Suzuki DL 650 V-Storm 2004-2009 Factory Service Repair Manual Pdf

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This factory service repair manual covers the Suzuki DL650 V-Strom, also known as the V-Strom 650, for the model years 2004 through 2009. Designed as an adventure touring motorcycle, the...

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Taper: Motorcycle

Distributeur:

UGS: 144458

Mots clés: 2004 2005 2006 2007 2008 2009 DL 650 V-Storm Motorcycle Motorcycles Suzuki V Storm Models

Variantes de produits

Description

This factory service repair manual covers the Suzuki DL650 V-Strom, also known as the V-Strom 650, for the model years 2004 through 2009. Designed as an adventure touring motorcycle, the V-Strom 650 is celebrated for its versatility, offering a balance of on-road comfort and off-road capability, making it suitable for commuting, long-distance touring, and light trail riding. It is powered by a proven, reliable 647 cc V-twin engine known for its smooth power delivery and features a durable chassis, adjustable suspension, and an upright riding position for enhanced rider comfort and control. This comprehensive manual provides detailed information for maintaining and repairing your Suzuki DL650 V-Strom. It covers all essential systems, including engine mechanicals, fuel and ignition systems, cooling and lubrication, transmission, chassis, suspension, brakes, and the electrical system. The manual includes routine maintenance procedures, detailed troubleshooting guides for common issues, engine and component rebuild instructions, and diagnostic procedures for the fuel injection and electrical systems. With this resource, owners and technicians can confidently perform everything from basic servicing to complex repairs, ensuring the longevity and optimal performance of the motorcycle.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DL650 V-Strom

Model Nickname:

V-Strom 650

Product Type:

Factory Service Repair Manual

Product Format:

PDF Download

👋 Introduction

Market Position

Model Category:

Adventure Touring Motorcycle

Target Audience:

Motorcyclists seeking a versatile, reliable, and capable machine for commuting, touring, and light off-road use.

Competitive Analysis

Key Competitors:

Kawasaki KLR650, BMW F650GS, Honda Transalp (depending on market)

Key Features

Versatility:

Balances on-road comfort with off-road capability, comfortable for long distances.

Engine Platform:

Proven V-twin engine known for its smooth power delivery and reliability.

Chassis Design:

Durable chassis, adjustable suspension, and a comfortable riding position.

Manual Value Proposition:

Provides dealer-level repair and maintenance information, enabling owners to perform complex tasks and save on service costs.

📋 Manual Details

Coverage Areas

Covered Years:

2004, 2005, 2006, 2007, 2008, 2009

Geographic Coverage:

Global (general specifications, variations may exist by region)

Page Count

Estimated Page Count:

Likely 500+ pages (typical for comprehensive factory service manuals)

Manual Type

Manual Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

File Format:

Printable:

Compatibility:

Windows, Mac

Reader Requirement:

Adobe PDF Reader

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Cylinder head, valves, piston, crankshaft, connecting rods, engine assembly/disassembly, timing chain, lubrication, cooling system.

Fuel System:

Fuel pump, fuel injectors, fuel pressure regulator, throttle body, idle speed control (ISC) system, fuel filter.

Ignition System:

Ignition coils, spark plugs, ignition control module.

Cooling System:

Radiator, fan, thermostat, water pump, coolant hoses, fluid specifications.

Lubrication System:

Oil pump, oil filter, oil passages, oil specifications.

Transmission:

Clutch operation, gear selection mechanism, transmission case, gear inspection, fluid specifications.

Chassis Suspension:

Front fork (USD), rear shock absorber, swingarm, linkage system, fork oil specifications, suspension adjustment.

Brakes:

Front and rear disc brakes, brake calipers, master cylinders, brake fluid specifications, bleeding procedures, pad replacement.

Electrical System:

Wiring diagrams, battery, charging system (stator, rectifier/regulator), starter motor, lighting, instrumentation, fuses, relays, ECU/ECM, sensors.

Fi System Diagnosis:

Troubleshooting common FI issues, diagnostic trouble codes (DTCs), sensor readings, actuator tests.

Emission Control:

Emissions related components, regulations, maintenance for emissions compliance.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, brake checks, tire pressure, coolant checks, spark plug replacement.

Troubleshooting:

Step-by-step diagnostic procedures for various system malfunctions, fault finding charts.

Engine Repair:

Complete engine overhaul, component replacement, torque specifications for critical fasteners, valve clearance adjustment.

Fuel System Service:

Throttle body cleaning and synchronization, injector cleaning and testing, fuel system pressure testing.

Suspension Service:

Front fork seal replacement, fork oil change, rear shock absorber inspection and replacement.

Brake System Service:

Brake pad replacement, brake fluid flush and bleed, caliper service.

Electrical Diagnostics:

Wiring harness inspection, circuit testing, component testing, multimeter usage for diagnostics.

Scheduled Maintenance:

Detailed schedules for periodic maintenance based on mileage or time intervals.

Technical Depth

Depth Of Coverage:

Comprehensive: Covers everything from basic checks and adjustments to complete engine and chassis overhauls.

Diagnostic Capability:

Advanced diagnostics for FI system, electrical faults, and mechanical issues.

Rebuild Procedures:

Detailed instructions for engine, transmission, and suspension component rebuilds.

Special Tools:

Identification of any special tools required for specific procedures.

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchability:

Typically searchable text within the PDF for quick reference.

Print Quality

Print Resolution:

High resolution, suitable for printing clear diagrams and text.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, V-twin

Displacement:

647 cc

Bore X Stroke:

81.0 mm x 62.6 mm

Compression Ratio:

11.5:1

Valvetrain:

DOHC, 4 valves per cylinder

Performance

Horsepower Estimated:

Approx. 65-70 HP @ 8800 rpm (model dependent, chassis dyno may vary)

Torque Estimated:

Approx. 45-50 lb-ft @ 6400 rpm (model dependent)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle valves (SDTV - Suzuki Dual Throttle Valve system)

Fuel Type:

Unleaded gasoline

Fuel Tank Capacity:

20 Liters (5.3 US gal)

Ignition System

Ignition System:

Electronic ignition (transistorized)

Spark Plugs:

NGK CR9EIA-9 or DENSO U27EPR-9 (refer to manual for exact spec and gap)

Cooling System

Cooling Medium:

Liquid

Lubrication System

Lubrication Type:

Wet sump

Engine Oil Type:

SAE 10W-40 API SG/SH/SJ or JASO MA recommended (Refer to manual for exact specification and capacity)

🔧 Transmission

Standard

Transmission Type:

6-speed, constant mesh

Primary Drive:

Final Drive:

O-ring sealed chain

Features

Clutch Type:

Wet, multi-plate

Transmission Oil Type:

API GL-4 SAE 80W or 75W/90 recommended (Refer to manual for exact specification and capacity)

📐 Dimensions

Exterior

Overall Length:

Approx. 2,180 mm (85.8 in)

Overall Width:

Approx. 840 mm (33.1 in)

Overall Height:

Approx. 1,375 mm (54.1 in)

Wheelbase:

Approx. 1,480 mm (58.3 in)

Ground Clearance:

Approx. 175 mm (6.9 in)

Weights

Dry Weight:

Approx. 195 kg (430 lbs)

Curb Weight:

Approx. 207 kg (456 lbs) (including all necessary fluids and full fuel tank)

Suspension Travel

Front Suspension Travel:

150 mm (5.9 in)

Rear Suspension Travel:

155 mm (6.1 in)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycles are not rated by typical automotive crash test agencies like NHTSA or IIHS)

Active Features

Braking System:

Disc brakes front and rear; ABS optional on some models/markets.

Lighting:

Halogen headlight, LED taillight.

Passive Features

Chassis Construction:

Rigid frame for stability.

Rider Ergonomics:

Upright riding position designed for comfort and control.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation)

Driver Assistance

ABS Availability:

Optional on certain trims/years within the 2004-2009 range.

Connectivity

Connectivity Features:

Instrumentation

Dashboard Layout:

Analog tachometer, digital speedometer, gear indicator, fuel gauge, clock, trip meters, odometer, coolant temperature gauge.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km or 12 months, whichever comes first.

Air Filter Check:

Every 6,000 km or 12 months.

Spark Plug Replacement:

Every 12,000 km or 24 months.

Chain Maintenance:

Lubricate and adjust chain every 1,000 km or after riding in rain/on dusty roads.

Valve Clearance Check:

Every 24,000 km or 48 months.

Fluid Specifications

Engine Oil Viscosity:

SAE 10W-40

Engine Oil Standard:

API SG/SH/SJ or JASO MA

Coolant Type:

Ethylene glycol based coolant with distilled water (50/50 mix recommended)

Brake Fluid Type:

DOT 4

Fork Oil Type:

SAE 10W (Refer to manual for capacity and exact grade)

Known Issues

Stator Failures:

Early models (including this range) were prone to stator failures due to heat and vibration. Testing and replacement procedures are vital.

Throttle Body Sync:

Periodic throttle body synchronization (TB sync) is crucial for smooth engine operation and idle stability.

Charging System Checks:

Regular checks of the charging system voltage are recommended due to potential stator issues.

Cam Chain Tensioner:

Some owners report a noisy cam chain tensioner, though often not a critical failure unless it deteriorates significantly.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation

Heritage Focus:

Known for reliable V-twin engines and innovative motorcycle designs.

Model Evolution

Introduction Year Dl650:

First Generation Period:

2004-2011

Model Designation:

DL650 V-Strom

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Model Recognition:

Praised for its value, reliability, and versatility in the adventure touring segment, often cited as a benchmark for accessible adventure bikes.