"service manual"
Contents
1. eee eee ATTACHED SHEET PAGE 4 Fuel Tank Drain Hose and Breather Hose Routing Diagram ATTACHED SHEET PAGE 5 No Spark or Poor ATTACHED SHEET PAGE 6 Wiring fe e ATTACHED SHEET PAGE 7 Wiring Harness Routing Diagram ATTACHED SHEET PAGE 8 Ignition Switch Inspection cesses ATTACHED SHEET PAGE 10 Fuel Tank Side Cover and Fuel Tank Front Cover ATTACHED SHEET PAGE 10 SUZUKI MOTOR CORPORATION SUZUKI 99500 36220 01E ATTACHED SHEET PAGE 1 OF 10 Section 0A Country and Area Codes The following codes stand for the applicable country ies and area s __________ Effective Frame No _ o EUo JS1C7114000007206 ___ ____ 0 L3 E2 JS1C721100100000 _ DL6s0A 13 E24 Australia JS1C711200100062 _ I ia USA DL650A L3 E 28 JS1VP56A D2100001 DL650A L3 E 33 California U S A JS1VP56A D2100001 E38 JS1VP56A 02100001 DL650A L3 E 38 Taiwan DL650A L3 E 99 Except the above Country or area E99 JS1C71213 00100001 UPDATED Warning Caution and Information Labels Location 10 For E 21 A B 10 E2. High beam indicator light Neutral position indicator light FI indicator light Freeze indicator light gt UJ 3 2 rm mmobilizer indicator light Schematic and Routing Diagram Fl System Wiring Diagram Combination meter Cooling fan relay Cooling fan motor 4 Immobilizer 2 Ignition switch P W R TPS Umm 5 Engine stop switch LM 4 EVAP system purge 30 control solenoid Ao 7 IG switch G B f3 4 Ignition coil i ie Neutral V aC cepe GN 1 2 O W light pr ii Side stand 1 switch 58 Battery Starter button LER Starter relay oy Clutch lever position Starter Switch motor B BI ue Oe TOS BriW r W B 99500 36220 01E ATTACHED SHEET PAGE 3 OF 10 Terminal Alignment of ECM Coupler 49 42 amp D GD B t 40 0 0 42 42 40 9 0 20 CD 52 Gp Gp 49 d D do d 5 Gp 39 82 GD 80 09 W D 26 25 W 23 22 Q 49 TERMINAL TERMINAL L 2 A 3 IAP sensor signal 1 IAP F 4 STPsemorsgna STP 30 6 2 sensor signal HO2S 32 Serial data for self diagnosis _______ 7 Glutch fever position switch CLT 38 8 GKP sensor signa
3. POSITION LIGHT R FRONT TURN SIGNNAL LIGHT R Y HEADLIGHT R FRONT TURN SIGNNAL LIGHT L POSITION LIGHT L ES AMBIENT AIR TEMP SENSOR dH ot 1 8 6 por STP IAP SENSOR FUEL SENSOR STV INJECTOR 1 ACTVATOR FUEL ECT 1 15A INJECTOR SENSOR S FUEL 40A SELECT J 2 4 IGNITION 10 BUTTON PUSH 5 oa 154 HAZARD DIMMER WITCH amp PASSING HORN SWITCH BUTTON CLUTCH TURN LEVER SIGNAL SWITCH POSITION SWITCH LEFT HANDLEBAR SWITCH 99500 36220 01E ATTACHED SHEET PAGE 8 OF 10 Section 9A Wiring Harness Routing Diagram E ae x ES CEA Toa J ge DM eer I 3 AG LA 1 Clamp 8 Clamp Clamp the ignition coil lead wire and generator lead wire Clamp the reservoir tank inlet hose 2 Clamp 9 Clamp Clamp the starter motor lead wire wire harness rear brake light switch lead Clamp the wire harness and regulator rectifier lead wires wire and rear wheel speed sensor lea
4. 1 Remove the air cleaner box Refer to Air Cleaner the reverse order of removal Pay attention to the Box Removal and Installation in Section 1D Page following point 1D 6 m Tighten the fuel tank side cover bolt 1 to the 2 Disconnect the ignition switch lead wire coupler 1 specified torque Tightening torque Fuel tank side cover bolt a 5 5 N m 0 55 kgf m 4 0 Ibf ft 3 Inspect the ignition switch for continuity with a tester If any abnormality is found replace the ignition switch with a new one Special tool 09900 25008 Multi circuit tester set Tester knob indication Continuity ADDED E 03 28 33 38 199 ADDED 4 After finishing the ignition switch inspection reinstall the removed parts
5. No Spark or Poor Spark Troubleshooting NOTE Check that the transmission is in neutral and the engine stop switch is in the RUN position Grasp the clutch lever Check that the fuse is not blown and the battery is fully charged before diagnosing Step 1 Check the ignition system couplers for poor connections Is there connection in the ignition system couplers Yes Goto Step 2 No Poor connection of couplers Step 2 Measure the battery voltage between input lead wires E 21 24 O G and B W 03 28 33 38 199 O W and B W at the ECM with the ignition switch in the ON position ADDED Is the voltage OK Yes Goto Step 3 No Faulty ignition switch Faulty turn signal side stand relay Faulty engine stop switch Broken wire harness or poor connection of related circuit couplers Step 3 Measure the ignition coil primary peak voltage Refer to Ignition Coil and Plug Cap Inspection Page 1H 7 NOTE This inspection method is applicable only with the multi circuit tester and the peak volt adaptor Is the peak voltage OK Yes Goto Step 4 No Go to Step 5 Step 4 Inspect the spark plugs Refer to Spark Plug Inspection and Cleaning in Section OB Page OB 9 Is the spark plug OK Yes Goto Step 5 No Faulty spark plugs ATTACHED SHEET PAGE 6 OF 10 Step 5 Inspect the ignition coils Refer to Ignition Coil and Plug Cap Inspection Page 1H 7 Is the ignition
6. switch signal Anti theft usb Co Idle speed control system Page 1A 85 In the LCD DISPLAY panel the malfunction code is indicated from small code to large code 1 To get the proper signal from the throttle position sensor the sensor basic position is indicated in the LCD DISPLAY panel The malfunction code is indicated in three digits In front of the three digits a line appears in any of the three positions upper middle or lower line If the indication is upper or lower line when engine rpm is 1 300 r min slightly turn the throttle position sensor and bring the line to the middle 99500 36220 01E ATTACHED SHEET PAGE 5 OF 10 ADDED Schematic and Routing Diagram Fuel Tank Drain Hose and Breather Hose Routing Diagram WM 22H NES A EL q Si y Uu 4 K aa _ D Align the tip of the hose The tip of the hose must not come to contact with the under cowling E The hose must not come to contact with the exhaust pipe support tightening part Pass the drain hose under the thermostat inlet connector G Pass the drain hose above the high tension cord l Clamp it within 10 mm more or less from the marked position Clamp the hose together with the starter motor lead wire J Connect the thinner side of water drain joint to the reservoir tank overflow hose B Insert the tip of the hose to the bottom of tank nipple 99500 36220 01E
7. MOTORCYCLE DATE Mar 15 2013 Service Bulletin SUBJECT YEARLY CHANGE MODEL INFORMATION APPLICABLE MODEL DL650A UEL3 EFFECTIVE ENGINE OR FRAME NO DL650AL3 E21 J81C7111100109726 E24 J81C7111200100962 E28 and 33 JS1VP56A 02100001 E38 JS1VP56A D2100001 E99 J81C71213D0100001 DL650AUEL3 E21 J81C7211100100090 REFERENCE E21 24 28 33 38 and 99 This bulletin is to inform you of the service information for the above models When you service above models please refer to the following service manuals Please note however that the contents indicated below in such manuals should be replaced by those in the attached sheet AFFECTED SERVICE MANUAL MANUAL NAME MANUAL NUMBER CORRESPONDING PAGE Page 7 0A 8 0 5 1A 5 DL650A SERVICE MANUAL BOOK 99500 36220 01 14 6 14 22 1H 4 9A 1 9A 7 94 8 9C 9 90 8 DL650A SERVICE MANUAL CD ROM 99560 36220 018 oY We believe that this information will be useful in your service activities CONTENTS Country and Area codes eee ATTACHED SHEET PAGE 1 Warning Caution and Information Labels Location ATTACHED SHEET PAGE 1 SEVICE D i ee ene ee ATTACHED SHEET PAGE 2 Fl System Wiring Diagram ATTACHED SHEET PAGE 2 Terminal Alignment of ECM Coupler ATTACHED SHEET PAGE 3 PIECE
8. coil OK Yes Goto Step 6 No Faulty ignition coil Step 6 Measure the CKP sensor peak voltage and its resistance Refer to CKP Sensor Inspection Page 1H 9 NOTICE The CKP sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Are the peak voltage and resistance OK Yes Faulty ECM Openor short circuit in wire harness Poor connection of ignition wire harness No Faulty CKP sensor Metal particles or foreign material being stuck on the CKP sensor and rotor tip 99500 36220 01E ATTACHED SHEET PAGE 7 OF 10 Wiring Systems Schematic and Routing Diagram Wiring Diagram Refer to Wire Color Symbols in Section OA Page OA 7 For 03 28 99 ADDED RIGHT HANDLEBAR SWITCH FRONT REAR ENGINE BRAKE OIL BRAKE STOP STARTER LIGHT PRESSURE LIGHT SWITCH BUTTON SWITCH SWITCH SWITCH IGNITION RUNS SENSOR FUEL FUEL ERS R SWITCH xx LI PUMP ump SENSO ON 4 JE RELAY Yrrr sEseges IGNITION 2 257 a ET a b g S L IGNITION n 2558 571 COIL 2 55 55 hl 4 B O zu WIBI zum O W xm COMBINATION METER ew
9. d wire 3 Clamp 10 Fixed clamp Clamp the wire harness ADDED 4 Clamp 11 Speed sensor Clamp the wire harness and radiator inlet hose 5 Clamp 12 Clamp Clamp the radiator hose clutch cable and ignition coil Clamp the side stand switch lead wires 6 Clamp A Set the HO2 sensor lead wire coupler and ABS lead wire inside Clamp the side stand switch lead wire Set the clamp between the crankcase the frame side cover and rear fender rear and engine sprocket outer cover bolt 7 Clamp 4 5 0 45 kgf m 3 3 Ibf ft Clamp the gear position switch lead wire generator lead wire side stand switch lead wire and speed sensor lead wire 99500 36220 01E ATTACHED SHEET PAGE 9 OF 10 Section 9A Lets UN No 1 Ambient air temperature sensor 15 Clutch cable 2 Clamp 16 10 terminals coupler of left handlebar lead wire Clamp the right handlebar switch lead wire immobilizer lead wire E 21 24 at the gray tape point and ignition switch lead wire 3 Clamp 17 4terminals coupler of left handlebar lead wire Clamp the right handlebar switch lead wire immobilizer lead wire E 21 24 and ignition switch lead wire 4 Clamp 18 Immobilizer lead wire coupler E 21 24 Clamp the stato
10. l CKP 34 Immobilizer communication for E21 24 8 Power source for fuel injector VM 35 STVA signal STVA 1B Senmorgowd EZ O f 38 OS 13 ECM ground E1 39 EVAP system purge control solenoid valve for E 33 38 0 Tachometer _______ 48 Ground TTY FwinedorEZ R 43 Immobilizer indicator for E 21 24 Ignition AA switch signal for E 03 28 33 38 99 19 ECT sensor signal EC 45 20 TO sensor signal TOS ADDED 46 F F Q INIO TP sensor signal TP pO 22 IAP sensor signal 42 IAP R ____ NENNEN _______ 24 Cooling fan relay 50 25 Starter switch signal Fuel injector 1 F Neutral switch signal Ignition coil 1 F 99500 36220 01E ATTACHED SHEET PAGE 4 OF 10 DTC Table Malfunction Part No defective 2 ibus ORUM 2 MERE ZT TE i A DERE ereo e SER end DEUM ewean _ C41 P0230 Page 1A 70 C42 P1650 Ignition switch for E 03 28 33 38 199 Page 1A 73 immobilizer for E 21 24 C44 P0130 P0135 EGG 1A 73 Heated oxygen sensor 2 5 ADDED C60 P0480 1 78 Cooling fan control system Cooling fan relay C62 P0443 EVAP system purge control solenoid valve 82 Fuel pump control system FP control system Fuel pump fuel pump relay Ignition
11. r motor lead wire and oil pressure switch lead wire 5 Clamp 19 Ignition switch lead wire coupler Clamp the wiring harness and battery minus wire 6 Clamp 20 Right handlebar switch lead wire coupler Clamp the oil pressure switch lead wire ADDED 7T Clamp 21 Front wheel speed sensor wire coupler Clamp the right handlebar switch lead wire and grommet sleeve on the front brake hose No 1 8 Clamp A Pass the immobilizer lead wire ignition switch lead wire right Clamp the left handlebar switch lead wire and grommet sleeve on the handlebar switch lead wire under the front brake pipes clutch cable 9 Fixed clamp B Pass the right handlebar switch lead wire through the guide 10 Right handlebar switch lead wire C Pass the right handlebar switch lead wire in front of throttle cables Pass the right handlebar switch lead wire inside throttle cables 11 Ignition switch lead wire D Pass the ignition switch lead wire in front of immobilizer lead wire E 21 24 12 Immobilizer lead wire E 21 24 E Do not twist the ignition switch lead wire 13 Throttle cable F Pass the left handlebar switch lead wire through the guide 99500 36220 01E ATTACHED SHEET PAGE 10 OF 10 Section 9C Section 9D Ignition Switch Inspection Fuel Tank Side Cover and Fuel Tank Front Cover Installation Inspect the comin switch in the as Install the fuel tank side cover and fuel tank front cover in
12. xcept for E 28 C 11 12 16 D 10 For E 28 1 Noise label For E 03 24 33 11 I D label For E 21 24 2 Information label For E 03 28 33 99 If equipped 12 Safety plate For E 03 28 33 99 if equipped 3 ICES Canada label For E 28 13 Brake fluid information mark For E 21 4 Vacuum hose routing label For E 33 14 Brake approval mark For E 21 5 Manual notice label For E 03 33 15 Radiator cap label For E 21 6 Tire information label For E 03 21 24 28 33 38 99 If equipped 16 Manufacture label For E 38 99 If equipped 7 General warning label For E 03 21 24 28 33 38 99 If equipped A Rear front fender 8 Rear carrier warning label For E 03 21 24 28 33 38 99 If equipped B Meter panel 9 Steering warning label For E 03 21 24 28 33 38 99 If equipped C Frame RH 10 Screen label For E 03 21 24 28 33 38 99 If equipped D Radiator cap 99500 36220 01E ATTACHED SHEET PAGE 2 OF 10 Section 0C Service Data Wattage ADDED Unit W 3 mmj Position Parking light Brake light Taillight icense plate light Turn signal indicator light High beam indicator light Neutral position indicator light Oil pressure Engine coolant temp Position Parking light ______ Brake light Taillight Turn signal light opeedometer light Tachometer light Turn signal indicator light
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