Suzuki SVF650K9 Setup Manual
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Suzuki SVF650K9 Setup Manual

Suzuki SVF650K9 Setup Manual

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FOREWORD
This motorcycle has been designed and produced utilizing Suzuki's most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this motorcycle.
Please review this set-up manual carefully before performing any work. Take special
care to properly perform the required assembly and servicing marked by either a
Warning or a Caution. Failure to follow the directions in either of these two (2) cate-
gories could lead to serious problems.  and  areas are
denoted to emphasize certain areas and carry the following meanings:
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in motorcycle damage.
This set-up manual is based on a motorcycle of standard specification. Some minor
differences from this manual may be found in other specifications.
K9
99505-01149-01E
December '08 Printed in Japan (TK) 19

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Summary of Contents for Suzuki SVF650K9

  • Page 1 FOREWORD This motorcycle has been designed and produced utilizing Suzuki’s most modern technology. The finest product, however, cannot perform properly unless it is cor- rectly assembled and serviced. This set-up manual has been produced to aid you in properly assembling and servicing this motorcycle.
  • Page 2 PREPARATION WORKSHOP  The workshop where the machine is assembled should be clean, spacious, and have a level floor. A: Packed motorcycle B: Working space SELF PROTECTION  The technician should wear protective clothing such as leather gloves, a long sleeve shirt, eye protection and safety shoes as shown in the illustration when handling metal crates.
  • Page 3 Remove the bolts of the bracket. A: Bolt Remove the bolts from the crate. A: Bolt Lift the steel frame to separate it from the base of the crate. Carefully remove the various component parts pack- aged around the motorcycle. ...

  • Page 4: Location Of Parts

    LOCATION OF PARTS Check all the components which have been removed from the base of the crate. Item Part Name Q’ty Remarks Item Part Name Q’ty Remarks Handlebars assembly Handlebar balancer Right weight Clamp Screw 6 × 65 mm Allen bolt 8 ×...
  • Page 5 The photograph shown indicates the parts dismounted from the motorcycle in addition to the items shown in the preceding page. A: Front brake master cylinder B: Throttle assembly C: Left switch D: Clutch cable...

  • Page 6: Removing The Bracket

    Before assembling the motorcycle, thoroughly understand the “Safety Check Out” described on page 32. After completion of assembly, carefully check the motorcycle referring to the “Safety Check Out”, then deliver the motorcycle to the customer. ASSEMBLY REMOVING THE BRACKET Remove the bolt to take off the front brake master cyl- inder from the bracket.
  • Page 7 HANDLEBARS Loosen the throttle housing retaining screws. Insert the throttle assembly onto the handlebars. A: Throttle assembly B: Handlebars Install the handlebars assembly with the two clamps, four Allen bolts and washers. NOTE: Install the burring washer in the direction as shown in the illustration.

  • Page 8: Front Brake Master Cylinder

     The line drawings on page 29, 30 and 31 show the proper routing of the control cables, hose and wirings. Refer to them in addition to following the instructions carefully. A: Front brake hose B: Throttle cables C: Right switch wiring harness D: Clutch cable E: Left switch wiring harness THROTTLE...

  • Page 9: Left Switch

    NOTE: Install the holder in position according to the mark “UP”. Make sure that the holder has no clearance at the upper side as shown.  Check for brake fluid leakage. A: Bolt B: Holder C: Front brake master cylinder D: Handlebars Connect the lead wires coupler to the front brake light switch.

  • Page 10: Clutch Cable

    Connect the lead wire coupler to the clutch lever posi- tion switch. A: Clutch lever position switch B: Lead wire coupler CLUTCH CABLE Pass the clutch cable through the lever cover. A: Clutch cable B: Lever cover Turn the clutch cable adjuster and lock nut in as far as possible and align the slots.

  • Page 11: Handlebar Balancer

    RIGHT CLAMP Clamp the right switch wiring harness and front brake hose union with strap. NOTE: Cut off the excess strap as shown in the photo- graph. A: Strap L:140 mm B: Front brake hose union C: Right switch wiring harness OUTSIDE LEFT Clamp the left switch wiring harness and clutch cable...
  • Page 12 Attach a hoist band. Pass the hoist band through the handlebar clamps as shown in the photograph. NOTE: Lift the motorcycle a little by using a hoist to prevent the motorcycle from falling down.  Don’t lift the motorcycle directly with the han- dlebar.

  • Page 13: Rear View Mirror

    REAR VIEW MIRROR Install the rear view mirror and tighten lock nuts securely after positioning them properly. Place the rubber boot. NOTE: Fix the mirror in the position so as to secure rear view. A: Rear view mirror B: Lock nut C: Rubber boot REMOVING THE WRAP FILM Remove the wrap film from the muffler.

  • Page 14: Warning Label

    WARNING LABEL (FOR E-19 CC AND E-19 CD SELECTION) Select the appropriate language label for your country. NOTE: For E-19 CC selection: seven kinds of labels, English, French, German, Spanish, Portu- guese, Dutch, and Italian, are supplied together with M/C. For E-19 CD selection: four kinds of labels, Finnish, Norwegian, Danish and Swedish, are supplied together with M/C.
  • Page 15 OWNER’S MANUAL Remove the seat by using the key. A: Key B: Seat Store the owner’s manual in place. A: Owner’s manual Reinstall the seat. Insert the seat hook into the seat hook retainer. Push the seat down to lock it. A: Seat assembly B: Seat hook C: Seat hook retainer...
  • Page 16 SERVICING BATTERY The battery is located under the seat. Remove the seat by using the key. Remove the prop stay. A: Prop stay Remove the screw. Unhook the hook. A: Battery holder B: Screw C: Hook Unhook the hook and remove the battery holder. Remove the battery from the motorcycle.
  • Page 17 Remove the caps from the electrolyte container. NOTE: Use the removed caps as the sealing cap of battery filler holes. Do not remove or pierce the sealed areas of the electrolyte container. A: Caps B: Sealed area With just enough force to break the nozzle seal of elec- trolyte container, push each nozzle of the electrolyte container into the battery’s electrolyte filler ports and hold the container firmly so that it does not fall.
  • Page 18 After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the battery. Wait for around 20 minutes. Insert the caps into the filler holes, pressing in firmly so that the top of the each caps does not protrude above the upper surface of the battery’s top cover.

  • Page 19: Brake Fluid

    1. Reinstall the battery in the battery box. 2. First connect the + lead to the + positive terminal of the battery. 3. Cover + terminal with rubber boot. 4. Connect the - lead to the - negative terminal of the battery.
  • Page 20 FRONT BRAKE AIR BLEEDING Any air which may have been trapped in the brake fluid circuit must be bled completely. If the brake lever or brake pedal feels spongy or weak, then most likely there is air in the brake fluid circuit. If air bleed is necessary, carry out the following proce- dure.

  • Page 21: Front Brake Lever

    FRONT BRAKE LEVER Make sure the front brake lever position is correct. The standard setting for this motorcycle is as indicated in the table below. Standard setting Position 3 A: Adjuster THROTTLE CABLE This motorcycle has a twin throttle cable system. Cable A is for pulling cable and cable B is for return- ing.

  • Page 22: Rear Brake Pedal

    CLUTCH CABLE Check the clutch lever play at the clutch lever end when squeezing the lever until pressure is felt. Clutch lever play: 10–15 mm NOTE: Minor adjustments can now be made with the clutch lever adjuster A. If adjustment is necessary, carry out the following pro- cedure.

  • Page 23: Drive Chain

    DRIVE CHAIN Check the drive chain slack. Drive chain slack: 20–30 mm If adjustment is necessary, carry out the following pro- cedure. 1. Loosen the axle nut. 2. Adjust the slack in the drive chain by turning the right and left chain adjuster bolts. 3.

  • Page 24: Rear Suspension

    REAR SUSPENSION Checking spring setting Make sure the spring setting of the rear suspension is correct. The standard setting of this motorcycle is as indicated in the table below. Standard setting Position 3 A: Adjuster TIRE PRESSURE Using an accurate air gauge, check the air pressure of the front and rear tires.

  • Page 25: Engine Coolant

    ENGINE COOLANT The engine coolant level should be kept between the “F” (Full) and “L” (Low) level. Inspect the level with the motorcycle held vertically on level ground. NOTE: The engine coolant reservoir is located under the left side of the fuel tank. A: Engine coolant reservoir If the level is lower than the “L”...

  • Page 26: Engine Oil

    3. Remove the reservoir tank cap and add 50 : 50 mix- ture of engine coolant and distilled water to the “F” (Full) level from the engine coolant filler hole. 4. Reinstall the reservoir tank cap. 5. Reinstall the fuel tank. 6.
  • Page 27 API: American Petroleum Institute JASO: Japanese Automobile Standards Organization SAE Engine Oil Viscosity ENGINE OIL VISCOSITY RATING SELECTION CHART Suzuki recommends the use of SAE 10W-40 engine oil. 20W - 50 If SAE 10W-40 engine oil is not available, select an 15W - 40 15W - 50 alternative according to the left chart.

  • Page 28: Idle Speed Adjustment

    Engine idle speed: 1 200–1 400 r/min NOTE: If the engine idle speed is not within the speci- fied range, ask your Suzuki dealer or a qualified mechanic to inspect and repair the motorcycle. SPEEDOMETER (FOR LIMITED MARKET) Set the meter to odometer, then press and hold ADJ and SEL button for 3 seconds to switch the display.

  • Page 29: Tightening Torque

    TIGHTENING TORQUE Item Part Name N·m kgf-m Item Part Name N·m kgf-m FRONT FORK Rear brake push rod lock nut Handlebar clamp bolt Brake caliper air bleeder valve (Front) 0.75 Steering stem head nut Brake caliper air bleeder valve (Rear) 0.60 Front fork upper bracket bolt AXLE...

  • Page 30: Harness Routing

    HARNESS ROUTING Clamp Wiring harness Clamp Clamp Rear brake switch lead wire Handlebar switch wiring harness (R) Starter motor lead wire Front brake hose Wiring harness sensor lead wire Starter motor lead wire Pass the ignition coil lead wire over the regulator/rectifier. Side stand switch lead wire Front brake hose Clamp...
  • Page 31 Speedometer wiring harness Pass the horn lead wire rear side the reservoir inlet hose. Frame Guide Guide Horn Wiring harness FAN AND HORN Clamp HEADLIGHT Throttle position sensor lead wire Pass the throttle position sensor lead wire between the high tension cord and cylinder head. Fuel hose Clamp Handlebar switch wiring harness (R)

  • Page 32: Cable Routing

    CABLE ROUTING Clutch cable Throttle cable (Pulling) Pass the clutch cable inside of the clutch cable guide and behind the Throttle cable (Returning) headlight housing brace. Headlight housing brace Pass the throttle cables inside of the throttle cable guide and behind the headlight housing brace. Pass the clutch cable left side of the frame head pipe.

  • Page 33: Safety Check-Out

    SAFETY CHECK OUT  ELECTRICALS ITEM CHECK FOR After completion of the setting-up the motorcy- Light cle all the following items should be double- Headlight high/low beam Lighting/Adjust checked to confirm that the operation and func- Tail/Brake light tion of the motorcycle are satisfactory. Turn signal light Now, setting-up the motorcycle and pre-deliv- Position light...

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