1991 Suzuki DR650S / DR650SM Service & Repair Manual (OEM)
Suzuki Models Covered & Key Technical Specifications
Models: Suzuki DR650S, DR650SM
Sub-models / Variants: E-02, E-03, E-04, E-15, E-16, E-17, E-18, E-21, E-22, E-24, E-25, E-28, E-33, E-34, E-39, E-53
Model Years: 1991
Technical Data:
- Engine: Four-stroke, air-cooled, OHC, 1 cylinder
- Displacement: 640 cm³ (39.0 cu in)
- Compression ratio: 9.7:1
- Carburetor: MIKUNI BST40SS, single
- Transmission: 5-speed constant mesh
- Ignition type: Suzuki PEI (CDI)
- Front suspension: Telescopic, pneumatic/coil spring, oil damped
- Rear suspension: Full floating suspension, coil spring, gas/oil damped
- Fuel tank capacity: 21 L (5.5/4.6 US/Imp gal) including reserve
Suzuki Manual Features & Content Preview
- 188-page OEM service document detailing engine, chassis, electrical, and fuel-delivery specifications for the 1991 Suzuki DR650S and DR650SM.
- Covers global configuration variants E-02 through E-53, including MIKUNI BST40SS carburetor jetting unique to the initial launch build.
- Features comprehensive technical data for the 640 cm³ air-cooled OHC four-stroke powerplant.
- Includes 47 exploded-view diagrams for chassis and internal engine components, backed by extensive electrical schematics and testing tables.
- Provides the definitive factory-spec reference for baseline calibration, component inspection limits, and timing values.
Engine and Chassis Documentation
The 1991 Suzuki DR650S service manual organizes its technical content across nine specialized chapters. It starts with periodic maintenance schedules and regional fuel recommendations before diving deep into the mechanical tolerances of the 640 cm³ engine. For the powerplant, the documentation outlines internal clearances for the cylinder head, camshaft journals, and transmission assemblies. Technicians will find extensive coverage of the PEI ignition system and charging circuits, complete with resistance values for pick-up and power source coils to help pinpoint electrical faults. Motorcycle maintenance, particularly involving high-voltage ignition components and fuel delivery, inherently carries shop risks. Reviewing the factory-specified safety protocols and handling procedures detailed in this document is a vital first step before tearing down the bike.
Specifications and Reference Values
Factory data is anchored throughout the text via precise specification tables and exploded views. The manual highlights critical mechanical thresholds, such as the cylinder head bolt torque set at 35–40 Nm (25.5–29.0 lb-ft) and intake/exhaust valve clearances established at 0.08–0.13 mm. You will also find exact fluid capacities, like the 2.0-liter engine oil requirement, alongside detailed carburetor setup charts for different global markets. This depth ensures mechanics have the exact tolerances needed for a factory-correct rebuild without second-guessing regional variations.
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