Oil Specification:

API SG, SAE 20W-40 or 10W-40 motorcycle specific oil (requires manual confirmation for exact grade and API rating)

Brake Fluid Specification:

DOT 3 or DOT 4 (requires manual confirmation for exact specification)

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, chain and sprockets, brake pads

Engine Reliability:

Generally considered a very reliable engine, but routine maintenance is key to longevity.

Suspension Performance:

Early models may have basic suspension; upgrades are common for more demanding riding.

📚 Vehicle History

Suzuki Motorcycle Legacy:

Suzuki has a long history of producing reliable and capable motorcycles, including many successful dual-sport and off-road models

Dr650 Lineage:

The DR650 platform has been a cornerstone of Suzuki's dual-sport offerings, evolving over decades. The 1991-1993 models represent the early iteration of the modern DR650, known for its simplicity and robust design.

Manufacturing Origin:

Likely manufactured in Japan (Suzuki's primary manufacturing base)

🏆 Awards & Recognition

Industry Acclaim:

The DR650 series has consistently been praised for its durability, affordability, and go-anywhere capability, making it a popular choice for adventure touring and commuting.

User Reviews:

Highly regarded by owners for its reliability and ease of maintenance.

Manual Quality Certification:

Manual is described as 100% complete and intact, ensuring high quality and usability.