Suzuki DL 650 V-Storm 2004-2009 Online Service Repair Manual

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UGS: 145111

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

Variantes de produits

Description

The Suzuki DL650 V-Strom, produced between 2004 and 2009, is a versatile adventure touring motorcycle renowned for its reliable V-twin engine, comfortable ergonomics, and capable chassis. This model, including variants like the DL650/A V-Strom with ABS, is engineered to provide a smooth power delivery and a stable ride, making it suitable for long-distance touring, daily commuting, and light off-road exploration. Its design emphasizes practicality and durability, establishing it as a strong contender in its segment, offering a blend of performance and value that has garnered high owner satisfaction. This comprehensive service and repair manual covers the Suzuki DL650 V-Strom models from 2004 through 2009. It provides detailed instructions for maintenance, troubleshooting, and repair of all major systems, including the engine, fuel injection, cooling, chassis, and electrical components. The manual includes step-by-step procedures, diagnostic guides, and essential technical specifications, such as torque values and wiring diagrams. Its purpose is to equip owners and technicians with the knowledge necessary to maintain the vehicle's performance, ensure its longevity, and carry out repairs effectively.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DL650 V-Strom

Model Designations:

DL650 V-Strom, DL650/A V-Strom (ABS)

Covered Years:

2004, 2005, 2006, 2007, 2008, 2009

Chassis Codes:

DL650K4 (2004), DL650K5 (2005), DL650K6 (2006), DL650K7 (2007), DL650K8 (2008), DL650K9 (2009)

Manual Product Name:

Suzuki DL 650 V-Storm 2004-2009 Online Service Repair Manual

👋 Introduction

Market Position

Segment:

Adventure Touring Motorcycle

Target Audience:

Motorcyclists seeking a versatile machine for long-distance touring, commuting, and light off-road exploration.

Competitive Analysis

Key Competitors:

Kawasaki KLR650, BMW F650GS, Honda NT700V Deauville (during the period).

Key Features

Engine Type:

V-twin engine, known for its smooth power delivery and torque.

Chassis Design:

Durable and capable chassis, suitable for varied road conditions and light off-road use.

Touring Capability:

Comfortable ergonomics, wind protection, and potential for luggage mounting make it a strong touring platform.

Manual Value Proposition

Owner Benefit:

Enables owners to perform maintenance, diagnose issues, and undertake repairs, leading to cost savings and a deeper understanding of their motorcycle.

📋 Manual Details

Coverage Areas

Scope:

Complete Service and Repair

Specific Supplements:

DL650K5 (05- MODEL), DL650K6 (06- MODEL), DL650/AK7 (07- MODEL), DL650/AK8 (08- MODEL), DL650/AK9 (09-MODEL)

Page Count

Estimated Pages:

Approximately 500-700 (typical for comprehensive manuals of this era)

Manual Type

Type:

Service Repair Manual / Workshop Manual / Factory Manual / Shop Manual / Technical Manual

Language

Primary Language:

English

Format

Digital Format:

PDF / WINRAR

Compatibility:

Win95/98/ME/XP/vista/7/8, Linux, MAC, iOS, Android

Delivery

Method:

Instant Download (via email)

📖 Manual Coverage

Systems Covered

Major Systems:

General Information, Periodic Maintenance, Engine, FI System Diagnosis, Fuel System and Throttle Body, Cooling and Lubrication System, Chassis, Electrical System, Emission Control Information

Procedures Included

Diagnostic Procedures:

Troubleshooting guides for fuel injection, ignition, and electrical systems; diagnostic trouble codes (DTCs) where applicable.

Repair Procedures:

Step-by-step instructions for disassembly, assembly, and repair of all major components and systems.

Maintenance Procedures:

Scheduled maintenance tasks, fluid changes, filter replacements, lubrication, and adjustments.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all model years and variations.

Technical Depth

Depth:

Detailed technical information, specifications, torque values, and repair procedures suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

File Type:

PDF (searchable text is highly probable), WINRAR archive

Print Quality

Printability:

Designed for digital access; high-resolution graphics and text suitable for printing individual pages or sections.

Binding Type

Binding:

Not applicable (Digital format)

Paper Type

Paper Quality:

Not applicable (Digital format)

⚙️ Engine Specifications

Primary Engine

Type:

Liquid-cooled, four-stroke, DOHC, 90-degree V-twin

Displacement:

645 cc (cubic centimeters)

Bore X Stroke:

81.0 mm x 62.6 mm

Compression Ratio:

11.5:1

Valve Train:

DOHC, 4 valves per cylinder

Performance

Horsepower:

Approximately 63-67 hp (at crankshaft, depending on specific model year and tuning)

Torque:

Approximately 60-63 Nm (at crankshaft, depending on specific model year and tuning)

Fuel System

Induction:

Digital Fuel Injection (DFI) with Twin Spark Plugs per Cylinder

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON+MON)/2

Lubrication

System Type:

Forced lubrication, Wet Sump

Cooling

System Type:

Liquid-cooled

Ignition

Type:

Electronic Ignition (transistorized)

🔧 Transmission

Standard

Type:

Constant mesh 6-speed, Return

Clutch Type:

Wet, multi-plate

Final Drive:

O-ring sealed chain

Features

Gear Ratios:

Detailed gear ratios are provided within the manual, essential for performance tuning and diagnostics.

📐 Dimensions

Exterior

Overall Length:

Approx. 2,255 mm (88.8 in)

Overall Width:

Approx. 835 mm (32.9 in)

Overall Height:

Approx. 1,370 mm (53.9 in)

Wheelbase:

Approx. 1,555 mm (61.2 in)

Ground Clearance:

Approx. 165 mm (6.5 in)

Seat Height:

Approx. 820 mm (32.3 in)

Weights

Dry Weight:

Approx. 198 kg (436.5 lbs)

Curb Weight:

Approx. 213 kg (470 lbs) (with ABS and full fluids)

Gross Vehicle Weight Rating:

Specific GVWR available in manual

Cargo

Luggage Capacity:

Designed for aftermarket luggage systems, extensive detail on mounting points and recommendations available in dedicated sections.

🛡️ Safety Features

Ratings

Crash Test Data:

Not applicable for motorcycles in the same way as cars. Manual covers component safety and structural integrity.

Active Features

Optional Anti-lock Braking System (ABS) available on certain models (indicated by 'A' in model designation like DL650/AK7).

Braking System Front:

Dual hydraulic discs, 310 mm

Braking System Rear:

Single hydraulic disc, 260 mm

Passive Features

Lighting:

Dual halogen headlights, LED taillight

Frame Construction:

Aluminum twin-spar frame, providing rigidity and light weight.

💡 Technology Features

Infotainment

Instrumentation:

Analog tachometer, digital speedometer, gear position indicator, odometer, trip meters, fuel gauge, clock, coolant temperature gauge, hazard warning light switch.

Driver Assistance

Optional ABS system available, providing enhanced braking control under various conditions.

Connectivity

Accessories:

Pre-wiring for auxiliary power outlets and accessory lighting is common; manual details electrical system access.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 6,000 km (3,700 miles) or 6 months, whichever comes first. Refer to manual for specific conditions.

Air Filter Inspection:

Every 6,000 km (3,700 miles) or annually. Cleaning/replacement as needed.

Spark Plug Replacement:

Typically around 24,000 km (15,000 miles). Refer to manual for specific type and gap.

Coolant Change Interval:

Every 2 years or 30,000 km (18,000 miles).

Fluid Specifications

Engine Oil Type:

SAE 10W-40, API SG or higher, JASO MA certified motorcycle oil.

Engine Oil Capacity:

Approx. 2.7 liters (2.8 US qt) without filter change, 2.9 liters (3.1 US qt) with filter change.

Coolant Type:

High-quality ethylene glycol-based antifreeze coolant, mixed with distilled water (50:50 ratio).

Brake Fluid Type:

DOT 4 brake fluid.

Fork Oil Type:

SAE 10W front fork oil (specific quantity per leg detailed in manual).

Known Issues

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, wheel bearings, fork seals due to mileage and usage.

Potential Electrical:

While generally reliable, some owners have reported occasional stator or rectifier issues on higher mileage units. The manual's electrical section is critical for diagnosis.

Fuel System Maintenance:

Periodic cleaning of throttle bodies and fuel injectors is recommended to maintain optimal performance, as detailed in the FI System Diagnosis section.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation

Heritage Focus:

Suzuki has a long history of producing reliable and innovative motorcycles, particularly in the V-twin engine segment.

Model Evolution

Introduction Year:

The DL650 V-Strom was introduced globally in 2004.

Key Evolution Points:

This generation (2004-2009) established the V-Strom's reputation for versatility and value. Minor updates were made over the years, including the introduction of ABS and cosmetic changes.

Production

Manufacturing Locations:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Recognitions

Market Perception:

The DL650 V-Strom is widely recognized for its excellent value for money, reliability, and versatility, often praised in motorcycle reviews and forums.

Ratings

Owner Satisfaction:

Consistently high owner satisfaction ratings due to its blend of performance, comfort, and affordability.

Certifications

Emissions:

Meets emissions standards relevant to the production years and regions; manual provides specific details in the Emission Control Information section.