Model Variant:
DR650S, DR650SE
Years Covered:
1996, 1997, 1998, 1999, 2000, 2001
Engine Code:
SP46B (DR650SE), SP45A (DR650S - early models)
Market Segment:
Dual-sport motorcycle, known for its versatility, reliability, and off-road capability.
Target Audience:
Adventure riders, commuters, off-road enthusiasts, DIY mechanics.
Key Competitors Era:
Honda XR650L, Kawasaki KLR650, Yamaha XT600/TT600.
Vehicle Strengths:
Robust air-cooled engine, simple design, durable construction, user-friendly maintenance.
Manual Value Proposition:
Empowers owners to perform all necessary maintenance and repairs, saving money and extending the life of the motorcycle.
Primary Coverage:
Comprehensive service, repair, and maintenance for Suzuki DR650 (1996-2001).
Secondary Coverage:
Troubleshooting, electrical diagrams, specifications, and adjustments.
Estimated Page Count:
300-400 pages (typical for this era of service manual)
Manual Type:
Service/Workshop Manual
Engine:
Top-end, bottom-end, lubrication, cooling, ignition, starting, carburetor systems.
Transmission:
Clutch, gearbox, shift mechanism, lubrication.
Chassis:
Frame, suspension (front forks, rear shock), steering, wheels, tires, brakes (front and rear).
Electrical:
Wiring diagrams, lighting, ignition system, battery, starter motor, charging system, instruments.
Fuel System:
Carburetor (Mikuni BSR33/34), fuel tank, fuel lines, fuel pump (if applicable).
Bodywork And Trim:
Fenders, seat, fuel tank, side covers, exhaust system.
Maintenance:
Oil changes, filter replacements, spark plug checks/replacement, chain adjustment, air filter cleaning/replacement, brake fluid flush, coolant flush.
Repair:
Engine disassembly and reassembly, transmission overhaul, suspension fork service, carburetor overhaul, brake caliper rebuild, wheel bearing replacement.
Troubleshooting:
Diagnosis of common problems, fault finding based on symptoms.
Adjustments:
Carburetor idle speed and mixture, clutch free play, throttle cable slack, chain tension, suspension preload.
Depth Level:
Comprehensive: Covers routine maintenance, diagnostics, component-level repair, and complete engine/transmission rebuilds.
Diagnostic Focus:
Detailed fault finding charts and procedures for electrical and mechanical issues.
Engine Type:
4-stroke, SOHC, 4-valve, air-cooled
Displacement:
644 cc (cubic centimeters)
Bore X Stroke:
100.0 mm x 82.0 mm (millimeters)
Compression Ratio:
9.0:1 (typical)
Horsepower Est:
Approximately 45-50 HP (at crankshaft)
Torque Est:
Approximately 50-55 Nm (at crankshaft)
Carburetor Model:
Mikuni BSR33/34
Fuel Type:
Unleaded gasoline
Oil Capacity:
2.1 L (with filter change)
Recommended Oil Viscosity:
10W-40 (API SG or higher)
Ignition System:
CDI (Capacitor Discharge Ignition)
Starter Type:
Electric Starter
Safety Ratings:
N/A (Motorcycles are not typically rated by agencies like NHTSA or IIHS in the same way cars are).
Braking System:
Front: Disc, Rear: Disc (some models may have drum rear brake).
Tire Specifications Front:
80/90-21 M/C 48S
Tire Specifications Rear:
130/90-17 M/C 65S
Lighting:
Halogen headlight, taillight, turn signals.
Engine Oil Change:
Every 4,000 km (2,500 miles) or 6 months
Oil Filter Replacement:
Every 8,000 km (5,000 miles) or 12 months (or with every oil change)
Spark Plug Inspection:
Every 4,000 km (2,500 miles)
Air Filter Cleaning:
Every 4,000 km (2,500 miles)
Chain Lubrication And Adjustment:
Every 1,000 km (600 miles)
Coolant Type:
Ethylene glycol based antifreeze (mixture of 50% coolant and 50% distilled water)
Common Wear Items:
Clutch plates, fork seals, wheel bearings, chain and sprockets, voltage regulator (early models).
Carburetor Tuning:
Can be sensitive to altitude and modifications, requiring periodic re-jetting or adjustment.
Oil Consumption:
Some air-cooled engines can consume a small amount of oil, especially under heavy load. Regular checks are essential.
Manufacturer Origin:
Suzuki Motor Corporation, Japan
Dr Series Lineage:
Successor to earlier DR models, designed as a rugged, versatile dual-sport.
Generation Changes 96-01:
This generation (1996-2001) saw a significant update with a new frame, revised engine tuning, and the introduction of the electric start as standard on the SE model, differentiating it from earlier kick-start only variants. The SE model typically featured spoke wheels and more off-road oriented tires.
Manufacturing Location:
Japan
Production Span For This Generation:
1996-2001
