🏷️ Basic Information Identification Make: Suzuki Model: DR650SE Generation Generation Name: Second Generation (SP46B) Production Start Year: 1996 Production End Year: 2013 Codes Chassis Code: SP46B 👋 Introduction Market Position Positioning: The Suzuki DR650SE is a long-standing and popular dual-sport motorcycle known for its ruggedness, reliability, and versatility, making it a favorite for both commuting and off-road adventures. This manual serves the owners and technicians working on these enduring machines. Competitive Analysis Competition: Competes with other dual-sport motorcycles such as the Kawasaki KLR650, Honda XR650L, and Yamaha XT660R (depending on region and model year comparisons). Key Features Manual Benefits: Empowers owners to perform their own maintenance and repairs, saving significant costs. Provides clear, step-by-step instructions with illustrative pictures for ease of understanding. Vehicle Attributes: Robust build, simple and reliable air-cooled engine, capable off-road and on-road performance, accessible for a wide range of riders. 📋 Manual Details Coverage Areas Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013 Models Covered: All DR650SE models/engines/trim/transmissions Page Count Estimated Page Count: Refer to manual for exact count, typically 300-500+ pages for a complete workshop manual Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel, ignition, starting, charging systems Transmission: Transmission, clutch, final drive (chain and sprockets) Chassis: Frame, suspension (front forks and rear shock), steering, wheels, tires, brakes Electrical: Wiring diagrams, lighting, instrumentation, battery, fuses, relays, starting system, ignition system, charging system Bodywork And Fittings: Body panels, seat, handlebars, controls, footpegs, exhaust system Procedures Included Maintenance: Routine maintenance, oil changes, filter replacements, chain adjustment, valve clearance checks Troubleshooting: Diagnostic procedures for common problems, fault finding Repair: Detailed step-by-step repair procedures for all major components and systems Disassembly And Assembly: Complete disassembly and reassembly instructions for engine, transmission, suspension, and other components Specifications And Data: Torque specifications, measurements, tolerances, clearances Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine rebuilds and advanced diagnostics 📊 Manual Specifications File Format Compatibility: Compatible with all PC & MAC computers, tablets, and mobile phones Required Software: Adobe Reader (free download available) Print Quality Print Options: Printable by page, chapter, or entire document Binding Type Binding Type Digital: N/A (Digital Download) Paper Type Paper Type Digital: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, air-cooled, OHC, 4-valve, single-cylinder 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 (Typical, may vary slightly by year) Performance Horsepower: Approx. 46 hp @ 6,500 rpm (Rear Wheel) Torque: Approx. 34 lb-ft @ 5,500 rpm (Rear Wheel) Fuel System Carburetor: Mikuni BSR40CV, constant velocity Fuel Tank Capacity: 13.0 L (3.4 US gal) Ignition Ignition System: Electronic ignition (CDI) Lubrication Lubrication System: Wet sump with oil cooler Engine Internal Components Valve Actuation: Single Overhead Camshaft (SOHC), 4 valves 🔧 Transmission Standard Transmission Type: 5-speed constant mesh Clutch Type: Wet, multi-plate Features Final Drive: RKGB525SM, O-ring sealed chain Gear Ratios: Refer to manual for specific gear ratios for each speed 📐 Dimensions Exterior Overall Length: Approx. 2,255 mm (88.8 in) Overall Width: Approx. 870 mm (34.3 in) Overall Height: Approx. 1,235 mm (48.6 in) Wheelbase: Approx. 1,465 mm (57.7 in) Weights Curb Weight: Approx. 166 kg (366 lbs) Load Capacity: Refer to manual for specific rider and luggage capacity Suspension Travel Front Suspension Travel: Approx. 218 mm (8.6 in) Rear Suspension Travel: Approx. 220 mm (8.7 in) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle specific safety ratings are not typically published by regulatory bodies in the same way as automobiles.) Active Features Braking System: Front: Disc brake, Rear: Disc brake. Anti-lock Braking System (ABS) was an optional feature on some later models. Lighting: Halogen headlight, LED taillight (on some models), turn signals. Passive Features Frame Construction: Semi-double cradle frame for stability and durability. 💡 Technology Features Infotainment Infotainment System: Basic analog instrumentation (speedometer, odometer, tachometer, indicator lights). No integrated infotainment system. Driver Assistance ABS: Optional ABS system available on certain model years. 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km (3,700 miles) or 6 months. Refer to manual for specific conditions. Oil Filter Replacement: Replace oil filter with every oil change. Valve Clearance Check: Every 12,000 km (7,500 miles). Air Filter Cleaning: Clean every 6,000 km (3,700 miles), replace as needed. Fluid Specifications Engine Oil Type: SAE 10W-40 API SG or higher (SE/SF/SG rated 4-stroke motorcycle oil) Engine Oil Capacity: 2.6 L (2.7 US qt) without filter change; 2.8 L (3.0 US qt) with filter change. Brake Fluid Type: DOT 4 Coolant Type: N/A (Air-cooled engine) Known Issues Common Wear Items: Clutch plates, front fork seals, wheel bearings, rear shock linkage bearings, cam chain. Carburetor...