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MOTORCYCLE
DATE:
Jul. 27, 2007
PAGE:
1
OF
14
SUBJECT:
NOTICE OF SET-UP MANUAL
APPLICABLE MODEL:
DL650AK8
EFFECTIVE ENGINE OR FRAME NO.:
REFERENCE:
This bulletin is to inform you of set-up procedures of DL650AK8.
Please inform your dealers of this notice.
DL650AK8 Set-Up Manual will not be issued because the set-up procedures for this model remain
unchanged from DL650K4 except the differences described below.
To set-up DL650AK8, please use the DL650K4 Set-Up Manual and this Service Bulletin.
DIFFERENCE BETWEEN DL650K4 AND DL650AK8
DL650K4 Set-Up Manual: 99505-01124-011
1. LOCATION OF PARTS [Page: 2, 3, 4]
Item Part Name Q’ty Remarks
A
Windscreen 1
Screw 4 5 × 20 mm
Collared spacer 4 OD:14.0 ID:5.5 T:5.0
Rubber cushion (with nut) 4 5 mm L:17.0
B
Windscreen cover 2
Tapping screw 2 5 × 16 mm
C
Handlebars assembly 1
Clamp 2
Allen bolt 4 8 × 30 mm
Burring washer 4 OD:13.0 ID:8.5
Plastic cap 4
OD11.0
For handlebar clamp
bolt
Screw 1
5 × 25 mm
For left switch
Screw 1
5 × 40 mm
For left switch
Screw 1
5 × 30 mm
For throttle assembly
Strap 2 L:140
Clutch lever cover 1
Item Part Name Q’ty Remarks
D
Handlebar balancer weight 1 Right
Screw 1 6 × 105 mm
Flange rubber cushion 1 L:34.0
Spacer 1 L:50.0
Spacer 1 OD:16.0 ID:6.5 T:4.0
Rubber cushion 1 L:15.0
Spacer nut 1 6 mm
E Rear view mirror 2 Right and Left
F Flange bolt 1
10 × 25 mm for
front brake caliper
G Front wheel assembly 1
H Helmet holder wire 2
I Washer 2 OD:13.0 ID:6.5
J Warning label set 7
For
E-19 CC selection
K Warning label set 4
For
E-19 CD selection
L
Battery electrolyte
container
1
MOwner’s manual set 1
N
Holder 1
For front brake
master cylinder
Flange bolt 2 6 × 22 mm
OD : Outside diameter (mm)
ID : Inside diameter (mm)
L : Length (mm)
T : Thickness (mm)
T
L
OD ID
NOTE:
The parts shown as Item J and K in the above table are supplied for limited markets.
Use washers of Item I for mounting the license plate.
Please hand over the parts shown as Items H and M in the above table to your customer together with
motorcycle.
MOTORCYCLE
DATE:
Jul. 27, 2007
PAGE:
2
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14
RIGHT LEFT
[Page: 5, 6 Paragraph: 1]
The photographs shown indicate the parts dismounted
from the motorcycle in addition to the items shown in
the preceding page.
A: Front brake master cylinder
B: Throttle assembly
C: Left switch
D: Clutch cable
E: Speedometer drive gearbox
F: ABS sensor assembly
2. ASSEMBLY
REMOVING THE BRACKET
[Page: 5, 6 Paragraph: 3]
Remove the bolt to take off the front brake master cyl-
inder from the bracket.
A: Front brake master cylinder
B: Bolt
C: Bracket
THROTTLE [Page: 9, 10 Paragraph: 2]
Insert the boss of the throttle housing into the hole on
the handlebars.
Tighten the throttle assembly with two screws.
A: Boss
B: Hole
C: 5 × 30 mm screw
Keep the position of the front brake master cyl-
inder with its cap facing upwards until it is
installed.
NOTE:
The bolt is no longer needed and this may be
discarded.
Check to ensure that the throttle operates
freely and closes automatically.
MOTORCYCLE
DATE:
Jul. 27, 2007
PAGE:
3
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14
FRONT BRAKE MASTER CYLINDER
[Page: 11, 12 Paragraph: 1]
Install the front brake master cylinder onto the handle-
bars.
Align the dot mark on the handlebars with the master
cylinder-to-holder fitting surface.
Tighten the front brake master cylinder mounting bolts
to the specified torque.
Front brake master cylinder mounting bolt:
10 N·m (1.0 kgf-m)
A: Holder
B: Front brake master cylinder
C: 6 × 22 mm flange bolt
D: 6 × 22 mm flange bolt
E: Dot mark
LEFT SWITCH [Page: 11, 12 Paragraph: 4]
Insert the boss of the left switch holder into the hole on
the handlebars.
Tighten the left switch assembly with the two screws.
A: Boss
B: Hole
C: 5 × 25 mm screw
D: 5 × 40 mm screw
RIGHT LEFT
CLAMP [Page: 13, 14 Paragraph: 4]
Clamp the wiring harness of handlebar right and left
switch with straps.
A: Strap L:140 mm
B: Handlebars
C: Right switch wiring harness
D: Left switch wiring harness
NOTE:
To install the holder correctly, first tighten the
bolt C of the upper side with specified torque
and then tighten the bolt D of the lower side.
Be careful not to pinch the wiring harness
between the housing and holder.
NOTE:
Cut off the excess strap as shown in the photo-
graph.
OUTSIDE
OUTSIDE
MOTORCYCLE
DATE:
Jul. 27, 2007
PAGE:
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FRONT WHEEL
[Page: 17, 18 Paragraph: 3 through
Page: 21, 22 Paragraph: 1]
When installing the front wheel onto the axle, special
attention must be paid to the arrow of the rotational
direction on the tire sidewall.
When the tire is properly installed, the arrow must indi-
cate forward rotation of the wheel.
Mount the front wheel assembly properly.
A: Right fork leg
B: Left fork leg
C: ABS sensor bracket
D: Speedometer drive gearbox
E: Front axle
RIGHT LEFT
Temporarily remove the front brake caliper.
A: Brake caliper
B: Flange bolt (Caliper mounting bolt)
C: Supporter
D: Pad
Insert tabs of the speedometer drive gearbox into front
wheel hub grooves.
A: Speedometer drive gearbox
B: Grooves
C: Tabs
D: Oil seal (Lip)
FRONT
FRONT
Put a suitable pad on the front fender to pre-
vent the front fender and front wheel from
being damaged.
Do not remove the supporter inserted between
the brake pads until the brake caliper is
installed.
When install the speedometer drive gearbox,
be careful not to damage the oil seal lip.
MOTORCYCLE
DATE:
Jul. 27, 2007
PAGE:
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Install the ABS sensor bracket to the front wheel hub.
A: ABS sensor bracket
B: Oil seal (Lip)
Align the ABS sensor bracket stopper with stopper on
the right fork leg.
A: ABS sensor bracket
B: Stopper (ABS sensor bracket)
C: Stopper (Right fork leg)
Insert the front axle from the right side of fork leg and
fix the front wheel assembly to the front fork.
A: Front axle
A: Stopper (Speedometer drive gearbox)
B: Stopper (Left fork leg)
When install the ABS sensor bracket, be careful
not to damage the oil seal lip.
FRONT
Never use force to install the front axle.
If it cannot be installed by hand, it is not cor-
rectly aligned.
Before tightening the front axle, turn the speed-
ometer drive gearbox until the stopper on the
speedometer gearbox and the stopper on the
left fork leg come in contact as shown.
FRONT
MOTORCYCLE
DATE:
Jul. 27, 2007
PAGE:
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RIGHT LEFT
[Page: 23, 24 Paragraph: The next of 2]
A: ABS sensor lead wire
B: Speed sensor lead wire
C: Boss (Fork leg)
WARNING LABEL
[Page: 27, 28 Paragraph: 2]
Stick the label selected for your country.
A: For E-19 CC selection
B: For E-19 CD selection
C: Warning label (General warning)
D: Warning label (Windscreen)
E: Fuel tank
F: Meter panel
3. SERVICING
FRONT BRAKE LEVER
[Page: 37, 38 Paragraph: 2]
Make sure the front brake lever position is correct.
The standard setting for this motorcycle is as indicated
in the table below.
A: Adjuster
Pass the speed sensor lead wire and ABS sen-
sor lead wire to inside of the boss of front fork.
NOTE:
When sticking the new label, remove the origi-
nal label.
Standard setting 3
MOTORCYCLE
DATE:
Jul. 27, 2007
PAGE:
7
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THROTTLE CABLE
[Page: 37, 38 Paragraph: 3, 4]
This motorcycle has a twin throttle cable system.
Cable A is for pulling cable and cable B is for return-
ing.
Check the throttle cable play at the throttle grip.
Throttle cable play: 2.0–4.0 mm
If adjustment is necessary, carry out the procedure
below:
1. Loosen the lock nut C of the throttle returning cable
and fully turn in the adjuster D.
2. Loosen the lock nut E of the throttle pulling cable.
3. Turn the adjuster F in or out until the correct play is
obtained.
4. Tighten the lock nut E while holding the adjuster F.
5. While holding the throttle grip at the fully closed
position, slowly turn out the adjuster D of the throt-
tle returning cable to feel resistance.
6. Tighten the lock nut C while holding the adjuster D.
2.0–4.0 mm
After the adjustment is completed, check that
handlebar movement does not raise the engine
idle speed and that the throttle grip returns
smoothly and automatically.
MOTORCYCLE
DATE:
Jul. 27, 2007
PAGE:
8
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REAR SUSPENSION
[Page: 43, 44 Paragraph: 3]
Rebound Damping Force Adjustment
(For Canada)
Adjust the setting of the rebound damping force to the
standard position.
Standard setting: 1 turn back
To adjust, turn the adjuster B clockwise until it stops
and then turn it counterclockwise until approximately 1
turn and the two punch marks align.
ENGINE COOLANT
[Page: 45, 46 Paragraph: 2 through 4]
The engine coolant level should be kept between the
“FULL” and “LOW” level lines as shown in the photo-
graph.
Inspect the level with the motorcycle held upright on
level ground.
A: Engine coolant reservoir
If the level is lower than the “LOW” level line, add the
properly mixed engine coolant as follows.
1. Remove the seat using the key.
Remove the bolt to take off the frame covers.
A: Frame cover
B: Stepped Allen bolt
C: Boss
Do not force the adjuster B past the stopped
position or you may damage the adjuster.
NOTE:
The engine coolant reservoir is located under
the fuel tank.
FULL
FULL
LOW
LOW
MOTORCYCLE
DATE:
Jul. 27, 2007
PAGE:
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2. Remove the fastener to take off the fuel tank front
cover.
A: Fuel tank front cover
B: Fastener
C: Boss
3. Remove the bolt.
A: Allen bolt
B: Meter panel
C: Side cowling
4. Unset the meter panel and side cowling from the
boss.
A: Meter panel
B: Side cowling
C: Boss
D: Hole
NOTE:
To remove the fastener, push in the center pin
and pull out the fastener.
MOTORCYCLE
DATE:
Jul. 27, 2007
PAGE:
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5. Remove the bolt to take off the prop stay.
Lift the fuel tank and prop it up.
A: Prop stay
B: Bolt
C: Fuel tank
D: Boss
E: Hook
6. Remove the reservoir tank cap and add 50 : 50 mix-
ture of engine coolant and distilled water to the
“FULL” level line from the engine coolant filler hole.
7. Reinstall the reservoir tank cap.
8. Reinstall the fuel tank with prop stay.
9. Reinstall the side cowling and meter panel.
10.Reinstall the fuel tank front cover.
11.Reinstall the frame covers.
A: Reservoir tank cap
ENGINE OIL [Page: 47, 48 Paragraph: 2]
Engine oil
Oil quality is a major contributor to your engine’s per-
formance and life.
Always select good quality engine oil.
Use oil with an API (American Petroleum Institute)
classification of SF/SG or SH/SJ, or with a JASO clas-
sification of MA.
SAE Engine Oil Viscosity
Suzuki recommends the use of SAE 10W-40 engine
oil.
If SAE 10W-40 engine oil is not available, select an
alternative according to the left chart.
SAE API JASO
10W-40 SF or SG –
10W-40 SH or SJ MA
API: American Petroleum Institute
JASO: Japanese Automobile Standards Organization
-30 -20 -10 0 10 20 30 40
-22 -4 14 32 50 68 86 104
10W - 30
20W - 50
10W - 40 10W - 50
15W - 40 15W - 50
˚C
˚F
ENGINE OIL VISCOSITY RATING SELECTION CHART
ENGINE OIL
TEMP.
MOTORCYCLE
DATE:
Jul. 27, 2007
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JASO T903
The JASO T903 standard is an index to select engine
oils for 4-stroke motorcycle and ATV engines.
Motorcycle and ATV engines lubricate clutch and
transmission gears with engine oil.
JASO T903 specifies performance requirements for
motorcycle and ATV clutches and transmission.
There are two classes, MA and MB.
The oil container shows the classification as shown.
A: Code number of oil sales company
B: Oil classification
Energy Conserving
Suzuki does not recommend the use of “ENERGY
CONSERVING” oils.
Some engine oils which have an API classification of
SH or higher have an “ENERGY CONSERVING” indi-
cation in the API classification doughnut mark.
These oils can affect engine life and clutch perform-
ance.
IDLE SPEED ADJUSTMENT
[Page: 49, 50 Paragraph: 2]
Check the engine idle speed.
Engine idle speed: 1 200–1 400 r/min
RecommendedNot recommended
E
N
E
R
G
Y
C
O
N
S
E
R
V
I
N
G
A
P
I
S
E
R
V
I
C
E
S
J
SAE
10W-40
A
P
I
S
E
R
V
I
C
E
S
J
SAE
10W-40
NOTE:
If the engine idle speed is not within the speci-
fied range, ask your Suzuki dealer or a qualified
mechanic to inspect and repair the motorcycle.
4. TIGHTENING TORQUE [Page: 51, 52, 53]
Item Part Name N·m kgf-m
FRONT FORK
A Handlebar clamp bolt 23 2.3
B Steering stem head nut 90 9.0
C Front fork upper bracket bolt 23 2.3
D Front fork lower bracket bolt 23 2.3
E Front axle clamp bolt 23 2.3
BRAKE
F
Front brake master cylinder mounting
bolt
10 1.0
G Front brake caliper mounting bolt 39 3.9
H
Rear brake master cylinder mounting
bolt
10 1.0
I Rear brake caliper mounting bolt 23 2.3
Item Part Name N·m kgf-m
J Rear brake push rod lock nut 18 1.8
K Brake caliper air bleeder (Front) 7.5 0.75
L Brake caliper air bleeder (Rear) 6.0 0.60
AXLE
M Front axle 65 6.5
N Rear axle nut 100 10.0
ABSORBER
O Rear shock absorber nut (Upper) 50 5.0
P Rear shock absorber nut (Lower) 50 5.0
OTHERS
Q Rear swingarm pivot nut 100 10.0
R Front footrest bolt 26 2.6
MOTORCYCLE
DATE:
Jul. 27, 2007
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5. HARNESS ROUTING [Page: 55, 56]
Wiring harness
Clamp
Clamp
Clamp
Starter motor lead wire
Wiring harness
Stop lamp lead wire
ABS sensor lead wire
Clamp
Rectifier lead wire
Breather hose
ISC valve coupler
Speed sensor lead wire
Clutch cable
Handlebar switch lead wire (L)
Throttle cable
Fuse
High tension cord
Water hose
Inside
Clamp
Clamp
Clamp
Side stand switch lead wire
Wiring harness
Side stand switch lead wire
Neutral switch lead wire
Side stand switch lead wire
Neutral switch lead wire
Handlebar switch lead wire (L)
Handlebar switch lead wire (L)
Handlebar switch lead wire (R)
Handlebar switch lead wire (R)
Pass the wiring harness
under the cowling boss.
Clamp
Clamp
Ignition coil
Generator lead wire
MOTORCYCLE
DATE:
Jul. 27, 2007
PAGE:
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Clamp
Clamp
Clamp
Clamp
Clamp
ABS brake hose
Reserver hose
Turn signal light lead wire
Wiring harness
Pass the license light lead wire in front of the seat lock cable.
Triangle mark of each spark plug cap must be brought to the exhaust side.
Pass the PAIR reed valve wire between
the frame and PAIR control solenoid valve.
High tension cold
There should be no slacking the lead wire.
Generator lead wire
MOTORCYCLE
DATE:
Jul. 27, 2007
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6. SAFETY CHECK OUT [Page: 57, 58, 59]
ENGINE AND TRANSMISSION
CHASSIS
SP: Spring setting
R.DF: Rebound Damping Force
COLD TIRE INFLATION PRESSURE
ELECTRICALS
ROAD TEST INSPECTION
After completion of the setting-up the motor-
cycle all the following items should be dou-
ble-checked to confirm that the operation and
function of the motorcycle are satisfactory.
Now, setting-up the motorcycle and pre-deliv-
ery inspection have been completed and the
motorcycle can be passed to the customer.
ITEM MEASURE SPECIFICATIONS
Engine oil Check/Refill 2 300 ml
Fuel tank Drain/Fill 22.0 L
Throttle cable Check/Adjust 2.0–4.0 mm
Idle r/min Check/Adjust 1 200–1 400 r/min
Exhaust system Leakage
Fuel system
connection
Leakage/Circlip
Engine coolant Check/Refill 1 900 ml
ITEM MEASURE SPECIFICATIONS
Disc brake Clean/Fluid level
Front brake lever Check/Adjust
Position 3
Rear brake pedal Check/Adjust 15–25 mm
Clutch cable Check/Adjust 10–15 mm
Drive chain
Check/Adjust/
Lubricate
20–30 mm
Oiling points All necessary points
Battery Filling electrolyte
Wiring and cable Routing/Operation
Wiring connectors Clean/Tight
Front fork Check/Adjust SP: Position 3
Rear shock absorber Check/Adjust
SP: Position 2
R.DF:
1 turn back
Tighten all nuts and
bolts
Torque those listed
in this manual
Cotter pins, circlip
and fasteners
Check
Paint and chrome
Inspect/
Wash and polish
Warning label
(For E-19 market)
Select/Stick
SOLO RIDING DUAL RIDING
FRONT
225 kPa
2.25 kgf/cm
2
33 psi
225 kPa
2.25 kgf/cm
2
33 psi
REAR
250 kPa
2.50 kgf/cm
2
36 psi
280 kPa
2.80 kgf/cm
2
41 psi
ITEM CHECK FOR
Light
Lighting/AdjustHeadlight high/low beam
Tail/Brake light
Turn signal light
Lighting
Position light (Except for
Canada and Australia)
License light
Instrument Lights
Lighting
Speedometer light
Tachometer light
High beam indicator light
Neutral indicator light
Turn signal indicator light
Coolant temperature indicator
light/Oil pressure indicator
light/Fuel injection system
indicator light
Meter Display
ABS indicator light
Switch Operations
Operation
Ignition switch
Dimmer switch
Turn signal switch
Horn switch
Passing light switch
Hazard warning switch
Engine stop switch
Starter button
Brake switch
Side stand/ignition interlock
switch
Clutch lever position switch
ITEM CHECK FOR
Engine
Starting/Acceleration/
Smoothness/Noise
Transmission Operation/Noise
Drive chain Operation/Noise
Clutch Operation/Noise
Brake Operation/Noise
Steering Stability
Suspension Operation
Control cables Operation/Proper return
Leakage Fuel/Oil/Coolant/Exhaust
Speedometer Operation
Tachometer Operation
Odometer/Trip meter Operation
Instrument panel Operation
/