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Suzuki DL650 V-Storm 2004-2009 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Suzuki Model: DL650 V-Strom Generation: First Generation (2004-2011) Product Name: Suzuki DL650 V-Storm 2004-2009 Workshop Service Repair Manual Codes Model Code: DL650 K4, K5, K6,...
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类型: Motorcycle
厂商:
斯库: 420349
Suzuki DL650 V-Storm 2004-2009 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Suzuki
Model:
DL650 V-Strom
Generation:
First Generation (2004-2011)
Product Name:
Suzuki DL650 V-Storm 2004-2009 Workshop Service Repair Manual
Codes
Model Code:
DL650 K4, K5, K6, K7, K8, K9 (Year dependent)
👋 Introduction
Market Position
Market Segment:
Adventure Touring Motorcycle
Target Audience:
Riders seeking a versatile, comfortable, and reliable motorcycle for long-distance touring, commuting, and light off-road exploration.
Competitive Analysis
Competitors:
BMW F650GS/F700GS, Kawasaki KLR650, Honda CB500X, Yamaha TDM900 (older models).
Key Features
Versatility:
Suitable for a wide range of riding conditions, from highways to unpaved roads.
Reliability:
Known for its robust engine and durable components.
Comfort:
Ergonomic seating position and effective wind protection for long rides.
Value Proposition:
Offers a strong balance of performance, features, and affordability within the adventure touring segment.
📋 Manual Details
Coverage Areas
Years Covered:
2004, 2005, 2006, 2007, 2008, 2009
Page Count
Page Count:
701
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Complete engine service, disassembly, assembly, troubleshooting, internal components, cooling system, lubrication system.
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel tank, fuel lines.
Transmission:
Clutch operation, gearbox disassembly/assembly, shift mechanism, maintenance.
Electrical System:
Ignition system, starting system, charging system, lighting, instrumentation, wiring diagrams, ECU diagnostics.
Chassis And Suspension:
Front fork assembly, rear shock absorber, swingarm, steering system, wheel bearings, bearings and seals.
Brakes:
Front and rear brake systems, hydraulic lines, calipers, master cylinders, brake disc service, ABS (if equipped).
Bodywork:
Fairing removal/installation, body panel service, seat, handlebars, footpegs.
Cooling System:
Radiator, coolant hoses, thermostat, fan operation.
Exhaust System:
Exhaust pipe, muffler service, emissions control systems.
Procedures Included
Maintenance:
Routine maintenance, oil changes, filter replacements, chain adjustment, lubrication points, periodic inspection.
Troubleshooting:
Diagnostic procedures for common problems, error code interpretation, electrical troubleshooting, engine performance issues.
Repair:
Step-by-step repair procedures for all major components and systems.
Disassembly And Assembly:
Detailed instructions for taking apart and reassembling vehicle components.
Adjustments:
Precise instructions for adjusting systems such as throttle, clutch, brakes, and suspension.
Removal And Installation:
Comprehensive guidance on removing and reinstalling parts and assemblies.
Tightening Torques:
Specific torque values for all critical fasteners and bolts.
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine rebuilds and electrical system diagnostics. Includes factory specifications, wear limits, and pictorial diagrams.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Printable:
Yes
Readability:
High resolution, clear text and diagrams.
Binding Type
Binding Type:
Digital (PDF Download)
Paper Type
Paper Type:
N/A (Digital File)
Requirements
Software Requirement:
Adobe Reader
Operating System Compatibility:
Windows, Mac, Linux OS
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 4-stroke, DOHC, V-twin
Displacement:
645 cc (39.3 cu in)
Bore X Stroke:
81.0 mm x 62.6 mm (3.19 in x 2.46 in)
Compression Ratio:
11.5:1
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
Approx. 67 HP @ 8,800 rpm (varies slightly by year/region)
Torque:
Approx. 60 Nm (44.3 lb-ft) @ 6,400 rpm (varies slightly by year/region)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle valves (SDTV)
Fuel Type:
Unleaded gasoline, 91 octane or higher
Fuel Tank Capacity:
20.0 liters (5.3 US gal)
Lubrication
Oil Type:
API SG or SH, SAE 10W-40 or 10W-50 (refer to manual for specific Suzuki recommendations)
Oil Capacity:
3.4 L (3.6 US qt) without filter change; 3.8 L (4.0 US qt) with filter change.
Cooling System
Cooling Method:
Liquid-cooled
Coolant Type:
Suzuki Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet, multi-plate
Final Drive:
O-ring sealed chain
Features
Gear Ratios:
Refer to manual for specific gear ratios for each of the 6 speeds.
Transmission Fluid Type:
API GL-5, SAE 80W-90 hypoid gear oil (for final gear reduction box if applicable, engine oil for gearbox lubrication)
📐 Dimensions
Exterior
Overall Length:
2,195 mm (86.4 in)
Overall Width:
840 mm (33.1 in)
Overall Height:
1,390 mm (54.7 in)
Wheelbase:
1,500 mm (59.1 in)
Ground Clearance:
170 mm (6.7 in)
Weights
Dry Weight:
Approximately 190 kg (419 lbs)
Curb Weight:
Approximately 213 kg (470 lbs) (fully fueled, all fluids)
Front Suspension Travel:
150 mm (5.9 in)
Rear Suspension Travel:
150 mm (5.9 in)
Seat Height:
820 mm (32.3 in)
🛡️ Safety Features
Ratings
Crash Safety Ratings:
Motorcycle safety is primarily dependent on rider skill, protective gear, and vehicle design. Specific crash test ratings are not typically applied to motorcycles in the same way as automobiles.
Active Features
Braking System:
Standard dual front disc brakes, single rear disc brake. Optional ABS (Anti-lock Braking System) available on some models/years.
Lighting:
Halogen headlights, LED taillight, turn signals.
Passive Features
Frame Construction:
Aluminum twin-spar frame for rigidity and light weight.
Tires:
Dual-purpose tires suitable for both on-road and light off-road use (e.g., 110/80R19 front, 150/70R17 rear).
💡 Technology Features
Infotainment
Infotainment Features:
Basic instrumentation: speedometer, tachometer, odometer, trip meter, fuel gauge, coolant temperature gauge, clock. No advanced infotainment systems like touchscreens or navigation as standard.
Driver Assistance
Driver Assistance Features:
Optional Anti-lock Braking System (ABS) on some models/years. No other electronic driver aids typical of modern automobiles.
Connectivity
Connectivity Features:
No integrated connectivity features like Bluetooth or Wi-Fi.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 12 months, whichever comes first.
Air Filter Inspection:
Inspect every 6,000 km (3,700 miles); replace as needed.
Spark Plug Replacement:
Replace every 12,000 km (7,500 miles).
Valve Clearance Check:
Check every 12,000 km (7,500 miles).
Chain Lubrication And Adjustment:
Lubricate every 1,000 km (600 miles) or after riding in rain; adjust slack every 1,000 km (600 miles).
Fluid Specifications
Engine Oil Spec:
API SG or SH, SAE 10W-40 or 10W-50 (refer to manual)
Coolant Spec:
Suzuki Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant
Brake Fluid Spec:
DOT 4
Fork Oil Spec:
Refer to manual for viscosity and quantity (e.g., Showa SS-8 or equivalent)
Known Issues
Common Issues:
Stalling at low RPM, cam chain rattle at startup (often normal), potential issues with early models' charging systems, stator wear (less common in this specific generation but worth noting).
Wear And Tear Items:
Tires, brake pads, chain and sprockets, clutch plates (depending on usage).
📚 Vehicle History
Brand Heritage
Brand History:
Suzuki has a long history in motorcycle manufacturing, known for innovation and reliable engines, particularly its V-twin configurations.
Model Evolution
Dl650 Introduction:
The DL650 V-Strom was introduced in 2004 as a mid-weight adventure touring motorcycle, sharing its engine with the SV650 naked bike.
First Generation Features:
The first generation (2004-2011) established the V-Strom's reputation for versatility, comfort, and value. It featured a distinctive beak fairing and adjustable windscreen.
Production
Manufacturing Location:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
The DL650 V-Strom has consistently received positive reviews from motorcycle publications and riders for its balance of performance, comfort, and value, often being cited as a benchmark in the mid-weight adventure touring class.
Ratings
Rider Satisfaction:
Generally high rider satisfaction due to its reliability, touring capability, and affordability compared to larger or European competitors.
Certifications
Emissions Compliance:
Meets relevant emissions standards for its production years (e.g., Euro 2 or 3 depending on region and year).
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