Suzuki DL 650 V-Storm 2004 Factory Service Repair Manual Pdf

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标签: 2004 DL650 V-Strom Motorcycle Motorcycles Suzuki V Storm Models

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Description

The Suzuki DL650 V-Strom, introduced in 2004, is a mid-weight adventure touring motorcycle renowned for its versatility, reliability, and affordability. It features a robust 647 cc V-twin engine, comfortable ergonomics suited for long-distance travel, and capability on both paved roads and light off-road conditions. The DL650 V-Strom is celebrated for its strong value proposition, extensive aftermarket support, and fuel efficiency, making it a popular choice among riders seeking a capable and dependable machine for diverse riding experiences. This factory service repair manual provides comprehensive guidance for maintaining and repairing the 2004 Suzuki DL650 V-Strom. It covers essential areas including engine, fuel system, cooling system, lubrication, chassis, and electrical system. The manual details routine maintenance, troubleshooting procedures, diagnostic steps, component removal and installation, and specific torque settings. Its high-resolution diagrams and searchable format are designed to assist owners, mechanics, and technicians in confidently performing all necessary service tasks, ensuring the optimal performance and longevity of the motorcycle.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

DL650 V-Strom

Year:

Engine Type:

V-Twin

Body Style:

Adventure Touring Motorcycle

👋 Introduction

Market Position

Market Segment:

Mid-weight Adventure Touring motorcycle, popular for its versatility, reliability, and affordability.

Competitive Analysis

Key Competitors:

Kawasaki KLR650, BMW F650GS (prior to F700GS), Honda Transalp (discontinued in many markets).

Key Features Vehicle

Vehicle Selling Points:

Robust V-twin engine, comfortable ergonomics for long-distance riding, capable on both paved roads and light off-road conditions, extensive aftermarket support, fuel efficiency.

Manual Value Proposition

Manual Benefit To Owner:

Empowers owners to perform maintenance and repairs confidently, reducing reliance on dealerships and saving money, while ensuring the longevity and optimal performance of the V-Strom.

📋 Manual Details

Coverage

Coverage Areas:

Engine, Fuel System, FI System Diagnosis, Cooling System, Lubrication System, Chassis, Electrical System, Servicing Information, Emission Control Information, Periodic Maintenance

Format

Format:

Requirements

Software Requirements:

Adobe PDF Reader, WinZip

Compatibility

Operating Systems:

All Versions of Windows & Mac

Features

Zoom Capability:

Language

Language:

English

Manual Type:

Factory Service Repair Manual

📖 Manual Coverage

Systems

Systems Covered:

Engine (internal components, assembly, disassembly), Fuel Injection System, Throttle Body, Cooling System (radiator, fan, coolant), Lubrication System (oil pump, oil filter, oil passages), Chassis (frame, suspension, wheels, brakes), Electrical System (wiring diagrams, lighting, ignition, starting, charging), Emission Control System

Procedures

Procedures Included:

Routine maintenance, troubleshooting, diagnostic procedures, component removal and installation, engine overhaul, clutch inspection and replacement, transmission servicing, brake system bleeding and repair, electrical diagnostics, suspension adjustments, fuel system cleaning and adjustment, torque specifications, fluid capacities and types

Depth

Technical Depth:

Comprehensive; from basic fluid changes to full engine rebuilds and detailed electrical diagnostics, suitable for both novice mechanics and professional technicians.

📊 Manual Specifications

File Properties

File Format Details:

Searchable PDF for efficient information retrieval.

Quality

Print Quality Notes:

High-resolution diagrams and text for clarity.

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Displacement:

647 cc

Engine Layout:

90-degree V-twin, DOHC, 8 valves

Performance

Bore X Stroke:

81.0 mm x 62.6 mm

Compression Ratio:

11.5:1

Horsepower Estimated:

67 hp @ 8,800 rpm (approx.)

Torque Estimated:

60 Nm @ 6,400 rpm (approx.)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (DFI) with dual throttle valves

Cooling System

Cooling Method:

Liquid-cooled

Lubrication

Oil Type Recommendation:

API SG/SH/SJ, JASO MA, SAE 10W-40 or 10W-50 (refer to manual for specifics)

Ignition

Ignition System:

Electronic Ignition (Transistorized)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Features

Clutch Type:

Wet, multi-plate

Drive

Final Drive:

Sealed O-ring chain

📐 Dimensions

Exterior

Overall Length:

2,175 mm (85.6 in)

Overall Width:

840 mm (33.1 in)

Overall Height:

1,390 mm (54.7 in)

Weights

Dry Weight:

191 kg (421 lbs)

Curb Weight:

213 kg (470 lbs)

Fuel Capacity

Fuel Tank Capacity:

20.0 L (5.3 US gal)

Wheels Tires

Front Tire Size:

110/80R19M/C 59H

Rear Tire Size:

150/70R17M/C 69H

Suspension

Front Suspension Type:

Telescopic, coil spring, oil damped, with adjustable preload

Rear Suspension Type:

Swingarm, link type, coil spring, oil damped, with adjustable preload and rebound damping

🛡️ Safety Features

Brakes

Front Brake Type:

Dual hydraulic disc

Rear Brake Type:

Single hydraulic disc

Lighting

Headlight Type:

Dual Halogen

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic motorcycle instrumentation)

Instrumentation

Dashboard Features:

Analog tachometer, digital speedometer, fuel gauge, clock, odometer, trip meter, indicator lights.

Driver Assistance

Not standard on the 2004 model. ABS became available on later iterations.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km or 12 months, whichever comes first (refer to manual for exact details).

Spark Plug Replacement Interval:

Refer to manual for specific mileage, typically around 24,000 km (15,000 miles).

Chain Maintenance:

Regular cleaning, lubrication, and tension adjustment recommended (e.g., every 1,000 km or after riding in wet conditions).

Fluid Specifications

Coolant Type:

Permanent type antifreeze coolant (refer to manual for specific mixture ratio).

Brake Fluid Type:

DOT 4

Known Issues

Common Wear Item:

Clutch slave cylinder seal can sometimes leak.

Electrical Component Concern:

Early models might have rectifier/regulator issues, though less common than on some other Suzuki models.

Torque Settings

Wheel Axle Torque Front:

44 Nm (32.5 lb-ft)

Wheel Axle Torque Rear:

98 Nm (72.3 lb-ft)

📚 Vehicle History

Brand Heritage

Brand Origin:

Japan, established in 1909.

Model Evolution

Dl650 Introduction:

The DL650 V-Strom was introduced in 2004, leveraging the proven engine from the SV650 and adapting it for adventure touring.

Predecessor Influence:

The DL1000 V-Strom, introduced earlier, provided a platform and design philosophy that influenced the DL650.

🏆 Awards & Recognition

Recognitions

Model Reputation:

Consistently praised for its value, reliability, and versatility in various motorcycle publications and owner reviews.