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• Suzuki Manuals

Suzuki SV 650 Manual

• Supplementary service manual (187 pages)
• Manual (137 pages)
• Owner's manual (63 pages)
• page of 137 Go / 137
• Table of Contents
• Troubleshooting

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• Table of Contents 4
• Controls 14
• Fuel, Engine Oil and Coolant Recommendations 48
• Riding Tips 58
• Inspection and Maintenance 68

Related Manuals for Suzuki SV 650

Summary of Contents for Suzuki SV 650

• Page 1 This manual should be considered a permanent part of the motorcycle and should remain with the motorcycle when resold or otherwise transferred to a new owner or operator. The manual contains important safety information and instructions which should be read carefully before operating the motorcycle.
• Page 2  WARNING new motorcycle. Suzuki parts are manufactured of high quality materi- Indicates a potential hazard that als, and machined parts are finished could result in death or serious to close tolerances.
• Page 3 Your autho- rized Suzuki dealer has experienced technicians that are trained to provide your machine with the best possible service with the right tools and equip- ment.

Page 4: Table Of Contents

Page 6: consumer information.

• Page 7 It is not possible for Suzuki to mounted. test each accessory on the market or • Inspect for proper ground clear- combinations of all the available ance and bank angle.
• Page 8 LOADING LIMIT LOADING GUIDELINES This motorcycle is primarily intended  WARNING to carry small items when you are not riding with a passenger. Follow the loading guidelines below: Overloading or improper loading • Balance the load between the left can cause loss of motorcycle con- and right side of the motorcycle trol and an accident.
• Page 9 MODIFICATION SAFE RIDING RECOMMENDATION Modification of the motorcycle, or FOR MOTORCYCLE RIDERS removal of original equipment may Motorcycle riding is great fun and an render the vehicle unsafe or illegal. exciting sport. Motorcycle riding also requires that some extra precautions be taken to ensure the safety of the rider and passenger.
• Page 10 FAMILIARIZE YOURSELF WITH LABELS THE MOTORCYCLE Read and follow all the labels on the Your riding skill and your mechanical motorcycle. Make sure you under- knowledge form the foundation for stand all of the labels. Do not remove safe riding practices. We suggest that any labels from the motorcycle.
• Page 11 SERIAL NUMBER LOCATION The frame and/or engine serial num- bers are used to register the motorcy- cle. They are also used to assist your dealer when ordering parts or refer- ring to special service information. The frame number 1 is stamped on the steering head tube.
• Page 12 NOISE CONTROL SYSTEM (AUSTRALIA ONLY) TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Owners are warned that the law may prohibit: (a) The removal or rendering inoper- ative by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the pur- pose of noise control prior to its...

Page 14: Controls

Page 15: location of parts.

• Page 16 SV650 0 Battery and fuses A Seat lock B Tools C Engine oil filter D Engine oil drain plug E Side stand F Gearshift lever SV650X...
• Page 17 SV650 G Rear brake fluid reservoir H Engine oil filler cap I Rear brake light switch J Rear brake pedal K Engine oil inspection window SV650X...

Page 18: Key

• Page 19 If the motorcycle falls down, turn the ignition switch off immedi- ately. Ask your authorized Suzuki dealer to inspect the motorcycle for unseen damage.
• Page 20 The key hole can be covered by turn- ing the lid. Align the lid hole position to the key hole position when inserting the key.

Page 21: Instrument Panel

• Page 22 TACHOMETER 3 By turning the ignition switch to ON, the meter will act as follows. The tachometer indicates the engine • All LCD segments appear and speed in revolutions per minute (r/ then show the normal display. min). • The following indicator lights come Press and hold the SEL button 1 and on for 3 seconds.
• Page 23 “” 6 in light still does not go out, have the display and the warning indicator your authorized Suzuki dealer or a light G comes on. As soon as the qualified mechanic inspect your engine is started, the symbol “” 6 motorcycle.
• Page 24 If the fuel injection system fails, the the battery voltage is lower. Ask malfunction indicator light 8 comes your authorized Suzuki dealer to on and the display indicates “FI” in the inspect the motorcycle. odometer display area in the following two modes;...
• Page 25 NOTE: • If the malfunction indicator light or master warning indicator is lit, consult your Suzuki Dealer immediately. • When the odometer display indicates “CHEC”, check the following items; Make sure that the ignition fuse is not blown. Make sure that the lead wire couplers are connected.
• Page 26 CLOCK 0 Time is shown when the ignition switch is in the “ON” position. The clock has a 12-hour display. Follow the procedure below to adjust the clock. HIGH BEAM INDICATOR LIGHT To adjust the clock, press and hold “” 9 the SEL button 1 and the ADJ button 2 simultaneously for 2 seconds until This blue indicator light will be lit...
• Page 27 NOTE: Set the meter A to odometer, • then press and hold the SEL but- ton 1 for 2 seconds to switch between km and mile. At this time, the speedometer will be changed between km/h and mph and the instantaneous/average fuel con- sumption meter will be changed between km/L (L/100 km) and...
• Page 28 To change the display, push the SEL ODOMETER button 1. The display changes in the The odometer registers the total dis- order below. tance that the motorcycle has been ridden. The odometer ranges from 0 to 999999. The odometer display locks at 999999 Odometer when the total distance exceeds 999999.
• Page 29 FUEL LEVEL INDICATOR “” B The fuel level indicator indicates the amount of fuel remaining in the fuel tank. The fuel level indicator displays all 6 segments when the fuel tank is full. The mark blinks when the fuel level drops below 4.2 L (4.4/3.7 US/ Imp qt).
• Page 30 INSTANTANEOUS FUEL To change the display, push the ADJ button 2. The display changes in the CONSUMPTION METER/AVERAGE FUEL CONSUMPTION METER/ order below. DRIVING RANGE METER C (Except for EU, UK) The display has 3 functions; instanta- Instantaneous fuel consumption neous fuel consumption meter, aver- age fuel consumption meter and driving range meter.
• Page 31 Instantaneous fuel consumption meter The instantaneous fuel consumption meter displays the fuel consumption value only when the motorcycle is moving. However, when the motorcy- cle is stopping, the fuel consumption meter displays “– – . –”. This meter ranges from 0.1 to 50.0 (km/L), from 2.0 to 50.0 (L/100 km), or from 0.1 to 99.9 (MPG IMP, US).
• Page 32 Driving range meter INSTANTANEOUS FUEL The driving range meter displays esti- CONSUMPTION METER/AVERAGE mated driving range (distance) based FUEL CONSUMPTION METER/ on the remaining fuel within the range VOLTMETER/DRIVING RANGE METER C (EU, UK) from 1 to 999 km (mile). The driving range is recalculated when you refuel, The display has 4 functions;...
• Page 33 Instantaneous Fuel Consumption Meter and Average Fuel Consumption Meter To change between “km/L (L/100 km)” and “MPG”, set the meter A to odom- eter, then press and hold the SEL but- ton 1 for 2 seconds. At the same time, the odometer will be changed between km and mile.
• Page 34 (distance) Suzuki dealer. and the calculation result may not be the same as indicated by the average fuel consumption meter. •...
• Page 35 NOTICE Riding the motorcycle with the engine coolant temperature warn- ing indicator light lit can cause serious engine damage due to overheating. If the engine coolant temperature warning indicator light comes on, stop the engine to let it cool. Do not run the engine until the engine ENGINE COOLANT coolant temperature warning indi-...
• Page 36 Suzuki dealer as soon as have the system checked by an possible. authorized Suzuki dealer as soon as possible.

Page 37: Left Handlebar

• Page 38 HORN SWITCH “” 4 TURN SIGNAL LIGHT SWITCH “” 3 Press the switch to sound the horn. Moving the switch to the “” position HEADLIGHT FLASHER SWITCH 5 will flash the left turn signals. Moving (EU, Australia) the switch to the “” position will Press the switch to flash the head- flash the right turn signals.

Page 39: Right Handlebar

• Page 40 • If the neutral indicator light and the electric starter switch is pushed. the gear position indicator are not working properly, consult your Suzuki dealer. NOTICE Engaging the starter motor for more than five seconds at a time can damage the starter motor and wiring harness from overheating.

Page 41: Fuel Tank Cap

Page 42: gearshift lever, page 43: rear brake pedal, page 44: luggage straps, page 45: suspension adjustment.

• Page 46 FRONT SUSPENSION (SV650X) Spring Pre-load Adjustment To change the spring pre-load, turn the adjuster 1 clockwise or counter- clockwise. Turning the adjuster clock- wise will increase the spring pre-load. Turning the adjuster counterclockwise will decrease the spring pre-load. There are 4 grooved lines on the side of the adjuster 1 for reference.
• Page 47 Mishandling can cause explosion. • Keep away from fire and heat. • Read owner’s manual for more information. NOTE: Ask your Suzuki dealer to dis- pose of the rear suspension unit. The rear suspension spring pre-load is adjustable to compensate for rider, load, riding style and road conditions.

Page 48: Fuel, Engine Oil And Coolant Recommendations

Page 49: fuel octane rating, page 50: engine oil.

• Page 51 SAE Engine Oil Viscosity Energy Conserving Suzuki recommends the use of SAE Suzuki does not recommend the use 10W-40 engine oil. If SAE 10W-40 “ENERGY CONSERVING” engine oil is not available, select an “RESOURCE CONSERVING” oils. alternative according to the following Some engine oils which have an API chart.

Page 52: Engine Coolant Solution

• Page 53 SUZUKI LONG LIFE COOLANT (Green) Water for mixing Use distilled water only. Water other than distilled water can corrode and clog the aluminium radiator. Required amount of water/coolant Solution capacity (total): 1850 ml (2.0/1.6 US/Imp. qt) 925 ml Water (1.0/0.8 US/Imp. qt)

Page 54: Break-In (Running-In) And Inspection Before Riding

• Page 55 160 km (100 miles) before attempting ing maximum life and performance maximum performance. Avoid hard from your new Suzuki. The following acceleration, hard cornering, and guidelines explain proper break-in hard braking for the first 160 km (100 procedures.
• Page 56 OBSERVE YOUR FIRST AND MOST INSPECTION BEFORE RIDING CRITICAL SERVICE  WARNING The initial service (1000 km mainte- nance) is the most important service Failure to inspect your motorcy- your motorcycle will receive. During cle before riding and to properly break-in operation, all of the engine maintain your...
• Page 57 Before riding the motorcycle, be sure Drive chain • Correct tension or slack to check the following items. Never ( 6-28) • Adequate lubrication underestimate importance • No excessive wear or damage these checks. Perform all of them before riding the motorcycle. Tires •...

Page 58: Riding Tips

Page 59: starting the engine.

• Page 60 When the Engine is Cold or Warm: NOTICE Close the throttle completely and push the electric starter switch. After starting the engine, opening the throttle or running the motor- When the Engine is Hard to Start: cycle with the oil pressure warn- Open the throttle slightly and push the ing indicator light turned on, may electric starter switch.

Page 61: Starting Off

Page 62: using the transmission.

• Page 63  WARNING NOTICE Downshifting when engine speed Revving the engine into the red is too high can: zone can cause severe engine • cause the rear wheel to skid and damage. lose traction due to increased engine braking, resulting in an Never allow the engine to rev into accident;...

Page 64: Riding On Hills

• Page 65  WARNING  WARNING Inexperienced riders tend to under Failure to use good judgment with utilize the front brake. This can ABS can be hazardous. ABS can- cause excessive stopping dis- not make up for bad road condi- tance and lead to a collision. tions, bad judgement, or improper Using only the front or rear brake operation of the brakes.
• Page 66 How the ABS Works Stopping and Parking ABS works by electronically con- 1. Twist the throttle grip away from trolling braking pressure. A computer yourself to close the throttle com- monitors wheel rotation speed. If the pletely. computer detects that a braked wheel 2.
• Page 67 5. Park the motorcycle on a firm, flat  WARNING surface where it will not fall over. Hard braking on wet, loose, rough,  CAUTION or other slippery surfaces can cause wheel skid and loss of con- A hot muffler can cause severe trol.

Page 68: Inspection And Maintenance

Page 69: maintenance schedule.

• Page 70 If you have any when electric circuit questions regarding maintenance shorted. intervals, consult your Suzuki dealer or a qualified mechanic. Turn off the ignition switch before servicing the electric parts to avoid short-circuit damage. NOTICE Poorly-made replacement parts can cause your motorcycle to wear more quickly and may shorten its useful life.
• Page 71 – – – (if equipped) “SUZUKI SUPER LONG LIFE Replace every 4 years or 48000 km (29000 miles) COOLANT” (Blue) “SUZUKI LONG LIFE * Engine coolant COOLANT” (Green) ( 6-27) or an engine coolant – – – other than “SUZUKI SUPER LONG LIFE COOLANT”...
• Page 72 – – – (if equipped) “SUZUKI SUPER LONG LIFE – – – – COOLANT” (Blue) “SUZUKI LONG LIFE * Engine coolant COOLANT” (Green) ( 6-27) or an engine coolant – – – other than “SUZUKI SUPER LONG LIFE COOLANT” (Blue) Radiator hose (...

Page 73: Fuel Tank Lift

• Page 74 (SV650) (SV650) (SV650X) 4. Remove the bolts 2. (SV650X) 3. Remove the bolts and fasteners. Remove the right and left frame covers 1 by unhooking the frame covers.
• Page 75 5. Lift the front end of the fuel tank and prop it up as shown above. Put the circle end of the prop stay onto the steering stem nut. NOTE: A prop stay is available at your Suzuki dealer. The prop stay part number is 44560-23H00.

Page 76: Lubrication Points

Page 77: battery.

• Page 78 BATTERY REMOVAL To remove the battery, follow the pro- cedure below: 1. Place the motorcycle on the side stand. 2. Remove the seat by referring to the SEAT LOCK section. 3. Remove the fuel cut sensor 1 from the battery holder 2. 4.
• Page 79 NOTICE Reversing the battery lead wires can damage the charging system and the battery. Always attach the red lead to the (+) positive terminal and the black (or black with white tracer) lead to the (–) negative terminal. 5. Disconnect the negative (–) termi- nal 3.

Page 80: Air Cleaner

• Page 81 NOTICE Failure to inspect the air cleaner element frequently if the vehicle is used in dusty, wet, or muddy con- ditions can damage your motorcy- cle. The air cleaner element can become clogged under these con- ditions, and engine damage may result.
• Page 82 6. Reinstall the cleaned element or Air Cleaner Drain Plug new air cleaner element in reverse order of removal. Be absolutely sure that the element is securely in position and is sealing properly. NOTICE A torn air cleaner element will allow dirt to enter the engine and can damage the engine.

Page 83: Spark Plugs

• Page 84 Rear Side INSPECTION 1. Lift the fuel tank by referring to the FUEL TANK LIFT section. 0.8 – 0.9 mm (0.031 – 0.035 in) 2. Pull off the spark plug caps. Adjust the spark plug gap to 0.8 – 0.9 3.
• Page 85 If the spark or their equivalent. Consult your plug is new, tighten it with a Suzuki dealer if you are not sure wrench about 1/2 turn past finger which spark plug is correct for tight. If you are reusing the old your type of usage.

Page 86: Fuel Hose

Page 87: engine oil.

• Page 88 If oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil. Available from Suzuki dealer Recycle or properly dispose of Oil filter wrench (Part No. 09915-40620) used oil and filters.
• Page 89 4. Turn the oil filter 4 counterclock- 6. Smear a little engine oil around the rubber gasket 6 of the new oil wise and remove it with a Suzuki “cap type” oil filter wrench or a filter. “strap type” filter wrench of the 7.
• Page 90 Tighten the filter 2 turns or to Engine damage may occur if you specified torque. use oil that does not meet Suzuki’s specifications. 8. Mark the top dead center position on the “cap type” filter wrench or Be sure to use the oil specified in on the oil filter.

Page 91: Engine Idle Speed Inspection

Page 92: throttle cable play, page 93: clutch, page 94: coolant, page 95: drive chain.

• Page 96 Chain replacement requires a spe- 5. Lubricate with motorcycle cial riveting tool and a high-qual- sealed drive chain lubricant or ity, non-joint-clip type chain. Ask high viscosity oil (#80 – 90). an authorized Suzuki dealer or a qualified mechanic to perform this work. 6-29...
• Page 97 DRIVE CHAIN ADJUSTMENT NOTICE Adjust the drive chain slack to the proper specification. The chain may Some drive chain lubricant con- require more frequent adjustments tains solvents and additives which than indicated in the periodic mainte- could damage the seal rings in the nance schedule depending upon your drive chain.
• Page 98 To adjust the drive chain, follow the procedure below:  CAUTION A hot muffler can burn you. The 20 – 30 mm muffler will be hot enough to burn (0.8 – 1.2 in) you for some time after stopping the engine. 3.

Page 99: Brakes

• Page 100 Check the brake fluid level in both the  WARNING front and rear brake fluid reservoirs. If the level in either reservoir is below Brake fluid is harmful or fatal if the lower mark, inspect for brake pad swallowed, and harmful if it comes wear and leaks.
• Page 101 1. If a front or rear pad is worn to the grooved wear limit line, both front or both rear pads must be replaced with new ones by your authorized Suzuki dealer or a quali- fied service mechanic.  WARNING FRONT...
• Page 102 NOTE: Do not squeeze/depress the REAR BRAKE PEDAL brake lever/pedal when the pads are ADJUSTMENT not in their positions. It is difficult to The rear brake pedal position must be push the pistons back and brake fluid properly adjusted at all times or the leakage may result.

Page 103: Tires

• Page 104 TIRE PRESSURE AND LOADING  WARNING Proper tire pressure and proper tire loading are important factors. Over- Failure to perform break-in of the loading your tires can lead to tire fail- tires could cause tire slip and loss ure and loss of motorcycle control. of control, which could result in an accident.
• Page 105 TIRE CONDITION AND TYPE Proper tire condition and proper tire type affect motorcycle performance. Cuts or cracks in the tires can lead to tire failure and loss of motorcycle con- trol. Worn tires are susceptible to puncture failures and subsequent loss of motorcycle control.
• Page 106 • Do not use an external repair wear out sooner. plug to repair a puncture since the plug may work loose as a • Ask your Suzuki dealer or a result of the cornering forces qualified mechanic to perform experienced by a motorcycle tire repair, replacement, and bal- tire.

Page 107: Side Stand/Ignition Interlock System

Page 108: front wheel removal.

• Page 109  WARNING Failure to extend brake pads after installing the wheel can cause poor braking performance and may result in an accident. Before riding, “pump” the brake lever repeatedly until the brake pads are pressed against the brake disks and proper lever 8.

Page 110: Rear Wheel Removal

• Page 111 1. Place the motorcycle on the side stand. 6. Draw out the axle shaft. 2. Remove the rear wheel speed sensor by removing the mounting bolt. 7. With the wheel moved forward, remove chain from sprocket. 3. Remove the axle nut 1. 4.
• Page 112 NOTE: Never depress the rear brake dure, have your authorized pedal with the rear wheel removed. It Suzuki dealer or a qualified is very difficult to force the pads back mechanic do this. into the caliper assembly.

Page 113: Light Bulb Replacement

• Page 114 Right 3. Unhook the hooks and remove the headlight assembly. Left 4. Disconnect the socket 1 from the 2. Remove the right and left screws. headlight and remove the rubber cap 2. 6-47...
• Page 115 Position light (if equipped) 5. Unhook the bulb holder spring 3 1. Pull out the socket. and pull out the bulb 4. 6. To replace the headlight bulb, reverse the above sequence. NOTICE The headlight bulb’s life may be shortened by oil from your fingers if you touch it.
• Page 116 HEADLIGHT BEAM ADJUSTMENT TURN SIGNAL LIGHT The headlight beam can be adjusted To replace the turn signal light bulb, both up and down or right and left if follow these directions. necessary. 1. Remove the screw and take off the lens. To adjust the beam up and down: Loosen the adjuster 1.

Page 117: Fuses

• Page 118 FUSE LIST • 30A MAIN fuse protects all electri- cal circuits. • 10A HEAD-HI fuse protects the headlight high beam and speed- ometer. • 10A HEAD-LO fuse protects the headlight low beam. • 15A IGNITION fuse protects the cooling fan relay, oxygen sensor, ECM, solenoid, fuel pump relay, starter relay, side stand relay, igni- The main fuse is located under the...

Page 119: Catalytic Converter

Page 120: diagnostic connector, page 122: troubleshooting.

• Page 123 Suzuki dealer. Refer to the “INSTRU- MENT PANEL” section for an explana- NOTICE tion of the malfunction indicator light.
• Page 124 3. If there is no spark, clean the spark plug. Replace it if neces- sary. Retry the above procedure with the cleaned spark plug or a new one. 4. If there is still no spark, consult your Suzuki dealer for repairs.
• Page 125 2. If the odometer displays “FI” and malfunction indicator light comes on, trouble in the fuel injection system, take your machine to an authorized Suzuki dealer. Refer to the “INSTRUMENT PANEL” sec- tion for an explanation of the mal- function indicator light.

Page 126: Storage Procedure And Motorcycle Cleaning

Page 127: storage procedure, page 128: procedure for returning to service, page 129: motorcycle cleaning.

• Page 130 NOTE: The headlight lens can be NOTICE fogged after washing the motorcycle or riding in the rain. Headlight fogging High pressure washers such as will be cleared gradually when the those found at coin-operated car headlight is turned on. When clearing washes have enough pressure to the headlight lens fogging, run the damage the parts of your motorcy-...

Page 131: Inspection After Cleaning

Page 133: specifications.

• Page 134 ELECTRICAL Ignition type .............Electronic ignition (Transistorized) Spark plug ............NGK MR8E-9 (Except for EU, UK) NGK CR8EIA-9 (EU, UK) DENSO IU24D (EU, UK) Battery .............12V 36 kC(10 Ah)/10 HR Generator ............Three-phase A.C. generator Fuse ..............30/10/10/15/15/10/15/10A ABS fuse ............20/15A Headlight ............12V 60/55W (H4) Position light (if equipped) .......12V 5W Brake light/Taillight...........LED License plate light..........12V 5W...
• Page 135 INDEX ACCESSORY USE AND FRONT WHEEL REMOVAL ..6-41 MOTORCYCLE LOADING ....1-2 FUEL HOSE ........6-19 AIR CLEANER....... 6-13 FUEL OCTANE RATING ....3-2 AVOID CONSTANT FUEL SUPPLY CHECK....7-2 LOW SPEED ........4-2 FUEL TANK CAP......2-24 FUEL TANK LIFT......6-6 FUSES...........
• Page 136 MAINTENANCE SCHEDULE ..6-2 SAFE RIDING RECOMMENDATION MAXIMUM ENGINE SPEED FOR MOTORCYCLE RIDERS ..1-4 RECOMMENDATION...... 4-2 SEAT LOCK........2-26 MOTORCYCLE CLEANING .... 8-4 SERIAL NUMBER LOCATION ..1-6 SIDE STAND ......... 2-27 SIDE STAND/IGNITION NOISE CONTROL SYSTEM INTERLOCK SYSTEM ....6-40 (AUSTRALIA ONLY)......

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