12 SV650SK1 `01 Mode..
Contents
1. s ul E so m ERE BD H um ji IIIS Hi H i m Jig lig a tini 16 869i Bl 6i 12 32 SV650SK1 01 MODEL WIRE HARNESS ROUTING lgnition switch Oil pressure switch f Clamp Starter motor Clamp Pass through the starter motor lead wire and the battery lead wire under the frame Guide Handlebar switch R amp L After loosen the lead wire about 20 30 mm clamp it Wiring harness Handlebar switch R amp L Cl mp Face the triangle mark to V exhaust side Side stand switch Side stand switch Neutral switch Generator Signal generator Clamp For E 33 Clamp Wiring harness Clamp Wiring harness Oil pressure switch Cooling fan thermo switch arburetor heater lead wire Cooling fan motor Thermo switch Carburetor heater lead wire Thermo switch Clamp For E 33 Regulator rectifier Clamp Wiring harness Battery Generator Signal generator Clamp Wiring harness Wiring harness Battery amp Clamp Wiring harness SV650SK1 01 MODEL 12 33 Clamp Wiring harness Battery O Signal generator Generator Rear brake light switch L Wiring harness E rake light Taillight License light Clamp The throttle cables must be passed inside of the cable guide lt jd Throttle cable No 12. Install the circlips 09900 06108 Snap ring pliers A CAUTION The round edge side of the circlip must be against to inside 12 24 SV650SK1 01 MODEL Install the dust cover and the dust boot Install the brake lever and the brake light switch NOTE Apply grease to the brake lever pivot bolt when installing AGE 99000 25010 SUZUKI SUPER GREASE A Align the projection on the brake light switch with the hole on the master cylinder Install the reservoir to the master cylinder When remounting the brake master cylinder onto the handle bar align the master cylinder holders mating surface with punched mark B on the handlebar and tighten the upper clamp bolt first as shown WI Front brake master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 Ib ft Install the brake hose 12 35 Tighten the brake hose union bolt to the specified torque m Brake hose union bolt 23 N m 2 3 kgf m 16 5 Ib ft 4 CAUTION Use new seal washers to prevent fluid leakage SV650SK1 01 MODEL 12 25 Connect the brake light switch lead wire A CAUTION Bleed air from the brake system after reassembling the master cylinder L7 2 24 of the SV650 Service Manual 12 26 SV650SK1 01 MODEL SPEEDOMETER REMOVAL Remove the side cowling R L and center cowling 7 12 9 Remove the meter panel by remo
3. Rear 12 700 12 743 0 5000 0 5017 Master cylinder piston diam Front 15 827 15 854 0 6231 0 6242 Rear 12 657 12 684 0 4983 0 4994 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Rear Brake caliper piston diam Front 38 180 38 256 1 5031 1 5061 30 150 30 200 1 1870 1 1890 Rear 38 098 38 148 1 4999 1 5019 Brake fluid type DOT 4 Wheel rim runout Axial Radial Wheel rim size Front 17 x MT3 50 Rear 17 x MT4 50 Wheel axle runout Front Rear SV650SK1 01 MODEL 12 45 TIRE Unit mm in ITEM STD SPEC LIMIT Cold inflation tire pressure Front 225 kPa Solo riding 2 25 kgf cm 33 psi 250 kPa Rear 2 50 kgf cm 36 psi Cold inflation tire pressure Front 225 kPa Dual riding rog 2 25 kgf cm 33 psi 250 kPa Rear 2 50 kgf cm 36 psi uu Tire size Front 120 60ZR17 55W Rear 160 60ZR17 69W Tire type Front METZELER MEZ4 FRONT Rear METZELER MEZ4 Tire tread depth 1 6 Front 0 06 2 0 Rear 0 08 SUSPENSION Unit mm in ITEM STD SPEC LIMIT Front fork stroke 130 5 1 Den Front fork spring free length 314 6 308 12 39 12 13 Front fork oil level without spring E 03 33 102 inner tube fully compressed 4 02 104
4. 5 Rear shock absorber mounting nut 50 5 0 36 0 Rear shock absorber mounting bolt 50 5 0 36 0 7 Cushion lever mounting nut 78 7 8 56 5 8 Cushion rod mounting nut 78 7 8 56 5 Q9 Rear axle nut 65 60 Rear sprocket nut 60 12 7 SV650SK1 01 MODEL 128 SV650SK1 01 MODEL EXTERIOR PARTS CONSTRUCTION 7 Wind screen Upper panel 3 Side cowling 4 Center cowling Cowling brace Front side cover D Front fender 8 Front seat Rear seat 0 Seat tail cover e SV650SK1 01 MODEL 12 9 COWLING Remove the left and right upper panels Remove the rear view mirrors Remove the wind screen Remove the left and right side cowling Remove the turn signal lights 12 10 SV650SK1 01 MODEL e Remove the center cowling L LJ Remove the combination meter panel e e Remove the headlight assembly e e Remove the combination meter e e Remove the cowling brace Remount the cowling in the reverse order of removal e SV650SK1 01 MODEL 12 11 FRONT FORK REMOVAL Remove the brake hose clamp bolts and speed sensor clamp e bolt Remove the front brake calipers 777 6 48 of the SV650 Ser vice Manual Remove the front wheel C7 6 7 of the SV650 Service Manual e Remove the front fender C7 6 3 of the SV650 Service Manual Loosen the front fork upper clamp bolt 1 NOT
5. Others 4 09 ms Front fork oil tType UZUKI FORK OIL G10 10 or equivalent fork oil Front fork oil capacity 491 ml each leg E 03 33 16 6 17 3 US Imp oz 489 ml Others 16 5 17 2 US Imp oz m Rear shock absorber spring SV650S 4 7 adjuster SV650 2 7 Rear wheel travel 125 4 9 Swingarm pivot shaft runout 0 3 Bs 0 01 1246 SV650SK1 01 MODEL FUEL 4 OIL STD SPEC Use only unleaded gasoline of at least 87 pump octane 83 or 91 octane or higher rated by the research method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corro Sion inhibitor is permissible E 03 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended The others Fuel tank capacity 15 L 4 0 3 3 US Imp gal E 33 16 L 4 2 3 5 US Imp gal The others Engine oil type SAE 10W 40 API SF or SG Engine oil capacity 2 300 ml Change 2 4 2 0 US Imp qt 2 400 ml Filter change 2 5 2 1US Imp at 3 000 ml Overhaul 3 2 2 6 US Imp qt SV650SK1 01 MODEL 12 47 PRIMARY DRIVEN GEAR CONSTRUCTION The primary driven gear washer has been united to the spacer from SV650K1 SK1 01 model as shown in the illustration amp Washer D Spacer Spacer 2 Primary driven gear assembly 2 Primary driven gear assembly Wa
6. The clutch cable and the starter cable must be passed inside the cable guide Starter cable The throttle cables must be passed in front of the brake hose Nd The throttle cables T of the brake hose NA mustbe passed inside The throttle cables must be passed Throttle cable No 1 inside of the cable guide The starter cable must be The clutch cable must be passed inside of the cable guide 77 The clutch cable must be passed inside of the cable guide The starter cable and the clutch cable must be passed inside of the cable guide Wiring harness Throttle cable Starter cable Throttle cable clamped outside of the bracket SNILNOY 3 18VO vezi 1300 10 LMSOS9AS Reserve tank Meter cylinder Pass through the brake hose behind the throttle cables D Brake hose p E 42 joint Speed lead wire v serit 2 After touchin 2 ps the brake ho union to the stopper Ee in s x unions to the stoppers toten the union e tighten the union bolts to the 43 ne ry 35 specified torque pecified torque ko Brake hose Brake hose Clamp ue After touching Speed sensor the brake hose lead wire union to the sto tighten the unio It to the specified torque brake hose union to the stopper tighten the union It to the specified torque Brake caliper SNILNOY 3SOH 35VH8 LNOHJ 13a0 10
7. take care not to get dust into the fluid When washing brake components use new brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean the disc with high quality brake cleaner or a neutral detergent A CAUTION Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc BRAKE FLUID REPLACEMENT Place the motorcycle on a level surface and keep the handle bars straight Remove the brake fluid reservoir cap and diaphragm by re moving the cap stopper Suck up the old brake fluid as much as possible Fill the reservoir with new brake fluid PAW Brake fluid type Specification DOT 4 Connect a cleaner hose to the caliper air bleeder valve and insert the other end of hose into a receptacle Loosen the air bleeder valve and pump the brake lever until old brake fluid flows out of the bleeder system Close the caliper air bleeder valve and disconnect a clear hose Fill the reservoir with new brake fluid to the upper mark of the reservoir A CAUTION Bleed air from the brake system C7 2 24 of the SV650 Service Manual SV650SK1 01 MODEL 12 21 FRONT MASTER CYLINDER REMOVAL AND DISASSEMBLY Drain brake fluid 7 6 47 of the SV650 Service Manual Disconnect the brake light switch lead wire Place a rag underneath the brake hose uni
8. 150 V Generator coil resistance 0 2 0 55 Q Generator Max output Approx 300 W at 5 000 r min Generator no load voltage When cold More than 70 V AC at 5 000 r min Regulated voltage 13 5 15 0 V at 5 000 r min Starter relay resistance 3 60 Battery Type designation YT12A BS Capacity 12 V 36 0 KC 10Ah 10HR Fuse size HI 15A Headlight LO 15A Signal 15A Ignition 10A Meter 10A Main 30A WATTAGE STD SPEC ITEM SV650S SV650 E 02 03 24 The other E 03 33 The other 28 33 countries J countries Headlight H 45Wx2 55 W 60 W m O 45Wx2 55W 55W c Parking or position light 5W 5 W Brake light Taillight 21 5W x2 e c e Turn signal light 21W e c License light 5W e e Speedometer light 0 84 W x 3 17Wx2 Turn signal indicator light 3W 17W c High beam indicator light 17W c Neutral indicator light 17W Oil pressure indicator light 17W LED c Water temp indicator light LED c 1244 SV650SK1 O1 MODEL BRAKE 4 WHEEL ITEM STD SPEC Unit mm in Rear brake pedal free travel 20 30 0 8 1 2 Rear brake pedal height 55 65 2 17 2 56 Brake disc thickness 4 5 0 18 5 0 0 20 Brake disc runout Master cylinder bore Front 15 870 15 913 0 6248 0 6265
9. 385 EX 33 480 33 530 33 18 3 1 318 1 320 1 306 Camshaft journal oil clearance IN 8 EX 0 032 0 066 0 150 1 0 0013 0 0026 0 0059 Camshaft journal holder I D 22 012 22 025 IN amp EX 0 8666 0 8671 Camshaft journal O D 21 959 21 980 IN amp EX 0 8645 0 8654 a Camshaft runout IN amp EX 0 10 Cam chain pin at arrow 3 16th pin Cylinder head distortion CYLINDER PISTON PISTON RING unit mm in ITEM STD SPEC LIMIT Compression pressure 1 500 kPa 1 100 kPa 15 KOTA Gi koleni 213 psi 156 psi Compression pressure difference 200 kPa i Koli 28 psi Piston to cylinder clearance 0 055 0 065 0 120 0 0022 0 0026 0 0047 Cylinder bore 81 000 81 015 81 075 3 1890 3 1896 3 1919 Piston diam 80 940 80 955 3 1866 3 1872 Grea Measure at 20 mm 0 79 in from the skirt end 3 Cylinder distortion 0 05 aan 0 002 Piston ring free end gap 9 9 7 9 1st Approx 0 39 0 31 10 5 8 4 2nd Approx 0 41 0 33 Piston ring end gap ist 0 20 0 35 0 70 0 008 0 014 0 028 2nd 0 20 0 35 0 70 0 008 0 014 0 028 Piston ring to groove clearance 1st 0 180 s 0 0071 0 150 2nd 0 0059 Piston ring groove width ist 1 21 1 23 0 0476 0 0484 2 1 01 1 03 2nd 0 0398 0 0406 Oil 2 01 2 03 0 0791 0
10. 6 s Clutch release screw 1 4 turn s back Drive plate thickness No 1 2 92 3 08 2 62 5 0 115 0 121 0 103 3 42 3 58 3 12 No 2 0 135 0 141 0 123 Drive plate claw width No 1 15 9 16 0 15 1 amp No 2 0 626 0 630 0 59 Driven plate distortion Clutch spring free length TRANSMISSION 4 DRIVE CHAIN 58 9 2 32 Unit mm in 22 2 4 ITEM STD SPEC LIMIT Primary reduction ratio 2 088 71 34 Final reduction ratio SV650S 2 933 44 15 SV650 3 000 45 15 Gear ratios Low 2 461 32 13 2nd 1 777 32 18 3rd 1 380 29 21 4th 1 125 27 24 5th 0 961 25 26 Top 0 851 23 27 Shift fork to groove clearance 0 1 0 3 0 5 0 004 0 012 0 020 Shift fork groove width 5 5 5 6 0 217 0 220 Shift fork thickness 53 54 0 209 0 213 Drive chain Type Sveso DID525V8 SV650S DID525V9 1 SV650 110 Links Links 6505 108 Links 20 pitch 319 4 length 12 57 Drive chain slack on side stand 20 30 0 79 1 18 Gearshift lever height 60 70 9 SV650S 24 28 SV650 be SV650SK1 01 MODEL THERMOSTAT 4 RADIATOR 4 FAN 4 COOLANT ITEM 12 41 STD SPEC Thermostat valve openin
11. Front fork upper clamp bolt 23 N m 2 3 kgf m 16 5 Ib ft Connect the ignition switch lead wire coupler Tighten the handlebar clamp bolts and the set bolts to the speci fied torque m Handlebar clamp bolt 23 N m 2 3 kgf m 16 5 Ib ft Handlebar set bolt 10 N m 1 0 kgf m 7 0 Ib ft Install the following items to the right handlebar CD Front brake master cylinder reservoir 2 Throttle grip 8 Handlebar balancer 4 Throttle cables 5 Right handlebar switch NOTE Apply grease to the throttle cable and the cable drum AX 99000 25010 SUZUKI SUPER GREASE A Align the portion of the right handlebar switch with the hole B of the handlebar Adjust the throttle cable play gt 2 16 of the SV650 Service Manual 12 16 SV650SK1 01 MODEL Tighten the front brake master cylinder mounting bolts to the specified torque NOTE Align the front brake master cylinder holder s matching surface with the punched mark on the handlebar and tighten the upper mounting bolt first then lower one F Front brake master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 Ib ft Install the following items to the left handlebar Clutch cable Clutch lever holder 2 Grip rubber 9 Handlebar balancer Left handlebar switch NOTE Align the portion amp of the left handlebar switch with the hole B of the handlebar Lightly adhere the grip rubber to the handlebar Tighten the
12. GIA ccn Seren HERE TUIS EN ELECTRICAL Ignition type Ignition timing Spark plug Battery Generator Main fuse Fuse Headlight Turn signal light Brake light Taillight License plate light Speedometer light Neutral indicator light High beam indicator light Turn signal indicator ligh Oil pressure indicator light Fuel level indicator light Water temp indicator light CAPACITIES Fuel tank including reserve sss Engine oil Coolant SA UR E IE EI IET with filter change overhaul Telescopic coil spring oil damped Link type system gas oil damped coil spring 130 mm 5 1 in 125 mm 4 9 in 30 right amp left 25 100 mm 3 94 in 3 1 m 10 2 ft Disc brake twin hydraulically operated Disc brake hydraulically operated 120 60 ZR17 55 W tubeless 160 60 ZR17 69 W tubeless Electronic ignition Transistorized 5 B T D C at 1 300 r min NGK CR8E DENSO U24ESR N 12V 36 0 kC 10 Ah 10HR Three phase A C Generator 30A 15 15 15 10 10A 12V 45 45W x 2 12V 24W 12V 21 5W x 2 12V 5W 12V 0 84W x 3 12V 1 7W 12V 1 7W 12V 3W 12V 1 7W 12V 1 7W LED 16 0 L 4 2 3 5 US Imp gal E 03 15 0 L 4 0 3 3 US Imp gal E 33 2 300 ml 2 4 2 0 US Imp qt 2 400 ml 2 5 2 1 US Imp gt 2 700 ml 2 9 2 4 US Imp gt 1 600 ml 1 7 1 4 US Imp qt These specifica
13. LMSOS9AS S E 00 4 Seal tail cover 1 S LA dfi L3S H3AOO IYL 1V3S GNV 9NITMOO Sel 1300W 10 LMSOS9AS SV650SK1 01 MODEL 12 37 SERVICE DATA VALVE 4 GUIDE Unit mm in ITEM STD SPEC LIMIT Valve diam IN 31 1 1 2 i 25 5 EX 1 0 SS Valve clearance IN 0 1 02 When cold 0 004 0 008 0 2 0 3 EX 0 008 0 012 Valve guide to valve stem IN 0 020 0 047 clearance zi 0 0008 0 0019 ema V EX 0 030 0 057 0 0012 0 0022 Fa Valve guide I D 4 500 4 512 IN EX 0 1772 0 1776 Valve stem O D IN 4 465 4 480 0 1758 0 1764 Lc EX 4 455 4 470 0 1754 0 1760 a Valve stem deflection 0 35 IN amp EX 0 014 Valve stem runout 0 05 IN amp EX 0 002 Valve head thickness IN amp EX moj Valve seat width 0 9 1 1 IN amp EX 0 035 0 043 Valve head radial runout 0 03 IN amp EX 0 001 Valve spring free length 36 8 IN amp EX INNER a 1 45 OUTER ge s Valve spring tension 4 2 4 8 kgf IN amp EX INNER 9 26 10 58 Ibs at length 29 9 mm 1 18 in 17 0 19 6 kg OUTER 37 48 43 21 Ibs at length 33 4 mm 1 31 in 12 388 SV650SK1 01 MODEL CAMSHAFT CYLINDER HEAD Unit mm in ITEM STD SPEC LIMIT Cam height IN 35 480 35 530 35 18 1 397 1 399 1
14. 0799 SV650SK1 01 MODEL 12 39 ITEM STD SPEC Piston ring thickness ist 1117 1119 0 0461 0 0469 0 97 0 99 2nd 0 0382 0 0390 Piston pin bore 20 002 20 008 0 7875 0 7877 Piston pin O D 19 992 20 000 0 7871 0 7874 CONROD 4 CRANKSHAFT Unit mm in ITEM STD SPEC LIMIT Conrod small end I D 20 010 20 018 20 040 0 7878 0 7881 0 7890 Conrod big end side clearance 0 170 0 320 0 5 0 0067 0 0126 0 02 Conrod big end width 20 95 21 00 0 825 0 827 Crank pin width 42 17 42 22 1 660 1 662 Conrod big end oil clearance 0 032 0 056 0 080 0 0013 0 0022 0 0031 Crank pin O D 37 976 38 000 1 4951 1 4960 em Crankshaft journal oil clearance 0 008 0 035 0 080 0 0003 0 0014 0 0031 Crankshaft journal O D 41 985 42 000 1 6529 1 6535 ux d Crankshaft thrust bearing 1 925 2 175 thickness 0 0758 0 0856 ik a Crankshaft thrust clearance 0 050 0 110 0 0020 0 0043 E Crankshaft runout 0 05 Tm 0 002 OIL PUMP ITEM STD SPEC Oil pressure at 60 C 140 F Above 200 kPa 2 0 kgf cm 28 psi Below 600 kPa 6 0 kgf cm 85 psi at 3 000 r min 12440 SV650SK1 01 MODEL CLUTCH ITEM STD SPEC Unit mm in Clutch cable play 10 15 0 4 0
15. ARBURETOR STD SPEC ITEM E33 E 22 U Type Carburetor type MIKUNI BDSR39 e Bore size 39 mm c 1 D No 20F4 20F5 Idle r min 1 300 x 100 r min Fuel level 16 9 0 5 mm 0 68 0 02 in c Float height 7 0 0 5 mm 0 28 0 02 in Main jet MJ 1915 137 5 Jet needle J N 6E43 54 6E38 54 2 Needle jet N J P 0M P 0 Throttle valve Th V 95 Pilot jet PJ 5 1175 Pilot screw PS PRE SET PRE SET 3 turns back Throttle cable play 2 0 4 0 mm 0 08 0 16 in CARBURETOR STD SPEC E 18 Carburetor type MIKUNI BDSR39 Bore size 39 mm I D No 20F3 1 300 50 r min 16 9 0 5 mm 0 68 0 02 in 7 0 0 5 mm 0 28 0 02 in 137 5 Idle r min Fuel level Float height Main jet Jet needle 6E38 54 2 Needle jet P 0 Throttle valve 95 Pilot jet 15 Pilot screw Throttle cable play PRE SET 2 turns back 2 0 4 0 mm 0 08 0 16 in SV650SK1 01 MODEL 12 43 ELECTRICAL ITEM STD SPEC NOTE Firing order 1 2 Spark plug NGK CR8E TER DENSO U24ESR N 0 7 0 8 mm Gap 0 028 0 031 in Spark performance Over 8 mm 0 3 in at 1 atm Signal coil resistance 140 230 Q Signal coil peak voltage More than 3 V Ignition coil resistance F Terminal Primary 3 5 5 5Q Terminal Plug cap Secondary 20 31 KQ Terminal Ignition coil primary peak voltage More than
16. E Slightly loosen the front fork cap bolt before loosening the lower clamp bolts to facilitate later disassembly Loosen the handlebar clamp bolt 2 Loosen the handlebar set bolt Loosen the front fork lower clamp bolts 4 NOTE Be careful not to drop the front fork when loosening the bolts Remove the front forks 1242 SV650SK1 O1 MODEL REMOUNTING Align the upper surface amp of the inner tube with the upper B surface of the steering stem upper bracket Tighten the front fork lower clamp bolts to the specified torque o Front fork lower clamp bolt 23 N m 2 3 kgf m 16 5 Ib ft Tighten the handlebar set bolt 2 to the specified torque WI Handlebar set bot 10 N m 1 0 kgf m 7 0 Ib ft Tighten the handlebar clamp bolt 3 to the specified torque Tighten the front fork cap bolt Tighten the front fork upper clamp bolt 4 m Handlebar clamp bolt 23 N m 2 3 kgf m 16 5 Ib ft Front fork cap bolt 23 N m 2 3 kgf m 16 5 Ib ft Front fork upper clamp bolt 23 N m 2 3 kgf m 16 5 Ib ft Install the front fender C7 6 3 of the SV650 Service Manual Install the front wheel gt 6 9 of the SV650 Service Manual Install the brake calipers 7 6 50 of the SV650 Service Manual STEERING CONSTRUCTION SV650SK1 01 MODEL 12 13 D Steering stem upper bracket Steering stem nut ust seal Steering stem upper bearing 5 St
17. SV650SK1 01 MODEL 12 1 SV650SK1 01 MODEL This manual describes service data service specifications and servicing procedures which differ from those of the SV650K1 01 MODEL NOTE Any differences between the SV650K1 01 MODEL and SV650SK1 01 MODEL in specifications and service data are clearly indicated with an asterisk mark Please refer to the SV650 Service Manual for details which are not given in this manual CONTENTS INFORMATION LABELS CHASSIS BOLT AND NUT EXTERIOR PARTS CONSTRUCTION COWLING FRONT FORK REMOVAL REMOUNTING STEERING CONSTRUCTION HANDLEBARS STEERING REMOVAL STEERING INSTALLATION FRONT BRAKE CONSTRUCTION BRAKE FLUID REPLACEMENT FRONT MASTER CYLINDER SPEEDOMETER REMOVAL CONSTRUCTION INSPECTION HEADLIGHT BULB REPLACEMEN WIRING DIAGRAM WIRE HARNESS ROUTING CABLE ROUTING FRONT BRAKE HOSE ROUTING COWLING AND SEAT TAIL COVER SET UI SERVICE DATA PRIMARY DRIVEI 12 2 SV650SK1 01 MODEL INFORMATION LABELS Noise label 6 Warning screen label E Information label Warning steering label 3 Vacuum hose routing label For E 33 8 Tire pressure label 4 Manual notice label Warning safety label Frame caution plate Safety plate SPECIFICATIONS DIMENSIONS AND DRY MASS Overalbl
18. angth x o NI NA E LU Overall width Overall height Wheelbase Ground clearnce Seat height Dry mass ENGINE IV DOG ua anasa tess ES E Fea pe teg ec ok Tg sec realen Number of cylinders Tappet clearance IN Piston displacement Compression ratio Carburetor Air cleaner Starter system Lubrication system TRANSMISSION Clutch Transmission Gearshift pattern Primary reduction ratio Gear ratios Low 2nd 3rd 4th 5th Top Final reduction ratio Drive chain SV650SK1 01 MODEL 12 3 2045 mm 80 5 in 740mm 29 1 in 1130 mm 44 5 in 1420 mm 55 9 in 140 mm 5 5 in 805 mm 31 7 in 169kg 372 Ibs Four stroke Liguid cooled DOHC TSCC 90 degree V twin 2 0 10 0 20 mm 0 004 0 008 in 0 20 0 30 mm 0 008 0 012 in 81 0 mm 3 189 in 62 6 mm 2 465 in 645 cm 39 4 cu in 11 5 1 MIKUNI BDSR39 x 2 Non woven fabric element Electric starter Wet sump Wet multi plate type 6 speed constant mesh 1 down 5 up 2 088 71 34 2 461 32 13 1777 82 18 1 380 29 21 1 125 27 24 0 961 25 26 0 851 23 27 2 933 44 15 D LD 525 V9 108 links 12 4 SV650SK1 01 MODEL CHASSIS Front suspension Rear suspension Front fork stroke Rear wheel travel Steering angle Caster Trail Turning radius Front brake Rear brake Front tire size FiBarstlte
19. be seated properly Loosen the stem nut by 1 4 1 2 turn NOTE This adjustment will vary from motorcycle to motorcycle Install the following items Front brake assembly C7 12 35 Horn Front fork C57 12 12 Handlebars C5 12 15 Front wheel C7 6 9 of the SV650 Service Manual Cowling FRONT BRAKE CONSTRUCTION SV650SK1 01 MODEL 12 19 Master cylinder reservoir cap 2 Diaphragm Dust boot Piston cup set Master cylinder clamp 6 Master cylinder Brake hose 1 9 Brake hose joint 9 Brake hose 2 R 0 Brake hose 2 L 1 Brake pads Brake pad mounting pin A Clip Spring Dust seal 6 Piston seal D Brake caliper pistons 6 Brake caliper i9 Brake caliper holder amp Master cylinder clamp bolt B Brake hose union bolt Air bleeder valve D Brake caliper mounting bolt 12 20 SV650SK1 01 MODEL A WARNING This brake system is filled with an ethylene glycol based DOT 4 brake fluid Do not use or mix different types of fluid such as silicone based or petroleum based fluids Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or which has been stored for long periods of time When storing brake fluid seal the container completely and keep it away from children When replenishing brake fluid
20. clutch holder mounting bolt to the specified torque NOTE Align the clutch holder s matching surface with the punched mark on the handlebar Clutch holder mounting bolt 10 N m 1 0 kgf m 7 0 Ib ft SV650SK1 01 MODEL 12 17 STEERING REMOVAL Remove the following items Cowling K 12 9 Front wheel C7 6 7 of the SV650 Service Manual Handlebars C7 12 14 Front fork C77 12 11 Horn NOTE Remove the horn with its bracket Remove the front brake assembly by removing the brake hose joint TA CAUTION Do not turn the front brake master cylinder upside down Remove the steering stem nut using the special tool 09940 14911 Steering stem nut wrench NOTE Hold the steering stem lower bracket to prevent it from falling Remove the steering stem Remove the dust seal the inner race and the bearing 12 18 SV650SK1 01 MODEL STEERING INSTALLATION Apply grease to the bearings and lip of dust seal AGH 99000 25010 SUZUKI SUPER GREASE A Install the lower bearing to the steering stem lower bracket Install the upper bearing bearing inner race and dust seal Tighten the steering stem nut to the specified torque with the special tools 09940 14911 Steering stem nut wrench 9 Steering stem nut 45 N m 4 5 kgf m 32 5 Ib ft Turn the steering stem lower bracket about five or six times to the left and right so that the angular ball bearings will
21. e the air cleaner L7 4 18 of the SV650 Service Manual Disconnect the speed sensor coupler Connect four 1 5 V dry cells 1kQ resistance and the tester to the speed sensor lead coupler as shown 09900 25008 Multi circuit tester Tester knob indication Voltage Lift and turn the front wheel and check that voltage varies be tween 0 6 V If any abnormal condition is noted replace the sensor SV650SK1 01 MODEL 12 29 1230 SV650SK1 01 MODEL HEADLIGHT Headlight bulb 12V 45 45W x 2 NOTE Adjust the headlight both vertical and horizontal after reassembling BULB REPLACEMENT Disconnect the socket 1 and remove the rubber cap 2 Remove the headlight bulb 4 by unhooking the bulb holder spring 3 Reassemble the bulb in the reverse order of removal A CAUTION If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure SV650SK1 01 MODEL 12 31 WIRING DIAGRAM nulgalbibillanenil HERRER HHN i ie HEH ioa i if ib Eu i685 c i AME EEATT STL TE FH IT PE AAA
22. eering stem lower bearing 6 Steering stem Handlebar 8 Handlebar balancer A Steering stem head nut Front fork upper clamp bolt Front fork lower clamp bolt D Handlebar clamp bolt Handlebar set bolt 12 14 SV650SK1 01 MODEL HANDLEBARS REMOVAL Remove the following items from the left handlebar D Left handlebar switch 2 Handlebar balancer 3 Grip rubber 4 Clutch cable Clutch lever holder Remove the following items from the right handlebar 5 Right handlebar switch 6 Throttle cables D Handlebar balancer 8 Throttle grip 9 Front brake master cylinder reservoir A CAUTION Do not turn the front brake master cylinder upside down Lift and support the fuel tank C 4 4 of the SV650 Service Manual Remove the air cleaner box C7 3 4 of the SV650 Service Manual Disconnect the ignition switch lead wire coupler Remove the handlebar set bolts Remove the steering stem upper bracket Loosen the handlebar clamp bolts and remove the handle bars SV650SK1 01 MODEL 12 15 INSTALLATION Install the handlebars to the front forks NOTE After installing the steering stem upper bracket tighten the handle bar set bolts and the clamp bolts Tighten the steering stem head nut and the front fork upper clamp bolts to the specified torque F Steering stem head nut 65 N m 6 5 kgf m 47 0 Ib ft
23. g temperature 82 C Approx 179 6 F Thermostat valve lift Over 8 0 mm 0 31 in at 95 C 203 F Engine coolant temperature switch 115 C operating temperature OFF ON Approx 239 F 108 C ON gt OFF Approx EAP Radiator cap valve opening 95 125 kPa pressure 0 95 1 25 kgf cm 13 5 17 8 psi Cooling fan thermo switch 96 C Ez temperature OFF ON Approx 504 gep 91 C ON gt OFF Approx 195 8 F Engine coolant type Use an anti freeze coolant compatible with alumi num radiator mixed with distilled water only at the ratio of 50 50 Engine coolant including reserve Reserve Approx 250 ml tank side 0 26 0 22 US Imp gt Engine Approx 1 350 ml side 1 43 1 19 US Imp qt CARBURETOR STD SPEC ITEM E 02 04 17 22 24 25 34 E 03 28 Carburetor type MIKUNI BDSR39 e Bore size 39 mm c D No 20F0 20F2 Idle r min 1 300 100 r min e Fuel level 16 9 0 5 mm 0 68 0 02 in e Float height 7 0 0 5 mm 0 28 0 02 in Main jet M J 3137 5 TS Jet needle J N 6E38 54 2 6E42 52 Needle jet N J P 0 P 0M Throttle valve Th V 95 e Pilot jet PJ 417 5 35 Pilot screw PS PRE SET 2 turns back PRE SET 3 turns back Throttle cable play 2 0 4 0 mm 0 08 0 16 in c 1242 SV650SK1 01 MODEL C
24. ially at 1 000 km 600 miles 1 month and every 6 000 km 4 000 miles 6 months Check that all chassis bolts and nuts are tightened to their specified torque Refer to the next page for the locations of the following nuts and bolts on the motorcycle Item Nem Steering stem head nut 65 2 Front fork upper clamp bolt 23 z 3 Front fork lower clamp bolt 23 2 3 16 5 4 Front fork cap bolt 23 23 16 5 Front axle 65 6 5 47 0 Front axle pinch bolt 23 2 3 16 5 Handlebar set bolt 10 1 0 7 0 8 Handlebar clamp bolt 23 2 3 16 5 9 Clutch lever holder mounting bolt 10 1 0 7 0 Front brake master cylinder mounting bolt 10 1 0 7 0 Front brake caliper mounting bolt 39 3 9 28 0 Brake hose union bolt 23 2 3 16 5 Air bleeder valve 7 5 0 75 5 5 9 Brake disc bolt Front and Rear 23 23 16 5 amp Rear brake caliper mounting bolt 26 2 6 19 0 0 Rear brake caliper housing bolt 30 3 0 21 5 f Rear brake master cylinder mounting bolt 10 1 0 7 0 9 Rear brake master cylinder rod lock nut 18 1 8 13 0 9 Front footrest bracket mounting bolt 23 2 3 16 5 20 Front footrest bolt 39 3 9 28 0 Swingarm pivot shaft nut 100 10 0 72 5 Swingarm pivot shaft lock nut 90 9 0 65 0 3 Swingarm pivot shaft 15 15 11 0 4 Torque link nut Front 8 Rear 35 3 5 25 5
25. ift the fuel tank and support it by prop C7 4 4 of the SV650 Service Manual Disconnect the oil pressure switch lead wire coupler The fuel indicator light lights up for approx 3 seconds after the ignition switch is turned on then the indicator light should go out Disconnect the fuel level indicator switch lead wire coupler 1 Connect a jumper wire between B W lead and R B lead com ing from the main wiring harness and check whether fuel indi cator light is flickering Check if the fuel indicator light will go out within approx 30 seconds when disconnecting a jumper wire B W Black with White tracer R B Red with Black tracer Connect jumper wires between B W lead and R B lead and B W lead and B Lg lead coming from the main wiring harness and check whether the fuel indicator light comes on Check if the fuel indicator light will go out within approx 30 seconds when disconnecting jumper wires R B Red with Black tracer B W Black with White tracer B Lg Black with Light green tracer If the fuel indicator light does not function properly chech the bulb If the bulb is in good condition replace the meter with a new one Je fuel level indicator switch Jumper wire B W To fuel level dorper indicator switch wire B Lg SPEED SENSOR INSPECTION Lift the fuel tank and support it by prop gt 4 4 of the SV650 Service Manual Remov
26. on bolt on the mas ter cylinder to catch any split brake fluid Remove the brake hose union bolt and disconnect the brake hose A CAUTION Immediately wipe off any brake fluid contacting any part of the motorcycle The brake fluid reacts chemically with paint plastics and rubber materials etc and will dam age them severely Remove the master cylinder with the reservoir Remove the reservoir from the master cylinder Remove the brake lever and the brake light switch 12 22 SV650SK1 01 MODEL Remove the dust cover and the dust boot Remove the circlips 09900 06108 Snap ring pliers Remove the brake hose connector the O ring the piston cup set and the return spring C3 REASSEMBLY AND REMOUNTING Reassemble the master cylinder in the reverse order of removal and disassembly Pay attention to the following points LA CAUTION SV650SK1 01 MODEL 12 23 Wash the master cylinder components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Do not wipe the components with a rag Apply brake fluid to the cylinder bore and all the com ponent to be inserted into the bore Install the piston cup set into the master cylinder Install the brake hose connector A CAUTION Dust boot Primary cap Secondary cap Use a new O ring to prevent the fluid leakage
27. sher 8 Washer amp Clutch sleeve hub Clutch sleeve hub amp Lock washer amp Lock washer 6 Clutch sleeb hub nut Clutch sleeb hub nut X Y MODELS From K1 MODEL
28. tions are subject to change without notice SV650SK1 01 MODEL 125 PERIODIC MAINTENANCE BRAKE BRAKE Inspect initially at 1 000 km 600 miles 1 month and ev ery 6 000 km 4 000 miles 6 months thereafter BRAKE HOSE AND BRAKE FLUID Inspect every 6 000 km 4 000 miles 6 months Replace hoses every 4 years Replace fluid every 2 years BRAKE FLUID LEVEL CHECK Keep the motorcycle upright and place the handlebars straight Remove the rear seat L7 6 3 of the SV650 Service Manual Check the brake fluid level by observing the lower limit lines on the front and rear brake fluid reservoirs When the level is below the lower limit line replenish with brake fluid that meets the following specification fen Specification and Classification DOT 4 A WARNING The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based and petroleum based fluids Do not use any brake fluid taken from old used or unsealed containers Never re use brake fluid left over from the last servicing or stored for a long period of time Brake fluid if it leaks will interfere with safe running and immediately discolor painted surfaces Check the brake hoses and hose joints for cracks and oil leakage before riding 12 6 SV650SK1 01 MODEL CHASSIS BOLT AND NUT thereafter Tighten init
29. ving the screws Disconnect the speedometer coupler Remove the nuts Remove the speedometer BULB REPLACEMENT Remove the sockets Remove the bulbs Reassemble and remount the speedometer assy is the reverse order of removal and disassembly SV650SK1 01 MODEL 12 27 CONSTRUCTION Meter panel 2 Meter assy S Bulb 9 Socket O ring 6 Meter housing Cap INSPECTION Using the tester check the continuity between terminals in the following diagram If the continuity measured is incorrect remove and check the bulb If the bulb is failure install the new bulb and check the continuity again If the bulb is correct replace the unit with a new one El Tester knob indication Diode test BATTERY IGNITION SPEED SENSOR IGNITION COIL SIGNAL FUEL LEVEL GAUGE B E 6 FUEL LEVEL GAUGE A ITEM Probe of Probe of OIL PRESSURE GAUGE um GROUND POWER TURN SIGNAL 3 7 3 E FUEL ILLUMINATION NEUTRAL HIGH BEAM HI BEAM 4 4 TURN L OIL TURN R OIL LED NEUTRAL SWITCH WATER TEMPERATURE m 4 SPEED SENSOR SIGNAL LED Ka WATER TEMPERATURE SWITCH METER ILLUMINATION 9 GROUND SIGNAL 12 28 SV650SK1 01 MODEL FUEL LEVEL INDICATOR LIGHT INSPECTION L
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