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

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UGS: 142559

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, a distinguished sport-touring motorcycle introduced in 2004, is renowned for its versatile performance, comfortable ergonomics ideal for long-distance journeys, and a robust 90-degree V-twin engine. Built upon Suzuki's reputation for engineering quality and reliability, the DL650 V-Strom offers a distinctive styling and a design philosophy that blends adventure bike capability with street bike comfort. This model, particularly the Standard variant, has garnered positive reviews for its value and practicality, making it a popular choice in its segment. This factory service repair manual, written in English, provides comprehensive guidance for the Suzuki DL650 V-Strom models from 2004 through 2009. It covers essential areas including detailed maintenance procedures, in-depth troubleshooting for engine, fuel, chassis, and electrical systems, and critical technical specifications. The manual is designed to assist owners, mechanics, and technicians in effectively maintaining, diagnosing, and repairing the motorcycle, ensuring optimal performance and longevity. Its searchable format allows for efficient access to information, from routine servicing like oil changes and valve adjustments to complete component overhauls.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DL650 V-Strom

Model Variant:

Standard

Generation

Generation Designation:

First Generation (DL650)

Codes

Chassis Code:

DL650

Engine Codes:

V-twin, 4-stroke, DOHC, 90° V-twin, 4 valves per cylinder, TSCC (Suzuki Tri-Valvular Secondary Combustion Chamber)

👋 Introduction

Market Position

Segment:

Sport Touring Motorcycle

Key Selling Points:

Versatile performance, comfortable ergonomics for long-distance riding, robust V-twin engine, distinctive styling.

Competitive Analysis

Primary Competitors Era:

Kawasaki KLR650, Honda VFR800, Yamaha FZ1, BMW F650GS.

Key Features

Engine Architecture:

90-degree V-twin, liquid-cooled, DOHC, 4 valves per cylinder.

Frame Type:

Aluminum twin-spar frame.

Braking System:

Dual front disc brakes, single rear disc brake.

📋 Manual Details

Coverage Areas

Model Years Covered:

2004, 2005, 2006, 2007, 2008, 2009

Specific Model Codes Covered:

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

Page Count

Estimated Page Count:

Detailed information suggests a comprehensive manual, likely exceeding 500 pages given the scope.

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

Digital Format:

PDF (Portable Document Format)

Compression Format:

WINRAR (for download/extraction)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine overhaul, internal components, piston, rings, cylinder, cylinder head, valves, camshafts, crankshaft, oil pump, oil passages, cooling system, lubrication system, emission control systems.

Fuel System:

Fuel injection system (FI System Diagnosis), fuel pump, fuel injectors, throttle body, sensors (TPS, MAP, IAT, O2), fuel tank, fuel lines.

Cooling Lubrication:

Radiator, coolant flow, thermostat, water pump, oil cooler, oil filter, oil change procedures, lubrication points.

Chassis Components:

Frame, suspension (front forks, rear shock absorber), steering system, wheels, tires, brakes (front and rear discs, calipers, master cylinders, hydraulic lines), swingarm, chain drive system.

Electrical System:

Battery, charging system (alternator, regulator/rectifier), ignition system (spark plugs, ignition coils), lighting system (headlights, tail lights, indicators), starter motor, wiring harness, fuses, relays, instrument cluster, diagnostic connectors.

Wiring Diagrams:

Comprehensive wiring diagrams for all electrical systems, including specific supplements for model year variations.

Procedures Included

Maintenance Procedures:

Regular scheduled maintenance, oil and filter changes, spark plug replacement, air filter cleaning/replacement, coolant checks and replacement, brake fluid checks and replacement, chain adjustment and lubrication, valve clearance inspection and adjustment.

Diagnostic Procedures:

Troubleshooting guides for engine performance issues, electrical faults, fuel system problems, and chassis-related concerns. Includes diagnostic codes and procedures for the FI system.

Repair Procedures:

Step-by-step instructions for disassembly, inspection, repair, and reassembly of all major motorcycle components. Includes engine rebuilds, transmission servicing, suspension overhauls, brake system repairs, and electrical component replacement.

Technical Depth

Technical Scope:

Factory-level technical data, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic adjustments to complete engine and chassis rebuilds.

Diagnostic Capabilities:

Detailed diagnostic flowcharts and troubleshooting trees for the electronic fuel injection system, emissions control, and electrical components.

📊 Manual Specifications

File Format

File Type:

Print Quality

Printability:

All pages are printable, allowing users to create hard copies for shop use.

Binding Type

Binding Method:

Digital download (no physical binding). Users can print and bind as needed.

Paper Type

Paper Recommendation:

Not applicable (digital format). Recommend durable paper for printouts.

Searchability

Text Searchability:

Completely bookmarked and searchable PDF for efficient information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type:

90-degree V-twin, four-stroke, liquid-cooled, DOHC, 4 valves per cylinder, TSCC

Displacement:

647 cc (39.5 cu. in.)

Performance

Bore X Stroke:

81.0 mm x 62.6 mm (3.19 in x 2.46 in)

Compression Ratio:

11.5:1

Horsepower Estimated:

Approximately 66 HP @ 8800 RPM (as per factory specifications)

Torque Estimated:

Approximately 45 lb-ft @ 6400 RPM (as per factory specifications)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with Twin Swirl Combustion Chamber (TSCC) technology, digital ignition.

Throttle Body Size:

36 mm x 2 (dual throttle bodies)

Fuel Type:

Unleaded gasoline, 87 octane or higher recommended.

Cooling Lubrication

Cooling Method:

Liquid-cooled

Lubrication System:

Wet sump with oil cooler

Oil Capacity W Filter:

3.0 L (3.2 US qt)

Oil Capacity Wo Filter:

2.7 L (2.9 US qt)

Recommended Oil Viscosity:

SAE 10W-40, API SG or SH

Recommended Coolant:

Permanent type antifreeze (ethylene glycol), 50% solution with distilled water.

🔧 Transmission

Standard

Transmission Type:

Constant-mesh, 6-speed

Clutch Type:

Wet, multi-plate

Features

Final Drive:

Sealed O-ring type chain

📐 Dimensions

Exterior

Overall Length:

2,140 mm (84.3 in)

Overall Width:

825 mm (32.5 in)

Overall Height:

1,375 mm (54.1 in)

Wheelbase:

1,500 mm (59.1 in)

Ground Clearance:

165 mm (6.5 in)

Weights

Curb Weight:

216 kg (476 lbs) (for DL650K5/K6 models)

Fuel Tank Capacity:

22.0 L (5.8 US gal)

🛡️ Safety Features

Ratings

Safety Features Integrated:

The manual details safety procedures for maintenance and repair, including brake system integrity and electrical safety. No specific crash ratings available for motorcycles in the same manner as cars.

Active Features

Braking System Description:

Dual 310 mm discs with 2-piston calipers (front), Single 260 mm disc with 2-piston caliper (rear).

Suspension Travel:

Front: 150 mm (5.9 in); Rear: 156 mm (6.1 in)

Passive Features

Lighting System:

Dual 12V 60/55W headlights, LED tail light, amber turn signals.

💡 Technology Features

Infotainment

Infotainment Features:

No integrated infotainment system in this model year; relies on aftermarket accessories for navigation or audio.

Driver Assistance

Driver Assistance Systems:

None from factory; this is a mechanically controlled motorcycle.

Connectivity

Connectivity Features:

Basic electrical connections for ignition, lighting, and charging. No advanced connectivity features.

Instrumentation

Instrument Cluster:

Analog tachometer, digital speedometer, LCD multi-function display (odometer, trip meters, fuel gauge, clock, engine temp).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Oil Filter Change Interval:

At every oil change.

Spark Plug Inspection:

Every 12,000 km (7,500 miles).

Valve Clearance Check:

Every 24,000 km (15,000 miles).

Coolant Replacement Interval:

Every 2 years or 24,000 km (15,000 miles), whichever comes first.

Brake Fluid Replacement Interval:

Every 2 years.

Fluid Specifications

Engine Oil Specification:

SAE 10W-40 API SG or SH.

Coolant Specification:

Permanent type antifreeze, 50% solution with distilled water.

Brake Fluid Specification:

DOT 4.

Known Issues

Common Wear Items:

Clutch plates, brake pads, tires, chain and sprockets, wheel bearings, fork seals.

Potential Electrical Gremlins:

Intermittent issues with the starter button or charging system components (rectifier/stator) have been reported by some owners, though generally considered reliable.

Fuel System Notes:

Regular cleaning of the throttle bodies and fuel injectors as per manual recommendations is advised for optimal performance. Fuel pump can be a point of failure if not maintained.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation, Japan.

Model Evolution

Introduction Year:

Design Philosophy:

Designed as a versatile sport-touring motorcycle, blending the capability of an adventure bike with the comfort and performance of a street bike.

Engine Basis:

Utilizes a detuned version of the V-twin engine from the Suzuki SV650.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Model Recognition:

The DL650 V-Strom has consistently received positive reviews for its value, versatility, and reliability in the sport-touring and adventure-lite segments.

Ratings

Owner Satisfaction:

Generally high owner satisfaction for its practicality and long-term durability.