Segment:
Lightweight dual-sport/adventure motorcycle
Target Audience:
Riders seeking a versatile, reliable, and capable off-road and on-road motorcycle
Competitors Era:
Honda XR650L, Kawasaki KLR650, Yamaha XT600/XT660
Engine Configuration:
Air-cooled, single-cylinder, SOHC, four-valve (DR650SE features the TSCC - Twin Swirl Combustion Chamber)
Fuel Delivery:
Carbureted (Mikuni BST40) for this generation
Suspension Setup:
Long-travel adjustable front forks and a link-type rear suspension with adjustable monoshock
Versatility:
Capable of both pavement commuting and moderate off-road excursions
Primary Coverage:
Comprehensive service, repair, and maintenance procedures
Diagnostic Coverage:
Troubleshooting guides and fault diagnosis for all major systems
Disassembly Reassembly:
Detailed step-by-step instructions for component removal and installation
Estimated Pages:
300-500 (typical for this era/scope)
Type:
Service and Repair Manual
Format:
PDF (likely digital download for sales)
Engine:
Engine mechanical, lubrication, cooling, fuel, ignition, and exhaust systems
Transmission:
Transmission operation, maintenance, and repair
Drivetrain:
Final drive, chain, sprockets
Suspension:
Front fork and rear shock absorber systems, including adjustments and overhaul
Brakes:
Front and rear brake systems (disc brakes), fluid replacement, caliper service
Electrical:
Lighting, starting system, charging system, battery, ignition system, wiring diagrams
Bodywork:
Frame, body panels, seat, fuel tank, fenders
Controls:
Throttle, clutch, brake levers, shifter, footpegs
Wheels Tires:
Wheel bearing service, tire mounting and balancing
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning
Engine Overhaul:
Piston removal/installation, valve adjustment, cylinder head service
Carburetor Service:
Cleaning, adjustment, jetting information
Suspension Rebuild:
Fork seal replacement, shock absorber servicing
Brake System Repair:
Bleeding, pad replacement, caliper rebuild
Electrical Troubleshooting:
Diagnosing electrical faults using wiring diagrams
Torque Specifications:
Detailed torque values for critical fasteners
Depth:
Complete disassembly, repair, and reassembly for all major components
Diagnostics:
Systematic troubleshooting and fault finding
Special Tools:
Identification of required special tools for specific procedures
Engine Type:
Four-stroke, SOHC, 4-valve, TSCC
Displacement:
644 cc (39.3 cu. in.)
Bore X Stroke:
100.0 mm x 82.0 mm (3.94 in x 3.23 in)
Cooling System:
Air-cooled with an oil cooler
Horsepower:
Approx. 45-50 HP (at the crank, varies by year and market)
Torque:
Approx. 36-40 lb-ft (at the crank, varies by year and market)
Carburetor:
Mikuni BST40 (Constant Velocity carburetor)
Fuel Capacity:
3.4 US gallons (13 Liters)
Fuel Type:
Unleaded gasoline, 87 octane (minimum)
Length:
Approx. 89.0 in (2260 mm)
Width:
Approx. 34.0 in (865 mm)
Height:
Approx. 48.0 in (1220 mm) (seat height varies)
Wheelbase:
Approx. 58.7 in (1490 mm)
Dry Weight:
Approx. 324 lbs (147 kg)
Wet Weight:
Approx. 366 lbs (166 kg) (fully fueled)
Ground Clearance:
Approx. 10.4 in (265 mm)
Seat Height:
Adjustable, typically around 35.0 in (890 mm)
Safety Ratings:
N/A (Motorcycle specific safety ratings differ from automobiles)
Braking System:
Hydraulic disc front and rear
Lighting:
Halogen headlight, LED tail light
Frame Construction:
Steel semi-double cradle frame
Oil Change:
Every 3,000 miles (4,800 km) or 6 months
Oil Filter Change:
Every oil change
Air Filter Cleaning:
Every 3,000 miles (4,800 km)
Chain Maintenance:
Lubricate every 500 miles (800 km), adjust every 1,000 miles (1,600 km)
Valve Clearance Check:
Every 7,500 miles (12,000 km)
Engine Oil:
Suzuki Performance Motor Oil SAE 10W-40 or equivalent API SG/SH/SJ
Engine Oil Capacity:
2.2 L (2.3 US qt) without filter change, 2.4 L (2.5 US qt) with filter change
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid
Fork Oil:
Suzuki Fork Oil SS-01 (or equivalent SAE 10W)
Fork Oil Capacity:
460 ml (15.6 US oz) per fork leg (check manual for exact fill level)
Common Wear Items:
Clutch plates, wheel bearings, swingarm bushings, brake pads
Engine Considerations:
Potential for cam chain tensioner noise on higher mileage units (manual will cover inspection/replacement)
Carburetor Tuning:
Mikuni BST40 can be sensitive to altitude and modifications; manual provides tuning guidance.
Manufacturer:
Suzuki Motor Corporation
Predecessors:
DR650 (air-cooled single), DR650R, DR650S
Generation Introduction:
1990s, evolving the DR650 platform with the 'SE' designation often referring to electric start and refined features.
Production Period:
1996-2002 (for this specific manual coverage)
Manufacturing Location:
Japan
