Suzuki DL650AK8 Service Bulletin

[Page 1] Suzuki DL650AK8

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 infor...

[Page 2] Suzuki DL650AK8

MOTORCYCLE DATE: Jul. 27, 2007 PAGE: 2 OF 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 cyl...

[Page 3] Suzuki DL650AK8

MOTORCYCLE DATE: Jul. 27, 2007 PAGE: 3 OF 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-hold...

[Page 4] Suzuki DL650AK8

MOTORCYCLE DATE: Jul. 27, 2007 PAGE: 4 OF 14 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 di...

[Page 5] Suzuki DL650AK8

MOTORCYCLE DATE: Jul. 27, 2007 PAGE: 5 OF 14 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 bra...

[Page 6] Suzuki DL650AK8

MOTORCYCLE DATE: Jul. 27, 2007 PAGE: 6 OF 14 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 sele...

[Page 7] Suzuki DL650AK8

MOTORCYCLE DATE: Jul. 27, 2007 PAGE: 7 OF 14 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 a...

[Page 8] Suzuki DL650AK8

MOTORCYCLE DATE: Jul. 27, 2007 PAGE: 8 OF 14 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...

[Page 9] Suzuki DL650AK8

MOTORCYCLE DATE: Jul. 27, 2007 PAGE: 9 OF 14 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 mete...

[Page 10] Suzuki DL650AK8

MOTORCYCLE DATE: Jul. 27, 2007 PAGE: 10 OF 14 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- tur...

[Page 11] Suzuki DL650AK8

MOTORCYCLE DATE: Jul. 27, 2007 PAGE: 11 OF 14 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 ...

[Page 12] Suzuki DL650AK8

MOTORCYCLE DATE: Jul. 27, 2007 PAGE: 12 OF 14 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 I...

[Page 13] Suzuki DL650AK8

MOTORCYCLE DATE: Jul. 27, 2007 PAGE: 13 OF 14 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 eac...

[Page 14] Suzuki DL650AK8

MOTORCYCLE DATE: Jul. 27, 2007 PAGE: 14 OF 14 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 Afte...