1991 Suzuki DR650S / DR650SM Service Manual (188 Pages)

1991 Suzuki DR650S and DR650SM Technical Documentation

• Covers 1991 Suzuki DR650S and DR650SM, including global configuration variants E-02 through E-53 with corresponding carburetor settings
• Original OEM publication, featuring detailed technical data for the 640 cm³ air-cooled OHC four-stroke engine
• Contains 47 exploded-view diagrams illustrating chassis and engine components, plus 2 major electrical schematic and testing tables
• 188-page factory service document providing technical standards for frame maintenance, fuel system calibration, and transmission overhaul
• Files download to your account within seconds of checkout
• Page spreads stay legible when printed at original size
• Indexed PDF search covers every chapter and appendix
• This specific publication provides the definitive factory-spec reference for the 1991 model-year launch build, documenting carburetor jets and timing values unique to the initial production run

Engine and Chassis Documentation

The 1991 Suzuki DR650S service manual organizes technical content into nine distinct chapters ranging from general information to specialized model data. The opening sections detail periodic maintenance schedules, frame-number identification, and fuel/lubrication recommendations for various world regions. Engine chapters cover the removal and overhaul of the 640 cm³ powerplant, documenting internal clearances for the cylinder head, camshaft journals, and transmission components. Electrical system coverage explains the PEI ignition system and charging circuit, providing resistance specifications for pick-up coils and power source coils for troubleshooting electrical integrity.

Specifications and Reference Values

Technical data is presented throughout the document via detailed specification tables and component diagrams. The cylinder head bolt torque is specified at 35–40 Nm (25.5–29.0 lb-ft). Valve clearance for the intake and exhaust is listed at 0.08–0.13 mm in the engine maintenance section. Engine oil capacity for an oil change is documented at 2.0 liters. Fuel system setup lists MIKUNI BST40SS carburetor main jet specifications for various regional identifiers. This 188-page factory workshop manual is for owners and technicians servicing the 1991 Suzuki DR650S and DR650SM, documenting engine, chassis, electrical, and fuel-injection specifications for the 1991 model build.