Segment:
Lightweight Adventure/Dual-Sport Motorcycle
Target Audience:
Riders seeking versatility for commuting, touring, and light off-road use.
Competitors:
Competed with bikes like the Honda Transalp, Kawasaki KLR650, and Yamaha Ténéré during its production run.
Engine:
Proven, reliable air-cooled SOHC V-twin (actually SOHC single-cylinder) engine known for its simplicity and durability.
Handling:
Nimble handling and comfortable ergonomics suitable for long rides and varied terrain.
Design:
Practical design with a substantial fuel tank and wind protection for touring comfort.
Engine:
Complete disassembly, assembly, troubleshooting, and repair procedures for the 641cc air-cooled SOHC 4-valve engine.
Fuel System:
Carburetor (Mikuni BSR33) tuning, cleaning, rebuilding, and synchronization. Fuel tank, fuel lines, and petcock maintenance.
Ignition System:
CDI ignition system analysis, troubleshooting, component testing, and specifications.
Transmission:
5-speed constant mesh gearbox maintenance, clutch service, and gearbox component inspection.
Cooling System:
Air-cooling system analysis and component inspection. Oil cooler and oil filter maintenance.
Chassis:
Frame inspection, fork and shock absorber service, wheel bearings, steering head bearings, and swingarm maintenance.
Braking System:
Front and rear hydraulic disc brake systems, including caliper overhaul, master cylinder service, brake fluid replacement, and bleeding procedures.
Electrical System:
Wiring diagrams, starter motor, alternator, battery, lighting system, horn, and instrument cluster troubleshooting.
Bodywork:
Fairing removal and installation, seat, fuel tank, fenders, and other body component service.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment and lubrication, spark plug replacement, air filter cleaning/replacement, and general inspections.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon issues across all vehicle systems.
Repair:
Detailed step-by-step instructions for component disassembly, repair, reassembly, and adjustment.
Tune Ups:
Comprehensive tune-up procedures including valve clearance adjustment, carburetor synchronization, and ignition timing checks.
Engine Rebuild:
Full engine rebuild procedures, including piston and cylinder inspection, crankshaft and connecting rod service.
Electrical Diagnostics:
Fault finding for electrical circuits, including using test equipment and interpreting wiring diagrams.
Suspension Service:
Front fork oil changes and seal replacement, rear shock absorber inspection.
Level Of Detail:
Factory-level technical detail suitable for professional mechanics and experienced DIY enthusiasts.
Diagnostic Charts:
Includes symptom-based diagnostic charts for efficient troubleshooting.
Torque Specifications:
Comprehensive list of all critical torque specifications for fasteners and engine components.
Clearances:
Precise specifications for valve clearances, bearing clearances, and other critical operating clearances.
Wiring Diagrams:
Detailed, schematic wiring diagrams for the entire electrical system.
File Type:
Portable Document Format (PDF)
Searchability:
Likely text-searchable if converted from OCR'd documents.
Resolution:
Variable, typically scanned from original factory manuals, aiming for clear text and diagrams.
Diagrams Quality:
Includes detailed diagrams, exploded views, and illustrations crucial for repair.
Binding:
N/A (Digital PDF format)
Paper Type:
N/A (Digital PDF format)
Completeness:
Comprehensive coverage intended for factory-level repair and maintenance.
Engine Type:
Air-cooled, 4-stroke, SOHC, 4-valve, single-cylinder
Displacement:
641 cc (39.1 cu in)
Bore X Stroke:
94.0 mm x 94.0 mm (3.70 in x 3.70 in)
Horsepower:
Approx. 47 hp @ 6,500 rpm (Varies slightly by region/year)
Torque:
Approx. 55 Nm (40.5 lb-ft) @ 5,000 rpm (Varies slightly by region/year)
Carburetor:
Mikuni BSR33 (single, diaphragm type)
Fuel Capacity:
18 Liters (4.75 US gal)
Oil Type:
SAE 10W-40 API SG
Oil Capacity W Filter:
3.0 Liters (3.17 US qt)
Oil Filter Part Number:
Suzuki OE: 16510-05240, HiFloFiltro: HF138
Crash Safety:
As a motorcycle, specific crash ratings are not applicable in the same way as cars. Focus is on rider protection via design and available gear.
Brakes:
Front: Hydraulic disc; Rear: Hydraulic disc. Designed for reliable stopping power.
Suspension:
Telescopic front forks and monoshock rear suspension provide stable handling and absorb road imperfections.
Lighting:
Halogen headlight and full array of tail lights, brake lights, and turn signals for visibility.
Ergonomics:
Upright riding position and comfortable seat contribute to rider fatigue reduction on long journeys.
Audio:
None (standard on this model).
Navigation:
None (standard on this model).
ABS:
Not available on this model.
Traction Control:
Not available on this model.
Bluetooth:
Not available on this model.
Dashboard:
Analog speedometer, tachometer, odometer, trip meter, and indicator lights (neutral, turn signals, high beam).
Oil Change:
Every 4,000 km (2,500 miles) or 6 months, whichever comes first.
Oil Filter Change:
At every oil change.
Air Filter Inspection:
Every 4,000 km (2,500 miles); clean or replace as needed.
Spark Plug Replacement:
Every 8,000 km (5,000 miles).
Valve Clearance Check:
Every 8,000 km (5,000 miles).
Brake Fluid Change:
Every 2 years or as needed.
Chain Lubrication Adjustment:
Every 1,000 km (600 miles) or after washing/riding in rain.
Engine Oil:
SAE 10W-40 API SG or JASO MA rated.
Brake Fluid:
DOT 3 or DOT 4.
Coolant:
Not applicable (air-cooled engine).
Carburetor Icing:
Can be susceptible to carburetor icing in cold, humid conditions due to the placement of the intake and vent.
Oil Leaks:
Occasional reports of minor oil leaks from valve cover or oil cooler seals, easily addressed with gasket replacement.
Starter Clutch:
Rare instances of starter clutch wear, typically related to excessive engine starting attempts or age.
Suspension Wear:
As with most bikes of this age, fork seals and rear shock absorbers may require service or replacement due to normal wear and tear.
