Suzuki DR600S User manual

SUZUKI

ORGOO"

SERVICE

MANUAL

tien

key

ios

2.&

FOREWORD

The

SUZUKI

DR6O00S

was

designed

offer

superior

performance

through

lightweight

design,

four

stroke-power

(TSCC

engine),

engine

counter-balancers

and

full-floating

suspen-

sion.

This

service

manual

has

been

produced

primarily

for

experienced

mechanics

whose

job

inspect,

adjust,

repair

and

service

Suzuki

Motorcycles.

Apprentice

mechanics

and

do-it-

yourself

mechanics

will

also

find

this

manual

extremely

useful

repair

guide.

This

manual

contains

up-to-date

information

the

time

publication.

The

rights

are

reserved

update

make

corrections

this

manual

any

time.

SUZUKI

MOTOR

CO.,LTD.

Motorcycle

Technical

Service

Department

SUZUKI

MOTOR

CO.,

LTD.

1985

VIEW

SUZUKI

DR6OOSF

(‘85—MODEL)

RIGHT

SIDE

LEFT

SIDE

GROUP

INDEX

GENERAL

INFORMATION

—lc

ile

FUEL

AND

LUBRICATION

SYSTEM

PERIODIC

MAINTENANCE

AND

TUNE-UP

PROCEDURES

SERVICING

ENGINE

ELECTRICAL

SYSTEM

ee.

CHASSIS

SERVICING

INFORMATION

DR600SG/

DR500SG

(‘86—MODEL)

DR600RG/

DR500RG

(‘86—MODEL)

DR600RH/DR500RH

DR600SH/DR500SH

(87—MODEL)

DR600SJ/DR600RJ

DR500SJ/DR500RJ(

88—MODEL)

APPENDIX

i20

DR600SK/RK

(‘'89-MODEL)

GENERAL

INFORMATION

CONTENTS

SERIAL

NUMBER

LOCATIONS

4h:

--ae

FUEL

AND

OIL

RECOMMENDATIONS

0000000000000:

eee

BREAKING-IN

PROCEDURES

«+++++>--2520s--22++0duestutabrties

soxsUnass-onseas

SPECIAL

IVA

TERIA

305:

0-8

res

scarey

ane

eogeeae

Cee

eaeaamatae>

PRECAUTIONS

AND

GENERAL

INSTRUCTIONS

SPECTFICA

TIONS

005+

-02

0cthies

sce

accatduaretant

dnensltses

ans

ues:

atv

Sena

1-1

GENERAL

INFORMATION

SERIAL

NUMBER

LOCATIONS

The

frame

serial

number

V.I.N.

(Vehicle

Identi-

fication

Number)

stamped

the

steering

head

pipe.

The

engine

serial

number

(2)

located

the

crankcase.

These

numbers

are

required

especially

for

registering

the

machine

and

ordering

spare

parts.

FUEL

AND

OIL

RECOMMENDA-

TIONS

FUEL

Gasoline

used

should

graded

—

octane

higher.

unleaded

low-lead

type

gasoline

recommended.

ENGINE

OIL

sure

that

the

engine

oil

you

use

comes

under

API

classification

and

that

its

viscosity

rating

SAE

10W-40.

SAE

10W-40

motor

oil

not

available,

select

the

oil

viscosity

according

the

following

chart:

-20 -10

30 40

=22_-4

104

FRONT

FORK

OIL

Use

fork

oil

10.

BRAKE

FLUID

SAE

J1703,

DOT

Specification

and

classification:

WARNING:

Since

the

brake

system

this

motorcycle

filled

with

glycol-based

brake

fluid

the

manufacturer,

not

use

mix

differ-

ent

types

fluid

such

silicone-based

and

petroleum-based

fluid

for

refilling

the

system,

otherwise

serious

damage

will

result.

not

use

any

brake

fluid

taken

from

old

used

unsealed

containers.

Never

re-use

brake

fluid

left

over

from

the

servicing

and

stored

for

long

Period.

BREAKING-IN

PROCEDURES

During

manufacture

only

the

best

possible

ma-

terials

are

used

and

all

machined

parts

are

finished

very

high

standard

but

still

necessary

allow

the

moving

parts

‘‘BREAK-IN”

before

subjecting

the

engine

maximum

stresses.

The

future

performance

and

reliability

the

engine

depends

the

care

and

restraint

exercised

during

its

early

life.

The

general

rules

are

follows.

Keep

this

break-in

throttle

position.

Below

4/5

throttle

After

the

engine

has

been

operated

for

600

000

miles)

the

motorcycle

can

subjected

full

throttle

operation

for

short

periods

time.

600

000

miles)

SPECIAL

MATERIALS

The

materials

listed

below

are

needed

for

maintenance

work

the

DR6OOS,

and

should

kept

hand

for

ready

use.

They

supplement

such

standard

materials

cleaning

fluids,

lubricants,

emery

cloth

and

the

GENERAL

INFORMATION

1-2

like.

How

use

them

and

where

use

them

are

described

the

text

this

manual.

Material

Part

SUZUKI

SUPER

GREASE

“A”

99000-25010

Oil

seals

Throttle

grip

Brake

pedal

shaft

Gearshift

lever

and

shaft

Speedometer

cable,

gear-

box and

dust

seal

Wheel

bearings

Steering

stem

bearings

Sprocket

drum

bearing

Brake

camshaft,

oil

seal,

spacer,

dust

seals,

bearing

and

bushing

Brake

cam

and

Shock

absorber

dust

seals

Cushion

lever

dust

seals,

spacers

and

bearings

Swingarm

dust

seals,

spacers

and

bearings

SUZUKI

SILICONE

GREASE

99000-25100

Caliper

axle

SUZUKI

MOLY

PASTE

99000-25140

Valve

stems

De-comp.

camshaft

Countershaft

and

drive-

shaft

gears

Piston

Camshaft

journals

Rocker

arm

shafts

De-comp.

shafts

SUZUKI

BOND

No.

1207B

99000-31140

Mating

surfaces

left

and

right

halves

crankcase

Magneto

lead

wire

grommet

Cylinder

base

and

head

gaskets

Cylinder

head

cover

THREAD

LOCK

SUPER

1303”

99000-32030

2nd

drive

gear

Crankcase

bearing

retainers

Kick

starter

pawl

guide/

stopper

bolt

and

screw

Gearshift

arm

stopper

Cam

sprocket

bolts

Material

1-3

GENERAL

INFORMATION

Part

Page

THREAD

LOCK

SUPER

“1360”

99000-32130

Gearshift

cam

stopper

3-48

Magneto

stator

coil

5-2

bolt

securing

screws

Gearshift

cam

guide/paw!

3-50

Front

fork

damper

rod

6-16

lifter

screws

bolts

Engine

oil

pump

mounting

3-54

screws

THREAD

LOCK

“1342”

99000-32050

Magneto

rotor

bolt

3-53

THREAD

LOCK

SUPER

"1305"

99000-32100

Disc

mounting

bolts

6-8

SUZUKI

BRAKE

FLUID

99000-23021

(0.5

Front

brake

GENERAL

INFORMATION

1-4

PRECAUTIONS

AND

GENERAL

INSTRUCTIONS

Observe

the

following

items

without

fail

when

disassembling

and

reassembling

motorcycles.

sure

replace

packings,

gaskets,

circlips,

O-rings

and

cotter

pins

with

new

ones.

CAUTION.

Never

reuse

circlip.

After

circlip

has

been

removed

from

shaft,

should

discarded

and

new

circlip

must

installed.

When

installing

new

circlip,

care

must

taken

not

expand

the

end

gap

larger

than

required

slip

the

circlip

over

the

shaft.

After

installing

circlip,

always

insure

that

it is

completely

seated

its

groove

and

securely

fitted.

Tighten

bolts

and

nuts

from

the

ones

larger

diameter

those

smaller

diameter,

and

from

inside

outside

diagonally,

with

specified

tightening

torque.

Use

special

tools

where

specified.

Use

specified

genuine

parts

and

recommended

oils.

When

than

persons

perform

work

cooperation,

pay

attention

the

safety

each

other.

After

the

reassembly,

check

parts

for

tightening

condition

and

operation.

Treat

gasoline,

which

extremely

flammable

and

highly

explosive,

with

greatest

care.

Never

use

gaso-

line

cleaning

solvent.

Warning,

Caution

and

Note

are

included

this

manual

occasionally,

describing

the

following

contents.

MOORS

INNINGS

cha.

sere

Personal

safety

the

rider

involved,

and

disregard

the

information

could

result

injury.

GATHON

oodce

ones

sews

For

the

protection

the

motorcycle,

the

instruction

rule

must

strictly

adhered

to.

DUNN

eri

tics

wesc

veoe

«tose

Advice

calculated

facilitate

the

repair

the

motorcycle

given

under

this

heading.

USE

SUZUKI

GENUINE

PARTS

replace

any

part

the

machine,

use

genuine

SUZUKI

replacement

part

equivalent.

Imita-

tion

parts

supplied

from

any

other

source

than

SUZUKI,

used

replace

SUZUKI

Parts,

can

reduce

the

machine’s

performance

and,

even

worse,

could

induce

costly

mechanical

troubles.

1-5

GENERAL

INFORMATION

SPECIFICATIONS

DIMENSIONS

AND

DRY

MASS

TANCE

Overall

width

Overall

height

Wheelbase

Ground

clearance

GIGI

ess

ENGINE

Petre

See

ose

See

des

Piston

displacement

Compression

ratio

Carburetor

Air

cleaner

Starter

system

Lubrication

system

TRANSMISSION

Clutch

Gearshift

pattern

Primary

reduction

Final

reduction

Drive

chain

215

(87.2

in)

875

(34.4

in)

235

(48.6

in)

465

(57.7

in)

275

(10.8

in)

139

(306

Ibs)

Four-stroke,

air-cooled,

OHC

94.0

(3.700

in)

85.0

(3.346

in)

589

cm?*

(35.9

cu.

in)

8.5:1

MIKUNI

VM38SS,

single

Polyurethane

foam

element

Primary

kick

Wet

sump

Wet

multi-plate

type

5-speed

constant

mesh

1-down,

4-up

2.310

(67/29)

2.625

(42/16)

2.416

(29/12)

1.625

(26/16)

1.263

(24/19)

1.000

(21/21)

0.826

(19/23)

TAKASAGO

RK520KSO

DAIDO

D.1.D.520VC-5,

108

links

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