Segment:
Dual-sport / Adventure touring motorcycle.
Target Audience:
Owners and mechanics seeking comprehensive maintenance and repair information for the Suzuki XF650 Freewind.
Key Competitors Era:
Honda Transalp, Kawasaki KLR650, Yamaha XT600/XT660 series.
Vehicle Philosophy:
Versatile, reliable, and affordable dual-purpose motorcycle suitable for commuting and light adventure touring.
Manual Value Proposition:
Provides factory-level technical data, enabling owners to perform detailed maintenance and repairs, extending the life and performance of the motorcycle.
Engine:
Complete engine disassembly, assembly, inspection, tuning, and troubleshooting for the GS500-derived engine.
Fuel System:
Carburetor inspection, cleaning, adjustment, and overhaul; fuel tank, fuel lines, and fuel pump (if applicable) servicing.
Ignition System:
Ignition timing, spark plug specifications, CDI unit, and related components diagnostics.
Transmission:
Gearbox inspection, repair, clutch operation, and maintenance procedures.
Chassis:
Frame inspection, alignment checks, and related components.
Suspension:
Front fork (telescopic) overhaul, oil changes, seal replacement, and rear shock absorber servicing.
Brakes:
Front and rear brake system servicing, including disc and pad replacement, caliper overhaul, hydraulic fluid bleeding, and master cylinder inspection.
Electrical System:
Wiring diagrams for all circuits, battery maintenance, charging system (alternator, regulator/rectifier), lighting, starter motor, and instrumentation.
Cooling System:
Oil cooler system inspection and maintenance.
Exhaust System:
Exhaust pipe and muffler inspection and repair.
Wheels And Tires:
Wheel bearing inspection and replacement, tire pressure recommendations, and tire replacement guidelines.
Bodywork:
Fairing removal and installation, seat, tank, and side cover servicing.
Maintenance:
Routine maintenance checks, oil changes, filter replacements, chain adjustment, and lubrication schedules.
Troubleshooting:
Diagnostic flowcharts and common problem identification for engine, electrical, and mechanical issues.
Repair:
Step-by-step repair instructions for all major components, including engine rebuilds and electrical system diagnosis.
Disassembly Reassembly:
Detailed instructions for complete disassembly and reassembly of the motorcycle and its systems.
Specifications Settings:
Torque specifications, valve clearances, ignition timing, carburetor settings, and other critical adjustments.
Diagnostic Capabilities:
Advanced diagnostic procedures for electrical systems and engine performance issues.
Rebuild Procedures:
Comprehensive instructions for engine, gearbox, and suspension component rebuilds.
Wiring Diagrams:
Detailed and comprehensive wiring diagrams illustrating all electrical circuits.
Visual Guidance:
Hundreds of photos to guide users through disassembly and reassembly processes.
Searchability:
Likely text-searchable, enabling quick information retrieval.
Print Capability:
Fully printable for physical reference.
Image Resolution:
GOOD QUALITY, ensuring clarity of diagrams and photos.
Binding:
Not specified, but implied to be a standard digital file format.
Paper Quality For Printing:
Assumed standard paper quality for printing.
Bookmarking:
Bookmarked for easy navigation through sections.
Engine Type:
Four-stroke, air-cooled, SOHC, 2-valve per cylinder, V-twin (derived from GS500).
Displacement:
644 cc (39.3 cu in)
Bore X Stroke:
72.0 mm x 78.0 mm (2.83 in x 3.07 in)
Horsepower:
Approximately 47 hp (35 kW) at 7,000 rpm (exact figure may vary slightly by market and year).
Torque:
Approximately 54 Nm (40 lb-ft) at 5,500 rpm (exact figure may vary slightly by market and year).
Carburetion:
Two Mikuni BST36 carburetors.
Fuel Tank Capacity:
18 liters (4.8 US gal).
Oil Capacity:
3.2 liters (3.4 US qt) with filter change.
Oil Type Specification:
API SG or SH, SAE 10W-40. (Manual will specify exact grades and approvals).
Overall Length:
Approximately 2,215 mm (87.2 in).
Overall Width:
Approximately 855 mm (33.7 in).
Overall Height:
Approximately 1,295 mm (51.0 in).
Wheelbase:
Approximately 1,470 mm (57.9 in).
Dry Weight:
Approximately 161 kg (355 lbs).
Curb Weight:
Approximately 180 kg (397 lbs) (with fluids).
Load Capacity:
Typically around 200 kg (440 lbs) including rider and luggage.
Crash Test Results:
N/A (Motorcycles are not subjected to standardized crash test ratings like cars).
Braking System:
Front: Single disc with twin-piston caliper. Rear: Single disc with single-piston caliper.
Lighting:
Halogen headlight, tail light, brake lights, turn signals.
Frame Construction:
Steel, double-cradle frame for stability.
Ergonomics:
Upright riding position promoting rider awareness and control.
Oil Change Interval:
Recommended every 4,000-6,000 km (2,500-3,700 miles) or 6 months, whichever comes first. (Refer to manual for precise interval).
Air Filter Cleaning Interval:
Recommended every 8,000-10,000 km (5,000-6,000 miles). (Refer to manual for precise interval).
Spark Plug Replacement:
Recommended every 12,000-16,000 km (7,500-10,000 miles). (Refer to manual for precise interval).
Valve Clearance Check:
Recommended every 10,000-12,000 km (6,000-7,500 miles). (Refer to manual for precise interval and adjustment procedure).
Brake Fluid:
DOT 4 (Manual will specify exact type and replacement interval).
Coolant:
Not applicable (air-cooled engine with oil cooler).
Transmission Oil:
Manual will specify grade and capacity for gearbox oil.
Common Wear Items:
Clutch plates, brake pads, fork seals, wheel bearings, and swingarm bearings are typical wear items on a motorcycle of this age and type.
Potential Electrical Issues:
Corrosion in connectors, aging voltage regulator/rectifier, and starter solenoid issues can occur on older models. Manual will detail troubleshooting.
Engine Performance Notes:
Carburetor synchronization and cleaning are crucial for optimal performance. Manual provides detailed procedures.
Manufacturer:
Suzuki Motor Corporation, Japan.
Brand Specialty:
Known for reliable, performance-oriented motorcycles across various segments.
Discontinuation Year:
2002
Key Changes During Production:
Primarily cosmetic color scheme updates; significant mechanical changes were minimal across the production run.
Manufacturing Location:
Japan (Assumed, consistent with Suzuki's primary motorcycle manufacturing).
