1996-2001 Suzuki DR650SE Service Manual (263 P.)
Complete service procedures for DR650SE air-cooled OHC single-cylinder engine with CDI ignition, wet multi-plate clutch, 5-speed transmission, and both front/rear disc brakes. Covers periodic maintenance schedules, engine disassembly/reassembly, fuel carburetor tuning, electrical systems, and chassis repairs.
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Sample pages from the 1996-2001 Suzuki DR650SE Service Manual (263 P.) manual
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Models Covered & Key Technical Specifications
Suzuki DR650SE — 1996–2001 Systematic Technical Resource | DR650SE Series Repository.
- Designated Print Quality: For engine performance, 644 cm³ (39.3 cu in) is standardized to define the piston displacement Architecture.
- Primary Securement Values: The bore dimension measures 100 mm (3.937 in) at peak cylinder specifications Mapping.
- Advanced Liquid Volume: Fuel tank capacity is calibrated to 13.0 L (3.4 US gal) for standard road operation Configuration.
- Design Power Rating: Engine stroke reaches 82 mm (3.228 in) — represents the crankshaft travel distance Benchmarks.
- Engineered Working Temperature: Intake valve clearance achieves 0.08–0.13 mm (0.003–0.005 in) cold gap Range.
- Certified Output Quality: Compression ratio corresponds to 9.5:1 for optimal combustion chamber pressure Baseline.
Professional Workshop Service Manual & Technical Specifications
Authoritative Training Reference-Archive Manual: Suzuki DR650SE 1996-2001 - Comprehensive Repair Manual
Validation-Data: Suzuki DR650SE (1996-2001) // Repair-Classification: Motorcycle Service and Technical Workshop Logic // Serial-Range: Engine and frame identification documentation included.
| Specification | Documentation Focus | Reference Material |
|---|---|---|
| Document Overview | Covers General Information, Periodic Maintenance, Engine Systems, Fuel and Lubrication, Chassis Components, and Electrical System | Complete service specifications documented |
| Chapter Index | General Information and Precautions, Periodic Maintenance Schedule and Procedures, Engine Disassembly and Reassembly | All major systems addressed |
| System Categories | Four-stroke OHC engine with SACS, transmission and clutch, fuel system with carburetor, brake systems (front and rear disc) | Comprehensive component coverage |
Coverage is segmented into foundational knowledge paired with fuel system procedures, structured alongside engine systems, concluding with chassis maintenance and electrical system diagnostics and wiring schematics. Maintenance information covers periodic service intervals including valve clearance, spark plug replacement, and fluid capacities for oil, coolant, and brake fluid. Technical data encompasses engine specifications, transmission gear ratios, electrical component locations, and system descriptions for charging and ignition operation.
Safety procedures are documented for general precautions, battery handling, and service warnings. Fluid capacities are listed for engine oil (2,300-2,600 ml depending on service type), fuel tank (12.0-13.0 L), cooling system, and brake fluid specifications. Tool requirements are listed for specialized service including compression testing, oil pressure measurement, and bearing installation. Installation guidelines are provided for major components including engine removal and reinstallation, front fork disassembly and reassembly, and steering stem bearing service. Maintenance guidelines are included for periodic inspection at 1,000 km, 6,000 km, 12,000 km, and 24,000 km intervals with specific procedures for each service requirement.
The manual documents torque specifications for critical engine fasteners to ensure proper assembly stress control.
Standard structure comprises 200 pages of instructional content with detailed exploded diagrams for component identification, tabular specifications for all major systems, wiring diagrams for electrical circuits, and step-by-step service procedures accompanied by photographic references and technical measurements.
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