Suzuki DR650SEX 1999 Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 89164

Etiquetas: 1999 DR650SEX Misc Motorcycle Motorcycles Suzuki

Variantes de producto

Descripción

The 1999 Suzuki DR650SEX is a versatile dual-sport motorcycle renowned for its robust air-cooled engine, durable construction, and comfortable riding position. Building on Suzuki's legacy of producing reliable and capable off-road machines, this model excels in adventure touring, commuting, and general utility riding. Its design emphasizes simplicity and resilience, featuring a 644cc single-cylinder engine, a 5-speed transmission, and long-travel suspension suitable for varied terrains. The DR650SEX offers a practical and dependable riding experience, making it a popular choice for riders seeking a capable all-around motorcycle. This comprehensive English-language Service Repair Manual provides detailed, step-by-step instructions for the maintenance, repair, and troubleshooting of the 1999 Suzuki DR650SEX. Covering all major systems including the engine, transmission, chassis, brakes, and electrical components, the manual offers guidance on routine servicing, component overhauls, and diagnostic procedures. It is designed to assist both home mechanics and professional technicians in keeping the motorcycle in optimal condition, ensuring its longevity and performance. The manual includes essential technical specifications, torque settings, and clear diagrams to facilitate accurate and efficient work.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DR650SEX

Year:

Product Name:

Suzuki DR650SEX 1999 Service Repair Manual PDF Download

👋 Introduction

Market Position

Segment:

Dual-sport motorcycle, known for its versatility and reliability in both on-road and off-road applications

Competitive Analysis

Competitors:

Yamaha XT500/XT600, Honda XR600R/Transalp, Kawasaki KLR650

Key Features

Design:

Robust air-cooled engine, simple yet durable construction, long-travel suspension, comfortable riding position

Purpose:

Adventure touring, commuting, off-road riding, general utility

📋 Manual Details

Coverage Areas

Primary Coverage:

Comprehensive service and repair for the 1999 Suzuki DR650SEX

Page Count

Estimated Page Count:

300-400

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, tuning, diagnostics, lubrication, cooling system, fuel system (carburetor), exhaust system, engine management (ignition)

Transmission:

Clutch, gearbox, shift mechanism, lubrication, disassembly and assembly

Chassis:

Frame, suspension (front forks, rear shock absorber), steering system, wheels, spokes, bearings

Brakes:

Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, rotor maintenance

Electrical:

Ignition system, lighting, charging system (stator, regulator/rectifier), starting system (starter motor, battery), wiring diagrams, troubleshooting electrical faults

Bodywork:

Body panels, seat, fuel tank, fenders, handlebars, controls, decals

Procedures Included

Maintenance:

Routine inspections, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance adjustment, brake fluid flush

Repair:

Engine rebuild, transmission repair, carburetor overhaul, suspension rebuild, brake system repair, electrical component replacement

Troubleshooting:

Diagnostic procedures for common issues, fault finding, symptom-based troubleshooting guides

Torque Specifications:

Torque settings for all critical fasteners and components

Technical Depth

Depth:

Detailed, step-by-step instructions suitable for home mechanics and professional technicians

📊 Manual Specifications

File Format

Quality:

High-resolution, searchable PDF with clear diagrams and text

Print Quality

Print Readability:

Optimized for printing, allowing clear reproduction of all diagrams and text

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Type:

4-stroke, SOHC, 4-valve, single-cylinder, air-cooled

Displacement:

644 cc (39.3 cu in)

Bore X Stroke:

100.0 mm x 82.0 mm (3.94 in x 3.23 in)

Compression Ratio:

9.5:1

Performance

Horsepower:

Approx. 46 hp (34 kW) @ 6,400 rpm (spec varies)

Torque:

Approx. 37 lb-ft (50 Nm) @ 4,500 rpm (spec varies)

Fuel System

Carburetor:

Mikuni BST40, 40mm CV carburetor

Fuel Type:

Unleaded gasoline, octane rating 87 or higher recommended

Lubrication

Oil Capacity:

2.1 L (2.2 US qt, 1.8 Imp qt) with filter change

Oil Type:

SAE 10W-40 API SG or SH, JASO MA

Ignition

System:

Digital CDI (Capacitor Discharge Ignition)

🔧 Transmission

Standard

Type:

5-speed constant mesh

Clutch:

Wet, multi-plate

Final Drive:

O-ring sealed chain

Features

Gear Ratios:

1st: 2.235, 2nd: 1.590, 3rd: 1.235, 4th: 1.000, 5th: 0.857

Transmission Fluid

Type:

API GL-4, SAE 80W-90 gear oil

📐 Dimensions

Exterior

Length:

2,255 mm (88.8 in)

Width:

895 mm (35.2 in)

Height:

1,215 mm (47.8 in)

Wheelbase:

1,470 mm (57.9 in)

Ground Clearance:

260 mm (10.2 in)

Seat Height:

870 mm (34.3 in)

Weights

Dry Weight:

163 kg (360 lbs)

Wet Weight:

Approx. 180 kg (397 lbs)

Fuel Capacity:

13.0 L (3.4 US gal, 2.9 Imp gal)

Wheels And Tires

Front Tire:

90/90-21 M/C 54S, tubed

Rear Tire:

130/90-17 M/C 63S, tubed

Front Wheel:

Spoked, 21-inch

Rear Wheel:

Spoked, 17-inch

🛡️ Safety Features

Ratings

Crash Safety:

Not formally rated as per modern automotive standards; rider safety depends on protective gear and riding practices.

Active Features

Braking:

Hydraulic disc brakes front and rear

Passive Features

Frame Construction:

Steel semi-double cradle frame

💡 Technology Features

Infotainment

Features:

Basic instrumentation: speedometer, odometer, trip meter, neutral indicator, high beam indicator. No advanced infotainment systems.

Driver Assistance

Features:

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 km (1,800 miles) or 6 months, whichever comes first

Oil Filter Replacement Interval:

Every 3,000 km (1,800 miles) or at every oil change

Air Filter Cleaning Interval:

Every 3,000 km (1,800 miles), clean and re-oil

Spark Plug Replacement Interval:

Every 6,000 km (3,600 miles) or as needed

Valve Clearance Check Interval:

Every 6,000 km (3,600 miles)

Chain Lubrication Interval:

Every 1,000 km (600 miles) or after riding in wet conditions

Fluid Specifications

Brake Fluid:

DOT 3 or DOT 4

Coolant:

N/A (Air-cooled engine)

Known Issues

Common Problems:

Carburetor adjustment can be finicky, some vibration at higher RPMs, potential wear on suspension components over time, clutch wear with heavy use.

Diagnostic Tips:

Refer to the manual for specific troubleshooting steps for hard starting, poor acceleration, or electrical gremlins. Carburetor cleaning and jetting are common maintenance items.

📚 Vehicle History

Brand Heritage

Legacy:

Suzuki has a long history of producing reliable and capable motorcycles, particularly in the dual-sport and off-road segments.

Model Evolution

Predecessors:

The DR650 lineage began with earlier models like the DR500 and DR600, evolving to incorporate modern features and improved performance.

Updates:

The 1999 model represents an established iteration of the DR650, having received incremental updates in the years prior, including the switch to a 650cc engine and improvements to suspension and ergonomics.

Production

Manufacturing Location:

Japan

Production Years:

The DR650 series has been in continuous production since the mid-1980s, with the DR650SEX being a specific variant within that family.

🏆 Awards & Recognition

Recognitions

Durability Reputation:

Widely recognized for its robust engineering and long-term durability, making it a popular choice for adventure and utility riders.