GR650 FAQ Page

Where can I obtain a service manual?

Last I heard, the Suzuki Tempter GR650 USA Service Manual was still available from your friendly Suzuki dealer.  Order part number 99500-36030-03E.  It was priced at about $50.

How can I reduce vibration at highway speeds?

Exchange the factory 15 tooth countershaft sprocket with a 16 tooth (Suzuki part number 27511-37200).  The last time I purchased one it cost about $16.  Note that this sprocket was originally used on a mid-eighties Suzuki motocross model and is designed for #520 chain, rather than the GR650's standard #530 chain.  That means it is slightly thinner than the original sprocket.  My experience has shown no problems with excessive wear when used with the #530 chain.  Since the sprocket is thinner than standard, you will need to add a washer between the sprocket and lock washer when installing.  If you don't, the sprocket will remain loose on the countershaft splines even after you torque the sprocket nut.  With the new 16/38 gearing, expect 4700 RPM at 65 MPH verses slightly over 5000 with the stock 15/38 sprockets - with no noticeable loss in performance or problems clutching off from a stop light.  At 65-70 MPH, you will be below the point were engine vibration and valve train noise becomes an issue.

How come my battery won't stay charged?

Early Suzuki's had consistent charging problems, resulting in run-down batteries, short battery life, hard starting and frequent stator and regulator/rectifier replacement.  Some of the problem is due to poor quantity or corroded electrical connectors, some to a poor ground to the regulator/rectifier and some just poor quality components or design.  I've had pretty good luck electrically by keeping the connectors on the three stator wires clean and by running a heavy ground wire directly from the negative terminal of the battery to the regulator/rectifier mounting bolt.  Still, be prepared to replace batteries, regulator/rectifiers and stators more often then you'd like.  You might try sourcing components from Electrex rather than using factory replacements.