Suzuki DR650SE (1996+) Maintenance Schedule and Service Intervals
This is the maintenance schedule and associated service intervals for the Suzuki DR650SE, which people more often call the DR650S or just DR650 (which is what we’ll call it here).
The Suzuki DR650 is quite possibly the best all-around, dual-purpose motorcycle available … ever. Well, it’s one of a few, striking its own balance between off-road prowess and on-road practicality. It is a competitor to the Honda XR650L and also to the Kawasaki KLR650.
The DR650 is a thumper with a rock-solid reliable 644 cc air/oil-cooled four-stroke single cylinder engine carried in a strong steel, semi-double cradle frame. The telescopic fork and link-style rear suspension can tackle tough trails or urban roads.
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What you might need to service the Suzuki DR650
To service your Suzuki DR650, you’ll need the following parts/consumables.
| Part | Suzuki DR650 spec |
|---|---|
| Engine oil | A bike like this isn’t fussy. The spec required is SAE 10W/40 oil rated at SE, SF, or SG under the API classification. Most oils meet this spec. Yamalube 10W-40 is a cheap and good quality option (there’s no Suzuki one but really brands don’t matter) |
| Oil filter | Use a Hiflofiltro HF137 for a good quality drop-in replacement. |
| Spark plug | Use a NGK CR10E gapped to 0.7-0.8mm. |
| Brake fluid | Use one of the appropriate spec, e.g. Castrol DOT 4. |
| Chain maintenance | Use either Motul chain paste or a Motul chain care kit if you need a brush, cleaner etc. |
| Grease | Use a lithium soap-based grease for external pivot points. |
| Air filter | You can usually clean the air filter. But if you have to replace it, use a K&N SU-6596. |
Suzuki DR650S Maintenance Schedule
Below is the maintenance schedule for the Suzuki DR650S.
The DR650 is a super easy bike to service. Valve clearance intervals of 24,000 km (14,500 miles), and there’s only one cylinder!
Notes on reading the maintenance schedule:
- Reference:
- I= Inspect and clean, adjust, replace or lubricate as necessary.
- R= Replace
- T= Tighten
- Interval: This interval should be judged by number of months or odometer reading, whichever comes first.
| months | 12 | 24 | 36 | 48 | |
|---|---|---|---|---|---|
| km x 1000 | 6 | 12 | 18 | 24 | |
| miles x 1000 | 4 | 7.5 | 11 | 14.5 | Periodic |
| Valve clearance | – | – | – | I | |
| Spark plugs (NGK CR10E) | I | R | I | R | |
| Air filter (K&N SU-6596) | Clean every 3,000 km (2,000 miles) | ||||
| Idle speed | I | I | I | I | |
| Fuel hose | I | I | I | I | |
| Clutch | I | I | I | I | |
| Evaporative emission control system (California model only) | – | I | – | I | |
| Fuel valve strainer | – | – | C | ||
| Engine oil (amalube 10W-40) | R | R | R | R | |
| Engine oil filter (HF137) | – | R | – | R | |
| Drive chain. Use a Motul chain care kit or Motul chain paste | I | I | I | I | Clean and lubricate every 1,000 km (600 mile) |
| Brakes | I | I | I | I | |
| Brake hoses | I | I | I | I | Replace every 4 year |
| Brake fluid (Castrol DOT 4) | I | I | I | I | Replace every 2 years |
| Steering | – | I | – | I | |
| Front fork | – | I | – | I | |
| Rear suspension | – | I | – | I | |
| Tires | I | I | I | I | |
| Spark Arrester | Clean every 6,000 km (4,000 miles) | ||||
| Exhaust pipe bolts and muffler bolts | – | T | – | T | |
| Chassis nuts and bolts | T | T | T | T | |
| Lubrication (Lithium soap-based grease) | Generally lubricate every 1,000 km (600 miles) |
Tyre size and tyre pressure for the Suzuki DR650
The manual gives the following tyre specs for the DR650S, as well as the following recommended tyre pressure ranges when cold.
Note: The DR650S runs tubed tyres. It ships with Bridgestone Trail Wings
| Tyre | Size | Tyre pressure (cold) |
|---|---|---|
| Front | 90/90-21M/C 54S | Solo: 150 kPa / 1.5 bar / 22 psi Dual: 175 kPa / 1.75 bar / 25 psi |
| Rear | 120/90-17M/C 64S | Solo: 150 kPa / 1.5 bar / 22 psi Dual: 200 kPa / 2 bar / 29 psi |
About the Suzuki DR650
The first Suzuki DR650 (of this kind, the DR650SE) was introduced in 1996, and while it has evolved since then, the more interesting thing is how much it hasn’t changed. The
An air- and oil-cooled 644 cc thumper engine powers the DR650. No water jacket or radiator to complicate things, no fandangled contraptions like ride-by-wire or traction control just waiting to fail and leave you stranded on the road/trail/service department. The DR650 breathes through an old-fashioned, Mikuni BST40 constant-velocity carburetor.
The pistons measure 100 mm x 82 mm — typical for thumpers to run oversquare — and it runs a relatively low compression ratio at 9.5 to 1. A five-speed, constant-mesh transmission and chain drive complete the drivetrain.
The engine may only put out 34 kW (46 hp), but for a bike this light, and for this purpose (on-and-off-roading), it’s perfect. No wonder Suzuki hasn’t changed it in literally decades.
The front suspension is composed of 43mm KYB forks with gold anodized lower legs. The 1996+ DR650 also has an oil cooler, an electric starter system without a back-up kick lever! (this is the E in the name DR650SE, by the way), and a small fairing.
Braking is through a 290mm floating front disc and a compact twin-piston Nissin caliper. The rear is also a disc, with a solid-mounted 245mm rotor and a single-piston Nissin caliper.
The DR650S definitely weighs in at the bottom of the range for true dual-sport machines at 166 kg (366 pounds) wet. This is partly due to its small gas tank — something many people upgrade for long-distance travel. But it’s also due to frame revision. The frame for the DR650 was state-of-the-art 25 years ago, computer-designed to provide as much rigidity as possible while minimising weight. Same for the swingarm.
Manual for the Suzuki DR650
The above maintenance schedule comes directly from the user’s manual for the Suzuki DR650.
You can download it from here.
