Description

This is the complete service manual for the 1991–1995 Suzuki DR650R and DR650S, covering both the Dakar-derived R and the S across all five model years — RP, SP, RER, SER, RES, and SES trim codes. It’s a 235-page PDF (12.32 MB), bookmarked by chapter.

These years use Suzuki’s first-generation DR650 engine: a 644cc SOHC, air/oil-cooled single fed by a 40mm Mikuni carburetor. This engine was tuned for stronger top-end power for Dakar-rally-style riding, before Suzuki replaced it with a smoother, more low-end-focused redesign starting in 1996 — so this manual is specific to the earlier, more race-oriented version of the DR650, not the later SE.

Suzuki made running changes within this window too: the Djebel/Dakar model was replaced by the DR650R in 1992, with a smaller fuel tank and revised exhaust. This edition includes three service supplements alongside the base manual specifically to cover those year-to-year differences, rather than treating 1991–1995 as one unchanged bike.

Included: full teardown and rebuild procedures for engine, top end, transmission, and chassis, a wiring diagram schematic, and troubleshooting guides. Delivered as an instant PDF download, works on Windows and Mac, and any page can be printed individually.

Frequently Asked Questions

What years and models does this manual cover?
1991 through 1995 Suzuki DR650R and DR650S, including the RP, SP, RER, SER, RES, and SES codes.

What format is it, and how do I get it?
A 235-page PDF (12.32 MB), delivered as an instant download after checkout — no physical shipping.

Does it include wiring diagrams?
Yes, a wiring diagram schematic is included, along with troubleshooting guides.

Is this the same manual as the one for the later DR650SE?
No. This covers the first-generation, pre-1996 DR650 engine and chassis only. The 1996+ DR650SE used a redesigned engine and is not covered by this manual.