Welcome to the comprehensive service and repair manual for the 2000 Suzuki DR650SEY. This dual-sport motorcycle, known for its versatility and ruggedness, is powered by a reliable 644cc SOHC 4-valve engine and features a durable steel semi-double cradle frame. Its long-travel suspension is designed to handle both on-road commuting and off-road adventures, making it a favored choice for adventure riders and enthusiasts. The DR650 platform, with a legacy dating back to the late 1980s, represents a proven engineering approach, offering a dependable and capable machine that balances performance with user-friendly maintenance. This factory service manual provides complete coverage for the DR650SEY, detailing everything from routine maintenance, such as oil changes and chain adjustments, to in-depth troubleshooting, diagnostics, and complete repair procedures for all major systems. You will find step-by-step instructions for engine disassembly and reassembly, fuel system servicing, ignition and electrical system checks, transmission and drivetrain maintenance, suspension overhauls, and brake system servicing. The manual is designed to be an essential resource for owners and technicians, enabling effective upkeep and repair to ensure the longevity and optimal performance of your Suzuki DR650SEY. 🏷️ Basic Information Identification Make: Suzuki Model: DR650SEY Year: 2000 Codes Vin Code: Varies (refer to vehicle owner's manual for specific VIN structure) Generation Generation Code: DR650 (Second Generation) 👋 Introduction Market Position Segment: Dual-sport motorcycle, known for its versatility, reliability, and off-road capability. Target Audience: Adventure riders, off-road enthusiasts, commuters seeking a durable and capable machine. Competitive Analysis Competitors: Honda XR650L, Kawasaki KLR650, Yamaha XT600 (and later XT660). Key Features Engine Type: Air-cooled, single-cylinder, 4-stroke with SOHC and 4 valves. Frame Type: Steel semi-double cradle frame. Suspension Setup: Long-travel suspension front and rear for off-road capability. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Diagnostics, Reassembly Page Count Estimated Pages: 300-400 (typical for this model and manual type) Manual Type Manual Type: Factory Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete disassembly, assembly, inspection, and repair procedures for the 644cc SOHC 4-valve engine. Fuel System: Carburetor (Mikuni BS40) adjustment, cleaning, rebuilding, fuel tank, fuel pump, fuel lines. Ignition System: CDI ignition, spark plug specifications, testing and replacement. Transmission: 5-speed gearbox, clutch operation, adjustment, and service. Drivetrain: Final drive chain, sprockets, lubrication, and adjustment. Suspension: Front telescopic forks (USD), rear monoshock with linkage. Oil change, seal replacement, spring rate information. Brakes: Front hydraulic disc brake, rear disc brake. Pad replacement, fluid flush, caliper service, master cylinder. Electrical System: Wiring diagrams, lighting, battery maintenance, charging system (stator, regulator/rectifier), starter motor. Cooling System: Air-cooled engine. Oil cooler service and inspection. Frame And Bodywork: Frame inspection, handlebars, seat, fenders, fuel tank removal and installation. Procedures Included Maintenance: Scheduled maintenance intervals, oil changes, filter replacements, chain adjustments, brake inspections. Troubleshooting: Diagnostic flowcharts for common performance issues, starting problems, electrical faults. Repair: Step-by-step instructions for component removal, repair, and reinstallation. Diagnostics: Component testing procedures for ignition, electrical, and mechanical systems. Technical Depth Depth: Comprehensive from basic rider maintenance to complete engine and transmission rebuilds, including torque specifications and tolerances. 📊 Manual Specifications File Format File Type: PDF Searchability: Typically text-searchable (OCR'd) for easy information retrieval. Print Quality Printability: Designed for printing specific sections or the entire manual. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: DR650SEY Engine Designation (specific internal codes may vary) Displacement: 644 cc Bore X Stroke: 100.0 mm x 82.0 mm Compression Ratio: 9.5:1 Valve Train: SOHC, 4 valves Performance Horsepower: Approx. 46 HP @ 6,400 RPM (stock) Torque: Approx. 54 Nm (40 lb-ft) @ 4,600 RPM (stock) Fuel System Carburetor Model: Mikuni BS40 (CV type) Fuel Capacity: 13 L (3.4 US gal) Fuel Type: Unleaded gasoline, minimum 87 octane 🔧 Transmission Standard Type: 5-speed constant mesh Clutch Type: Wet multi-plate Features Gear Ratios: Provided in manual (specific ratios vary by model year and transmission variant if applicable) 📐 Dimensions Exterior Length: Approx. 2,255 mm (88.8 in) Width: Approx. 895 mm (35.2 in) (at handlebars) Height: Approx. 1,205 mm (47.4 in) (seat height varies) Wheelbase: Approx. 1,465 mm (57.7 in) Ground Clearance: Approx. 265 mm (10.4 in) Weights Dry Weight: Approx. 145 kg (320 lbs) Curb Weight: Approx. 162 kg (357 lbs) (with all fluids) 🛡️ Safety Features Ratings Safety Ratings: Not typically rated by governmental agencies for motorcycles. Focus is on rider responsibility and vehicle design integrity. Active Features Braking System: Dual hydraulic disc brakes (front and rear) for responsive stopping power. Passive Features Frame Construction: Robust steel frame designed for stability and durability. Lighting: Halogen headlamp, taillight, and turn signals for visibility. 💡 Technology Features Infotainment Infotainment System: N/A (minimal electronic features on this model) Driver Assistance Driver Assistance Features: N/A Connectivity Connectivity Options: N/A 🔧 Maintenance Service Intervals Oil Change Interval:...