The 1999 Suzuki DR650SEX is a versatile dual-sport motorcycle renowned for its robust air-cooled engine, durable construction, and comfortable riding position. Building on Suzuki's legacy of producing reliable and capable off-road machines, this model excels in adventure touring, commuting, and general utility riding. Its design emphasizes simplicity and resilience, featuring a 644cc single-cylinder engine, a 5-speed transmission, and long-travel suspension suitable for varied terrains. The DR650SEX offers a practical and dependable riding experience, making it a popular choice for riders seeking a capable all-around motorcycle. This comprehensive English-language Service Repair Manual provides detailed, step-by-step instructions for the maintenance, repair, and troubleshooting of the 1999 Suzuki DR650SEX. Covering all major systems including the engine, transmission, chassis, brakes, and electrical components, the manual offers guidance on routine servicing, component overhauls, and diagnostic procedures. It is designed to assist both home mechanics and professional technicians in keeping the motorcycle in optimal condition, ensuring its longevity and performance. The manual includes essential technical specifications, torque settings, and clear diagrams to facilitate accurate and efficient work. 🏷️ Basic Information Identification Make: Suzuki Model: DR650SEX Year: 1999 Product Name: Suzuki DR650SEX 1999 Service Repair Manual PDF Download 👋 Introduction Market Position Segment: Dual-sport motorcycle, known for its versatility and reliability in both on-road and off-road applications Competitive Analysis Competitors: Yamaha XT500/XT600, Honda XR600R/Transalp, Kawasaki KLR650 Key Features Design: Robust air-cooled engine, simple yet durable construction, long-travel suspension, comfortable riding position Purpose: Adventure touring, commuting, off-road riding, general utility 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for the 1999 Suzuki DR650SEX Page Count Estimated Page Count: 300-400 Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete overhaul, tuning, diagnostics, lubrication, cooling system, fuel system (carburetor), exhaust system, engine management (ignition) Transmission: Clutch, gearbox, shift mechanism, lubrication, disassembly and assembly Chassis: Frame, suspension (front forks, rear shock absorber), steering system, wheels, spokes, bearings Brakes: Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, rotor maintenance Electrical: Ignition system, lighting, charging system (stator, regulator/rectifier), starting system (starter motor, battery), wiring diagrams, troubleshooting electrical faults Bodywork: Body panels, seat, fuel tank, fenders, handlebars, controls, decals Procedures Included Maintenance: Routine inspections, oil changes, filter replacements, chain adjustment, spark plug replacement, valve clearance adjustment, brake fluid flush Repair: Engine rebuild, transmission repair, carburetor overhaul, suspension rebuild, brake system repair, electrical component replacement Troubleshooting: Diagnostic procedures for common issues, fault finding, symptom-based troubleshooting guides Torque Specifications: Torque settings for all critical fasteners and components Technical Depth Depth: Detailed, step-by-step instructions suitable for home mechanics and professional technicians 📊 Manual Specifications File Format Quality: High-resolution, searchable PDF with clear diagrams and text Print Quality Print Readability: Optimized for printing, allowing clear reproduction of all diagrams and text Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Type: 4-stroke, SOHC, 4-valve, single-cylinder, air-cooled Displacement: 644 cc (39.3 cu in) Bore X Stroke: 100.0 mm x 82.0 mm (3.94 in x 3.23 in) Compression Ratio: 9.5:1 Performance Horsepower: Approx. 46 hp (34 kW) @ 6,400 rpm (spec varies) Torque: Approx. 37 lb-ft (50 Nm) @ 4,500 rpm (spec varies) Fuel System Carburetor: Mikuni BST40, 40mm CV carburetor Fuel Type: Unleaded gasoline, octane rating 87 or higher recommended Lubrication Oil Capacity: 2.1 L (2.2 US qt, 1.8 Imp qt) with filter change Oil Type: SAE 10W-40 API SG or SH, JASO MA Ignition System: Digital CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Type: 5-speed constant mesh Clutch: Wet, multi-plate Final Drive: O-ring sealed chain Features Gear Ratios: 1st: 2.235, 2nd: 1.590, 3rd: 1.235, 4th: 1.000, 5th: 0.857 Transmission Fluid Type: API GL-4, SAE 80W-90 gear oil 📐 Dimensions Exterior Length: 2,255 mm (88.8 in) Width: 895 mm (35.2 in) Height: 1,215 mm (47.8 in) Wheelbase: 1,470 mm (57.9 in) Ground Clearance: 260 mm (10.2 in) Seat Height: 870 mm (34.3 in) Weights Dry Weight: 163 kg (360 lbs) Wet Weight: Approx. 180 kg (397 lbs) Fuel Capacity: 13.0 L (3.4 US gal, 2.9 Imp gal) Wheels And Tires Front Tire: 90/90-21 M/C 54S, tubed Rear Tire: 130/90-17 M/C 63S, tubed Front Wheel: Spoked, 21-inch Rear Wheel: Spoked, 17-inch 🛡️ Safety Features Ratings Crash Safety: Not formally rated as per modern automotive standards; rider safety depends on protective gear and riding practices. Active Features Braking: Hydraulic disc brakes front and rear Passive Features Frame Construction: Steel semi-double cradle frame 💡 Technology Features Infotainment Features: Basic instrumentation: speedometer, odometer, trip meter, neutral indicator, high beam indicator. No advanced infotainment systems. Driver Assistance Features: N/A Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 km (1,800 miles) or 6 months, whichever comes first Oil Filter Replacement Interval: Every 3,000 km (1,800 miles) or at every oil change Air Filter Cleaning Interval: Every...