Suzuki SV650 Supplementary Service Manual
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Suzuki SV650 Supplementary Service Manual

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SV650/S/A/SA
USE THIS MANUAL WITH:
SV650 SERVICE MANUAL (99500-36123-01E)
9 9 5 0 1 - 3 6 1 4 0 - 0 1 E

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  • Page 1 SV650/S/A/SA USE THIS MANUAL WITH: SV650 SERVICE MANUAL (99500-36123-01E) 9 9 5 0 1 - 3 6 1 4 0 - 0 1 E...

  • Page 2: Table Of Contents

    AIR CLEANER AND THROTTLE BODY REMOVAL ......51 THROTTLE BODY DISASSEMBLY ............54 THROTTLE BODY CLEANING............... 56 THROTTLE BODY REASSEMBLY ............57 AIR CLEANER BOX AND THROTTLE BODY INSTALLATION.... 59 STP SENSOR ADJUSTMENT ..............60 © COPYRIGHT SUZUKI MOTOR CORPORATION 2006...

  • Page 3: Sv650K7/Sk7/Ak7/Sak7 ('07-Model

    PAIR (AIR SUPPLY) SYSTEM INSPECTION ..........151 HEATED OXYGEN SENSOR (HO2S) INSPECTION (For E-02, 19, 24, 33) ..................151 SPECIAL TOOLS..................... 152 TIGHTENING TORQUE ................... 152 SERVICE DATA (SV650/S) ................153 SERVICE DATA (SV650A/SA) ................ 165 WIRING DIAGRAM ................... 177...

  • Page 4: Country And Area Codes

    COUNTRY or AREA EFFECTIVE FRAME NO. E-02 U.K. JS1BY111200100001 – E-03 U.S.A. (Except for california) JS1VP53A 72100001 – E-19 E.U. JS1BY111100100001 – SV650 E-24 Australia JS1BY111300100001 – E-28 Canada JS1VP53A 72100001 – E-33 California (U.S.A.) JS1VP53A 72100001 – E-02 U.K.

  • Page 5: Abbreviations Used In This Manual

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) ABBREVIATIONS USED IN THIS MANUAL : Fuel Injection, Fuel Injector ABDC : After Bottom Dead Center : Fuel Pump : Anti-lock brake system : Fuel Pressure Regulator : Alternating Current FP Relay : Fuel Pump Relay : Air Cleaner, Air Cleaner Box : American Petroleum Institute ATDC : After Top Dead Center...
  • Page 6 : Pulsed Secondary Air Injection : Positive Crankcase Ventilation (Crankcase Breather) : Right Hand : Read Only Memory : Society of Automotive Engineers : Suzuki Diagnosis System STC System : Secondary Throttle Control System (STCS) STP Sensor : Secondary Throttle Position Sensor (STPS)

  • Page 7: Sae-To-Former Suzuki Term

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) SAE-TO-FORMER SUZUKI TERM This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in this manual in compliance with SAE recommendations, as well as their former SUZUKI names. SAE TERM FORMER SUZUKI TERM...
  • Page 8 SV650K7/SK7/AK7/SAK7 (’07-MODEL) SAE TERM FORMER SUZUKI TERM FULL TERM ABBREVIATION Idle Speed Control –––– Idle Speed Control Valve –––– ISC Valve Ignition Control Electronic Spark Advance (ESA) Ignition Control Module –––– Intake Air Temperature Intake Air Temperature (IAT), Air Tempera-...

  • Page 9: Specifications (Sv650K7/Sv650Sk7)

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) SPECIFICATIONS (SV650K7/SV650SK7) DIMENSIONS AND DRY MASS Overall length............2 080 mm (81.9 in) ......SV650 2 085 mm (82.1 in) ......SV650S Overall width ............745 mm (29.3 in) ......SV650 730 mm (28.7 in) ......SV650S Overall height............1 085 mm (42.7 in) ......SV650 1 170 mm (46.1 in) ......
  • Page 10 Headlight ............. 12 V 60/55 W (H4) ......SV650 12 V 60/55 W (H4) × 2....SV650S Position/Parking light........... 12 V 5 W ..Except E-03, 24, 28, 33..SV650 12 V 5 W × 2..........SV650S Brake light/Taillight ..........Licence plate light ..........

  • Page 11: Specifications (Sv650Ak7/Sv650Sak7)

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) SPECIFICATIONS (SV650AK7/SV650SAK7) DIMENSIONS AND DRY MASS Overall length............. ** 2 120 mm (83.5 in) ......SV650A ** 2 120 mm (83.5 in) ......SV650SA Overall width ............745 mm (29.3 in) ......SV650A 730 mm (28.7 in) ......SV650SA Overall height............
  • Page 12 SV650K7/SK7/AK7/SAK7 (’07-MODEL) CHASSIS Front suspension..........Telescopic, coil spring, oil damped Rear suspension ..........Link type, coil spring, oil damped Front fork stroke ..........130 mm (5.1 in) ......SV650A ** 130 mm (5.1 in) ......SV650SA Rear wheel travel ..........** 147 mm (5.8 in) ......SV650A Rear wheel travel ..........

  • Page 13: Periodic Maintenance Schedule

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilome- ters, miles and time for your convenience. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.

  • Page 14: Maintenance And Tune-Up Procedures

    This section describes the servicing procedures for each Peri- odic Maintenance item which differ from those of the SV650/SK6 (’06-MODEL). For details other than the following items, refer to the SV650/S Service Manual. SPARK PLUG Inspect every 6 000 km (4 000 miles, 12 months) and replace every 12 000 km (7 500 miles, 24 months).
  • Page 15 " 09930-10121: Spark plug socket wrench set NO.2 (REAR) SPARK PLUG REMOVAL • Lift and support the fuel tank with its prop stay. (#SV650/SK3 5-6) • Remove the spark plug caps. • Remove the spark plugs with the special tool.

  • Page 16: Throttle Valve Synchronization

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) SPARK PLUG GAP • Measure the plug gap with a thickness gauge. If out of specifi- cation, adjust it to the following gap. $ Spark plug gap A Standard: 0.7 – 0.8 mm (0.028 – 0.031 in) " 09900-20803: Thickness gauge ELECTRODES CONDITION •...

  • Page 17: Engine Components Inspection And Servicing

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) ENGINE COMPONENTS INSPECTION AND SERVICING For details other than the following, refer to the SV650/S Service Manual. PISTON AND PISTON RING $ Piston ring groove width Standard (1st) : 0.83 – 0.85 mm (0.0327 – 0.0335 in) 1 1.30 –...

  • Page 18: Thermostat

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) THERMOSTAT $ Thermostat valve opening temperature Standard: Approx. 76.5 °C (170 °F) $ Thermostat valve lift A Standard: 8.0 mm and over at 90 °C (0.31 in and over at 194 °F)

  • Page 19: Fi System Diagnosis

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) FI SYSTEM DIAGNOSIS FI SYSTEM WIRING DIAGRAM...

  • Page 20: Ecm Terminal

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) ECM TERMINAL TERMINAL TERMINAL CIRCUIT CIRCUIT GP switch signal (GP) — IAT sensor signal (IAT) ECT sensor signal (ECT) IAP sensor signal #1 (IAP. F) TO sensor signal (TOS) STP sensor signal (STP) TP sensor signal (TP) Power source for sensors (VCC) IAP sensor signal #2 (IAP.

  • Page 21: Fail-Safe Function

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY Intake air pressure sensor Intake air pressure is fixed to “YES”...

  • Page 22: Dtc Table And Defective Condition

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) DTC TABLE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The signal does not reach ECM for 2 CKP sensor wiring and mechan- sec. or more, after receiving the starter ical parts C12 (P0335) signal.
  • Page 23 SV650K7/SK7/AK7/SAK7 (’07-MODEL) DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 2 sec. and more, after igni- connection tion switch is turned ON. C23 (P1651) 0.2 V <...
  • Page 24 SV650K7/SK7/AK7/SAK7 (’07-MODEL) DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM Fuel injector CKP sensor (pickup coil) signal is pro- Fuel injector, wiring/coupler con- duced, but fuel injector signal is inter- nection, power supply to the C32 (P0201)/ rupted several times (Front 8 times, injector C33 (P0202) Rear 8 times) or more continuously.

  • Page 25: Dtc Troubleshooting

    ECM terminal ECM coupler (Harness side) are located as shown in the illustration. * Refer to the SV650/S service manual 4-23 for details. “C13” (P1750) or “C17” (P0105) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION...
  • Page 26 SV650K7/SK7/AK7/SAK7 (’07-MODEL) 4) Disconnect the IAP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the Red wire 3 and ground. 7) Also, measure the voltage at the Red wire 3 and B/Br wire 4. $ IAP sensor input voltage: 4.5 – 5.5 V (+ Red –...
  • Page 27 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Step 3 1) Turn the ignition switch OFF. 2) Remove the IAP sensor. 3) Connect the vacuum pump gauge to the vacuum port of the IAP sensor. 4) Arrange 3 new 1.5 V batteries in series 1 (check that total - voltage is 4.5 –...
  • Page 28 Step 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank with its prop stay. (#SV650/SK3 5-6) 3) Check the TP sensor coupler for loose or poor contacts. If OK, then measure the TP sensor input voltage.
  • Page 29 SV650K7/SK7/AK7/SAK7 (’07-MODEL) 6) Measure the voltage at the Red wire B and ground. 7) Also, measure the voltage at the Red wire B and B/Br wire C. $ TP sensor input voltage: 4.5 – 5.5 V (+ Red – - Ground) (+ Red –...
  • Page 30 ECM terminal ECM coupler (Harness side) are located as shown in the illustration. * Refer to the SV650/S service manual 4-31 for details. “C21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following •...
  • Page 31 Approx. 1.20 kΩ 60 °C (140 °F) Approx. 0.61 kΩ 80 °C (176 °F) Approx. 0.33 kΩ NOTE: IAT sensor resistance measurement method is the same way as that of the ECT sensor. Refer to SV650/S service manual 6-10 for details.
  • Page 32 ECM terminal ECM coupler (Harness side) are located as shown in the illustration. * Refer to the SV650/S service manual 4-35 for details. “C24” (P0351) or “C25” (P0352) IGNITION SYSTEM MALFUNCTION (When indicating C24/P0351 for IG coil #1) (When indicating C25/P0352 for IG coil #2) * Refer to the IGNITION SYSTEM for details.
  • Page 33 2) Lift and support the fuel tank with its prop stay. (#SV650/SK3 5-6) 3) Check the STVA coupler for loose or poor contacts. 4) Remove the air cleaner cap. (#SV650/SK3 2-4) 5) Turn the ignition switch ON to check the STV operation. (STV operating order: Full open → 15% open) Is the operating OK? Go to Step 2.
  • Page 34 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Disconnect the STVA coupler and remove the throttle body. (#Page 51) 3) Check the continuity between each terminal and ground. $ STVA continuity: ∞ Ω (Infinity) (Terminal – Ground) 4) If OK, then measure the STVA resistance (between terminal A and terminal B) and (between terminal C and terminal D).
  • Page 35 SV650K7/SK7/AK7/SAK7 (’07-MODEL) ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “Secondary throttle operating control” 1. 4) Click each button 2. At this time, if an operation sound is heard from the STVA, the function is normal.
  • Page 36 Step 1 1) Turn the ignition switch OFF. 2) Lift and support the fuel tank with its prop stay. (#SV650/SK3 5-6) 3) Check the STP sensor coupler for loose or poor contacts. If OK, then measure the STP sensor input voltage.
  • Page 37 On model K7, the connector terminals to be used for checking sensors for voltage, resistance or continuity at the ECM terminal ECM coupler (Harness side) are located as shown in the illustration. * Refer to the SV650/S service manual 4-41 for details.
  • Page 38 SV650K7/SK7/AK7/SAK7 (’07-MODEL) “C32” (P0201) or “C33” (P0202) FUEL INJECTOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE CKP signals produced but fuel injector signal is • Injector circuit open or short. interrupted continuous by several times (Front 8 • Injector malfunction. times, Rear 8 times) or more. •...
  • Page 39 SV650K7/SK7/AK7/SAK7 (’07-MODEL) 5) If OK, then check the continuity between each terminal and ground. $ STP sensor continuity: ∞ Ω (Infinity) " 09900-25008: Multi-circuit tester set ) Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2. Replace the injector with a new one.
  • Page 40 SV650K7/SK7/AK7/SAK7 (’07-MODEL) “C40” (P0505 or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The circuit voltage of motor drive is • ISC valve circuit open or shorted to ground unusual. (P0505) • Power source circuit open Idle speed is higher than the normal •...
  • Page 41 SV650K7/SK7/AK7/SAK7 (’07-MODEL) 4) Disconnect the ISC valve coupler and ECM coupler. 5) Check the continuity between terminals A and i, terminals B and 0, terminals C and g, terminals D and \, terminals E and 0, and terminals F and ^. When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage...
  • Page 42 SV650K7/SK7/AK7/SAK7 (’07-MODEL) ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the engine is running. 3) Click the “Active control”. 4) Click the “ISC rpm control” 1. 5) Check that the “Spec”...
  • Page 43 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Check 3 1) Click the button 1 and increase the “Spec” 2 to 1 400 rpm slowly. 2) Check that the “Desired idle speed” 3 is nearly equal to the “Spec” 2. Also, check that the number of steps 4 in the ISC valve position increases Check 4 1) Increase the “Spec”...
  • Page 44 ECM terminal ECM coupler (Harness side) are located as shown in the illustration. * Refer to the SV650/S service manual 4-44 for details. “C42” (P01650) IG SWITCH CIRCUIT MALFUNCTION * Refer to the SV650/S service manual 8-47 for details.
  • Page 45 Step 1 (When indicating C44/P0130:) 1) Turn the ignition switch OFF. 2) Remove the right frame side cover. (#SV650/SK3 7-4) 3) Check the HO2 sensor for loose or poor contacts. If OK, then check the HO2 sensor lead wire continuity.
  • Page 46 SV650K7/SK7/AK7/SAK7 (’07-MODEL) 7) Remove the front seat. (#SV650/SK3 7-4) 8) Disconnect the ECM coupler. 9) Check the continuity between W/G wire A and terminal 6. 10)Also, check the continuity between B/Br wire B and terminal When using the multi-circuit tester, do not strongly...
  • Page 47 Replace the HO2 sensor with a new one. Step 1 (When indicating C44/P0135:) 1) Turn the ignition switch OFF. 2) Remove the right frame side cover. (#SV650/SK3 7-4) 3) Check the HO2 sensor for loose or poor contacts. If OK, then measure the HO2 sensor resistance.
  • Page 48 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Step 2 (When indicating C44/P0135:) 1) Connect the HO2 sensor coupler. 2) Insert the needle pointed probes to the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between W/B wire and ground. 4) If the tester voltage indicates the battery voltage, it is good condition.
  • Page 49 SV650K7/SK7/AK7/SAK7 (’07-MODEL) “C49” (P1656) PAIR CONTROL SOLENOID VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE PAIR control solenoid valve voltage is not input to • PAIR control solenoid valve circuit open or short. ECM. • PAIR control solenoid valve malfunction. • ECM malfunction. Engine stop Side-stand Ignition...
  • Page 50 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Step 2 1) Connect the PAIR control solenoid valve coupler. 2) Turn the ignition switch ON. 3) Insert the needle pointed probes to the PAIR control solenoid valve coupler. 4) Measure the voltage at the wire side coupler between Brown wire and ground.

  • Page 51: Throttle Body

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) THROTTLE BODY CONSTRUCTION Only for E-33 1 STP sensor 8 Secondary throttle link rod 2 TP sensor 9 Throttle link rod & 3 O-ring 0 STVA 4 Fuel delivery pipe/hose A STP sensor mounting screw ITEM N·m kgf-m lb-ft 5 Fuel injector B TP sensor mounting screw...

  • Page 52: Air Cleaner And Throttle Body Removal

    REMOVAL AIR CLEANER BOX • Lift and support the fuel tank with its prop stay. (#SV650/SK3,5-6) • Remove the IAP sensor vacuum hoses (1, 2). • Disconnect the IAP sensor (R) coupler 3. • Disconnect the IAP sensor (F) coupler 4.
  • Page 53 SV650K7/SK7/AK7/SAK7 (’07-MODEL) THROTTLE BODY • Disconnect the fuel hose. • Disconnect the various lead wire couplers. 1 TP sensor 2 STP sensor 3 STVA • Remove the injector lead wire couplers. • Disconnect the ISC valve hoses.
  • Page 54 SV650K7/SK7/AK7/SAK7 (’07-MODEL) • Loosen the throttle body clamp screws. • Disconnect the throttle cables from their drum. • Dismount the throttle body assembly. * Be careful not to damage the throttle cable bracket and fast idle lever when dismounting or remounting the throttle body assembly.

  • Page 55: Throttle Body Disassembly

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) THROTTLE BODY DISASSEMBLY * Be careful not to damage the throttle lever when dis- assembling the throttle body. * The throttle body is assembled precisely in factory. Do not disassemble it other than shown in this man- ual. •...
  • Page 56 SV650K7/SK7/AK7/SAK7 (’07-MODEL) • Remove the TP sensor 7 and STP sensor 8 with the special tool. " 09930-11950: Torx wrench NOTE: Prior to disassembly, mark each sensor’s original position with a paint or scribe for accurate reinstallation. Never remove the STVA 9 and throttle body link plates 0.

  • Page 57: Throttle Body Cleaning

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) THROTTLE BODY CLEANING Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical man- ufacturer’s instructions for proper use, handling and storage. • Clean all passageways with a spray-type carburetor cleaner and blow dry with compressed air.

  • Page 58: Throttle Body Reassembly

    * Apply thin coat of the engine oil to the O-ring. * Align the throttle shaft end C with the groove D of TP sensor. * Apply SUZUKI SUPER GREASE “A” to the throttle shaft end C if necessary. - 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 59 SV650K7/SK7/AK7/SAK7 (’07-MODEL) • Apply thin coat of the engine oil to the new cushion seal 3, and the O-ring 4. Replace the cushion seal and O-ring with the new ones. • Install the fuel injector 5 by pushing it straight to the delivery pipe 6.

  • Page 60: Air Cleaner Box And Throttle Body Installation

    0 mm (0 in) cable so that the clearance is 0 mm (0 in). • Tighten each lock-nut. • Adjust the throttle cable play. (#SV650/SK3 2-16) 0 mm (0 in) • Connect the fuel injector couplers to the fuel injectors. Make sure that each coupler is installed in the correct position.

  • Page 61: Stp Sensor Adjustment

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) STP SENSOR ADJUSTMENT If the STP sensor adjustment is necessary, measure the sensor out put voltage and adjust the STP sensor position as follows: • Remove the air cleaner box. (#Page 51) • Disconnect the STVA coupler. (#Page 28) •...

  • Page 62: Tp Sensor Adjustment

    1. Warm up the engine and check the engine idle r/min. 2. Remove the right frame side cover. (#SV650/SK3 7-4) 3. Connect the special tool (Mode select switch) to the dealer mode coupler at the wiring harness. (#Page 65) 4.

  • Page 63: Throttle Valve Synchronization

    Step 1 • Lift and support the fuel tank with its prop stay. (#SV650/SK3 5-6) • Remove the rubber caps 1 from each vacuum nipple on the throttle body. • Connect the vacuum tester hoses 2 to each vacuum nipple.
  • Page 64 SV650K7/SK7/AK7/SAK7 (’07-MODEL) • Click “Active control”. • Click “ISC air volume control” 3. • Click “ON” bottom 4 to fix the ISC air volume between two cylinders. NOTE: When making this synchronization, be sure that the water tem- perature is within 80 – 100 °C (176 – 212 °F). A Engine speed: Approx.

  • Page 65: Isc Valve

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) ISC VALVE REMOVAL • Remove the air cleaner box. (#Page 51) • Disconnect the ISC valve coupler 1. Be careful not to disconnect the ISC valve coupler at least 5 seconds after ignition switch is turned to OFF. If the ECM coupler or ISC valve coupler is discon- nected within 5 seconds after ignition switch is turned to OFF, there is a possibility of an unusual valve posi-...

  • Page 66: Isc Valve Pre-Set

    When removing or replace the ISC valve, set the ISC valve to the following procedures: PROCEDURE 1) Turn the ignition switch OFF position. 2) Remove the seat. (#SV650/SK3 7-4) 3) Connect the special tool to the dealer mode coupler and turn its switch to ON position. " 09930-82720: Mode select switch 4) Turn the ignition switch to ON position.

  • Page 67: Ignition System

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) IGNITION SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Disconnect all the spark plug caps. (#Page 13) • Connect new spark plugs to each spark plug cap and ground them on the cylinder. NOTE: Be sure that all the spark plugs are connected properly and the battery used is in fully-charged condition.
  • Page 68 SV650K7/SK7/AK7/SAK7 (’07-MODEL) • Shift the transmission into neutral, turn the ignition switch to the “ON” position and grasp the clutch lever. • Press the starter button and allow the engine to crank for a few seconds, and then measure the ignition coil primary peak voltage.

  • Page 69: Introduction Of Abs (For Sv650A/Sa)

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) INTRODUCTION OF ABS (For SV650A/SA) FRONT AND REAR WHEEL SPEED SENSORS Wheel speed sensor consists of wheel speed sensor 1 and sensor rotor 2. ABS CONTROL UNIT The ABS control unit is located under the battery. ABS control unit ABS control unit calculates signals input from each one of front and rear wheel speed sensors, monitors the slipping conditions of the wheels and, at the same time, sends control signal to...
  • Page 70 SV650K7/SK7/AK7/SAK7 (’07-MODEL) ABS CONTROL UNIT CALCULATING PROCESS The ABS controls and its calculations, in addition to the self-diagnosing and the fail-safe processes, occur during the ABS control unit calculating process. In addition, if a malfunction is detected by the self-diagnosis function, the brake stops being controlled by the ABS and a diagnostic trouble code is stored.
  • Page 71 SV650K7/SK7/AK7/SAK7 (’07-MODEL) HYDRAULIC UNIT (HU) The hydraulic unit operates the solenoid valves based upon the signal which is output from the ABS control unit. The brake fluid pressure is then adjusted accordingly. The hydraulic unit controls the front and rear brake systems individually by operating separate components for the front and the rear, except for the pump drive motor, which is shared by both systems.
  • Page 72 SV650K7/SK7/AK7/SAK7 (’07-MODEL) FAIL-SAFE FUNCTION If malfunction occurs in the ABS electric system, this sets valve relay OFF. Consequently, motor relay will be set OFF and the indicator light ON, and no current will be applied to motor solenoid valve inactivating ABS and turning ABS indicator light ON.

  • Page 73: Cautions In Servicing

    NOTE: If all of the connections are not properly connected, the ABS may not operate correctly. For connector and coupler precau- tions. (#SV650/SK3 4-2 and 8-2) Click • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open.
  • Page 74 • Never disconnect the battery or any other lead wires while the engine is running. NOTE: For battery and battery connection precautions. (#SV650/SK3 4-4 and 8-3) ABS CONTROL UNIT/HU • Never allow dust or water to contact the ABS control unit/HU. Incorrect •...
  • Page 75 • Only use the specified tires. TESTER MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. • Since the resistance may differ depending on the tester used and the temperature, the resistance should be set to the spec- ification.

  • Page 76: Abs Components

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) ABS COMPONENTS ABS COMPONENTS LOCATION 1 ABS indicator light 4 ABS control unit/HU 2 Front wheel speed sensor rotor 5 Rear wheel speed sensor rotor 3 Front wheel speed sensor 6 Rear wheel speed sensor...

  • Page 77: Abs Coupler Connection Diagram

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) ABS COUPLER CONNECTION DIAGRAM B/Lg Br/B Bl/B 15 A 10 A SPARE SPARE W/R B/W Gr/R...

  • Page 78: Abs Wiring Diagram

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) ABS WIRING DIAGRAM ABS CONTROL UNIT IGNITION SWITCH SPEEDOMETER COUPLER ABS INDICATOR LIGHT LOCK MODE SELECT COUPLER 3. IGNITION 10 A 4. SIGNAL 10 A MOTOR VALVE FUSE BOX FUSE FUSE FWS RWS BATTERY 1: MAIN 30 A (40 A) (25 A) STARTER...

  • Page 79: Abs Unit System Diagram

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) ABS UNIT SYSTEM DIAGRAM...

  • Page 80: Abs Troubleshooting

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) ABS TROUBLESHOOTING ABS TROUBLESHOOTING DESCRIPTION Many of the ABS malfunction diagnosing operations are performed by checking the wiring continuity. Quick and accurate detection of malfunctions within the complex circuitry assures the proper operation of the ABS. Before beginning any repairs, thoroughly read and understand this Supplementary Service Manual. The ABS is equipped with a self-diagnosis function.

  • Page 81: Troubleshooting Procedure

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) TROUBLESHOOTING PROCEDURE Troubleshooting should be proceed as follows. If the order is performed incorrectly or any part is omitted, a misdiagnosis may result. 1. Gather information from the customer. (#Page 82) 2. Perform the pre-diagnosis inspection. (#Page 83) 3.
  • Page 82 SV650K7/SK7/AK7/SAK7 (’07-MODEL) BASIC TROUBLESHOOTING DIAGRAM 1. Gather information from the customer. ("Page 82) 2. Perform the pre-diagnosis inspection. ("Page 83) 3. Inspect the ABS indicator light. ("Page 86) 4. Output the DTCs stored in the ABS control unit. ("Page 89) 5.
  • Page 83 SV650K7/SK7/AK7/SAK7 (’07-MODEL) INFORMATION GATHERING To properly diagnose a malfunction, one must not make guesses or assumptions about the circumstances that caused it. Proper diagnosis and repair require duplicating the situation in which the malfunction occurred. If a diagnosis is made without duplicating the malfunction, even an experienced service technician may make a misdiagnosis and not perform the servicing procedure correctly, resulting in the malfunction not being repaired.
  • Page 84 These inspections may find problems that the ABS could not detect; thus, shortening repair time. BRAKE Brake fluid level check (#SV650/SK3 2-25) Brake pad inspection (#SV650/SK3 2-26) Brake fluid circuit air bleeding (#SV650/SK3 2-27) TIRE AND WHEEL Tire type : Front : DUNLOP D220FST (SV650A) : DUNLOP D220FST M (SV650SA)
  • Page 85 09900-20806: Thickness gauge ABS control unit/HU ground wire inspection • Turn the ignition switch to OFF. • Remove the front seat. (#SV650/SK3 7-4) • Disconnect the battery - lead wire. • Remove the ABS control unit/HU cover 1. • Remove the battery case bolts.
  • Page 86 SV650K7/SK7/AK7/SAK7 (’07-MODEL) • Lift up the battery case 2 and disconnect the ABS control unit coupler 3. Pull up lock lever • Check for continuity between 1 terminal of coupler and bat- tery - terminal, also 4 terminal of coupler and battery - ter- ABS control unit coupler (Harness end) minal.
  • Page 87 The ABS indicator light does not light up Step 3 1) Turn the ignition switch to OFF. 2) Remove the front seat. (#SV650/SK3 7-4) 3) Open the fuse box and inspect the signal fuse 1. Signal fuse: 10 A Is the signal fuse OK? Go to step 4.
  • Page 88 Step 6 The ABS indicator light does not go off 1) Turn the ignition switch to OFF. 2) Remove the front seat. (#SV650/SK3 7-4) 3) Open the fuse box and inspect the ignition fuse 1. Ignition fuse: 10 A Is the ignition fuse OK? Go to step 7.
  • Page 89 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Step 7 ABS control unit coupler (Harness end) 1) Disconnect the ABS control unit coupler. (#Page 85) 2) Turn the ignition switch to ON with the ABS control unit cou- pler disconnected, measure the voltage between H terminal and 4 terminal at the coupler.

  • Page 90: Dtc (Diagnostic Trouble Code) Output

    Connect the special tool to the mode select coupler to output the memorized DTCs on the ABS indicator light. • Turn the ignition switch to OFF. • Remove the front seat. (#SV650/SK3 7-4) • Connect the special tool to the mode select coupler 1 (Orange – B/W).
  • Page 91 SV650K7/SK7/AK7/SAK7 (’07-MODEL) UNDERSTANDING THE DTC (Diagnostic Trouble Code) A two-digit DTC is shown through the flashing pattern of the ABS indicator light. A number between 1 and 9 is represented by the number of times that the ABS indicator light lights up in interval of 0.4 seconds and the separation between the tens and ones are indicated by the light staying off for 1.6 seconds.

  • Page 92: Dtc Deleting And Abs Operation Check

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) DTC DELETING AND ABS OPERATION CHECK DTC DELETING • Connect the special tool to the mode select coupler (Orange – B/W) and output the DTCs. " 09930-82710: Mode select switch • While the DTCs are being output, set the special tool to OFF. The DTC deletion mode starts 12.5 seconds after the switch is set to OFF.
  • Page 93 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Ignition switch DTC indication 1 sec. 1 sec. 1 sec. Mode select switch Max. 12.5 seconds Cleaning start ABS indicator light (Malfunction exist) ABS OPERATION CHECK After deleting the DTCs, repeat the code output procedure and make sure that no DTCs remain (the ABS indicator light no longer flashes).

  • Page 94: Sds Check

    For example, when a motorcycle is brought in for service but the troubleshooting is difficult, comparison with the normal data that have been saved or filed can allow the specific ABS failure to be determined. • Remove the right frame side cover. (#SV650/SK3 7-4) • Set up the SDS tool. (#Page 94) "...

  • Page 95: Use Of Sds Diagnostic Procedures

    * Be sure to read “CAUTIONS IN SERVICING” (#Page 72) before inspection and observe what is written there. • Remove the right frame side cover. (#SV650/SK3 7-4) • Set up the SDS tool. (Refer to the SDS operation manual for further details) •...

  • Page 96: Use Of Sds Diagnosis Reset Procedure

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) USE OF SDS DIAGNOSIS RESET PROCEDURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the ABS button 1. • Click the “DTC inspection” button 2. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ABS HU.
  • Page 97 SV650K7/SK7/AK7/SAK7 (’07-MODEL) • Follow the displayed instructions. • Check that both “Current DTC” 4 and “Past DTC” 5 are deleted (NIL).
  • Page 98 SV650K7/SK7/AK7/SAK7 (’07-MODEL) ACTIVE CONTROL INSPECTION 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Turn the ignition switch ON. 3) Click “ABS” 1. 4) Click “Active control” 2. 5) Click “ABS HU operating” 3.
  • Page 99 SV650K7/SK7/AK7/SAK7 (’07-MODEL) 6) It progresses to the next according to the following indication of screens. Return Next Cancel Help Return Next Cancel Help NOTE: Skip this screen as this vehicle is not equipped with parking brake.
  • Page 100 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Return Next Cancel Help NOTE: * If the front wheel is selected, lift the front wheel off the ground using a jack. * Two operators are needed in this work; One should apply a rotational force to the front wheel. Return Next Cancel...
  • Page 101 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Return Next Cancel Help NOTE: * In normal cases, the front brake lever feels a reaction force and the front wheel turns discontinuously. At the same time, the ABS HU operating sound will be heard. * The ABS HU motor operates for 6 seconds and then stops automatically. Return Finish Cancel...

  • Page 102: Dtc Table Of Abs

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) DTC TABLE OF ABS DTC parameter Indicator DTC No. Page status Possible cause None Normal ON *1 — Wheel speed sensor related malfunction Incorrect tire size, poor tire pressure, deformed wheel, wheel spinning, (C1625) Page 102 incorrect tooth count, interference at one or more wheels, permanent bad signal, etc.

  • Page 103: Dtc Troubleshooting

    Rear: DUNLOP D220ST L 160/60ZR17M/C 69W Are the tires OK? Go to step 2. Use the specified tires. Step 2 1) Make sure the tire pressure for each tire. (#SV650/SK3 2-29) SOLO RIDING DUAL RIDING COLD INFLATION TIRE PRESSURE kPa kgf/cm²...
  • Page 104 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Step 4 1) Inspect the clearances of the front and rear wheel speed sen- sor – sensor rotor using the thickness gauge. $ Wheel speed sensor – sensor rotor clearance: 0.3 – 1.5 mm (0.012 – 0.059 in) "...
  • Page 105 Faulty HU motor Replace the ABS control unit/HU. Go to step 2. Step 2 1) Remove the front seat. (#SV650/SK3 7-4) 2) Inspect the ABS motor fuse. ABS motor fuse: 40 A Is the ABS motor fuse OK? Go to step 3.
  • Page 106 SV650K7/SK7/AK7/SAK7 (’07-MODEL) DTC “41” (C1641): WHEEL SPEED SENSOR SIGNAL MALFUNCTION (F) POSSIBLE CAUSE Too great air gap, worn or missing teeth, noise, interference between lines, loose contact in wheel speed sensor connector, wheel speed sensor not securely fastened, input amplifier in ABS control unit failure, etc.
  • Page 107 1) Turn the ignition switch to OFF. 2) Remove the ABS control unit/HU cover. (#Page 84) 3) Remove the headlight. (SV650A) (#SV650/SK3 8-37) 4) Check the ABS control unit coupler and front wheel speed sensor coupler for loose or poor contacts. If OK, then discon- nect the ABS control unit coupler.
  • Page 108 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Step 4 ABS control unit coupler 1) Measure the resistance between 5 terminal and ground at (Harness end) the ABS control unit coupler. $ Normal value: ∞ Ω (Infinity) ) Tester knob indication: Resistance (Ω) Is the resistance between 5 and ground OK? Go to step 6.
  • Page 109 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Step 8 ABS control unit coupler (Harness end) 1) Connect the front wheel speed sensor coupler. 2) Connect three 1.5 V dry cells A in series as shown and make sure that their total voltage is more than 4.5 V. Measure the current between + dry cell terminal and F ter- minal on the ABS control unit coupler.
  • Page 110 SV650K7/SK7/AK7/SAK7 (’07-MODEL) DTC “44” (C1644): WHEEL SPEED SENSOR SIGNAL MALFUNCTION (R) POSSIBLE CAUSE Too great air gap, worn or missing teeth, noise, interference between lines, loose contact in wheel speed sensor connector, wheel speed sensor not securely fastened, input amplifier in ABS control unit failure, etc.
  • Page 111 SV650K7/SK7/AK7/SAK7 (’07-MODEL) DTC “45” (C1645): WHEEL SPEED SENSOR CIRCUIT OPEN (R) POSSIBLE CAUSE Wheel speed sensor circuit open or short, loosen contact in wheel speed sensor connector, input amplifier in ABS control unit failure, etc. Step 1 1) Turn the ignition switch to OFF. 2) Remove the ABS control unit/HU cover.
  • Page 112 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Step 4 ABS control unit coupler 1) Measure the resistance between I terminal and ground at (Harness end) the ABS control unit coupler. $ Normal value: ∞ Ω (Infinity) ) Tester knob indication: Resistance (Ω) Is the resistance between I and ground OK? Go to step 6.
  • Page 113 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Step 8 ABS control unit coupler (Harness end) 1) Connect the rear wheel speed sensor coupler. 2) Connect three 1.5 V dry cells A in series as shown and make sure that their total voltage is more than 4.5 V. Measure the current between + dry cell terminal and 7 ter- minal on the ABS control unit coupler.
  • Page 114 Step 1 1) Turn the ignition switch to OFF. 2) Remove the front seat. (#SV650/SK3 7-4) 3) Measure the voltage between the + and - battery terminals using the multi-circuit tester. $ Battery voltage: 12.0 V and more "...
  • Page 115 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Step 3 ABS control unit coupler (Harness end) 1) Turn the ignition switch to OFF. 2) Remove the ABS control unit/HU cover. (#Page 84) 3) Check the ABS control unit coupler for loose or poor con- tacts. If OK, then disconnect the ABS control unit coupler. (#Page 85) 4) Run the engine at 5 000 r/min with the dimmer switch set to 5) Measure the voltage between H terminal and 4 terminal at...
  • Page 116 Step 1 1) Turn the ignition switch to OFF. 2) Remove the front seat. (#SV650/SK3 7-4) 3) Measure the voltage between the + and - battery terminals using the multi-circuit tester. $ Battery voltage: 12.0 V and more "...
  • Page 117 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Step 3 ABS control unit coupler (Harness end) 1) Turn the ignition switch to OFF. 2) Remove the ABS control unit/HU cover. (#Page 84) 3) Check the ABS control unit coupler for loose or poor con- tacts. If OK, then disconnect the ABS control unit coupler. (#Page 85) 4) Run the engine at 5 000 r/min with the dimmer switch set to 5) Measure the voltage between H terminal and 4 terminal at...
  • Page 118 SV650K7/SK7/AK7/SAK7 (’07-MODEL) DTC “55” (C1655): ABS CONTROL UNIT MALFUNCTION POSSIBLE CAUSE Faulty ABS control unit Step 1 1) Inspect the clearances of the front and rear wheel speed sen- sor – sensor rotor using the thickness gauge. $ Wheel speed sensor – sensor rotor clearance: 0.3 –...
  • Page 119 Step 1 1) Turn the ignition switch to OFF. 2) Remove the front seat. (#SV650/SK3 7-4) 3) Open the fuse box and inspect the ABS valve fuse. ABS valve fuse: 25 A Is the ABS valve fuse OK? Go to step 2.

  • Page 120: Abs Component Removal, Inspection And Installation

    * The wheel speed sensor cannot be disassembled. • Remove the front wheel speed sensor 1 by removing the mounting bolt. • Remove the front wheel assembly. (#SV650/SK3 7-9) Make sure that the motorcycle is supported securely. • Remove the front wheel speed sensor bracket 2.
  • Page 121 SV650K7/SK7/AK7/SAK7 (’07-MODEL) • Remove the headlight. (SV650A) (#SV650/SK3 8-37) • Disconnect the sensor coupler 4 and remove the front wheel speed sensor. (#Page 142 and 143) INSPECTION • Inspect the wheel speed sensor for damage. • Clean the sensor if any metal particle or foreign material stuck on it.
  • Page 122 SV650K7/SK7/AK7/SAK7 (’07-MODEL) • Install the front wheel assembly. (#SV650/SK3 7-15) • Align the recess A on the speed sensor bracket with the stop- per B on the right front fork. • Check the clearance between the front wheel speed sensor and sensor rotor using the thickness gauge.
  • Page 123 SV650K7/SK7/AK7/SAK7 (’07-MODEL) FRONT WHEEL SPEED SENSOR INSTALLATION Right Left Front wheel speed sensor 0.3 – 1.5 mm (0.012 – 0.059 in)
  • Page 124 * The wheel speed sensor cannot be disassembled. • Remove the rear wheel speed sensor 1 by removing the mounting bolt. • Remove the rear wheel assembly. (#SV650/SK3 7-42) Make sure that the motorcycle is supported securely. • Remove the rear wheel speed sensor rotor 2.
  • Page 125 SV650K7/SK7/AK7/SAK7 (’07-MODEL) INSPECTION • Inspect the wheel speed sensor for damage. • Clean the sensor if any metal particle or foreign material stuck on it. • Check that no wheel speed sensor rotor teeth are broken and that no foreign objects are caught in the wheel speed sensor. INSTALLATION Installation is in the reverse order of removal.
  • Page 126 SV650K7/SK7/AK7/SAK7 (’07-MODEL) REAR WHEEL SPEED SENSOR INSTALLATION Left Right 0.3 – 1.5 mm (0.012 – 0.059 in) Rear wheel speed sensor For E-03, 28, 33...
  • Page 127 * The ABS is made up of many precision parts; never subject it to strong impacts or allow it to become dirty or dusty. * The ABS control unit/HU cannot be disassembled. • Remove the front seat. (#SV650/SK3 7-4) • Remove the battery. • Disconnect the following parts from the battery case 1.
  • Page 128 SV650K7/SK7/AK7/SAK7 (’07-MODEL) • Remove the ABS control unit/HU cover A. • Drain the brake fluid. (#SV650/SK3 7-65) • Loosen the flare nuts B and disconnect the brake pipes. • Disconnect the ABS control unit coupler C. • Remove the ABS control unit/HU by removing the mounting bolts D.
  • Page 129 (#Page 135 to 137) * Make sure to hold the brake pipe when tightening the flare nut, or it may be misaligned. • Bleed air from the brake fluid circuit. (#SV650/SK3 2-27 and -28) Never ride the motorcycle before bleeding the air.

  • Page 130: Wiring Harness, Cable, Hose Routing And Sensor Installation

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) WIRING HARNESS, CABLE, HOSE ROUTING AND SENSOR INSTALLATION WIRING HARNESS ROUTING (For SV650/S) 1 Throttle cable *3 To fan motor. 2 ISC valve coupler *4 Clamp harness without contact to bracket. 3 Clutch cable *5 Be careful for the lead wire not to be slackened.
  • Page 131 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Cowling brace Clamp Clamp Combination Turn signal L & R Wiring harness meter Speed sensor Headlight connector (L) SV650S only SV650 only Magneto lead upper upper ICES label (E-28 only) Wiring harness (IN) (IN) Magneto (EX) (EX) GP switch...
  • Page 132 SV650K7/SK7/AK7/SAK7 (’07-MODEL) WIRE HARNESS ROUTING (For SV650A/SA) 1 Throttle cable 8 Rectifier 2 ISC valve coupler 9 Clamp 3 Clutch cable *1 To fan motor 4 ABS control unit *2 Clamp harness without contact to bracket. Base for assembling (White tape) 5 Brake pipe (ABS) TPS branch wire : Set upward Set rear turn and licence lamp leads pulled to...
  • Page 133 SV650K7/SK7/AK7/SAK7 (’07-MODEL) Clamp Cowling brace Turn signal L & R Clamp Speed sensor Combination meter Wheel speed sensor Wiring harness Headlight connector (L) SV650SA only Starter motor SV650A only upper upper Magneto lead ICES label (E-28 only) Wiring harness (IN) (IN) (EX) (EX)
  • Page 134 SV650K7/SK7/AK7/SAK7 (’07-MODEL) CABLE ROUTING (For SV650/A) 1 Throttle cable No.1 5 Wiring harness 2 Throttle cable No.2 6 Handle switch (L) 3 Clutch cable 7 Brake hose (For SV650A) 4 Guide...
  • Page 135 SV650K7/SK7/AK7/SAK7 (’07-MODEL) CABLE ROUTING (For SV650S/SA) 1 Throttle cable No.1 5 Wiring harness 2 Throttle cable No.2 6 Handle switch (L) 3 Clutch cable 7 Brake hose (For SV650SA) 4 Guide 8 Speed sensor (For SV650S)
  • Page 136 SV650K7/SK7/AK7/SAK7 (’07-MODEL) FRONT BRAKE HOSE ROUTING (For SV650) 35 ˚ 14 ˚ VIEW A VIEW B VIEW C VIEW D 14 ˚ 14 ˚ After positioning the brake hose junction with 1 Stopper the stopper, tighten the bolt. After positioning the clamp with the stopper, 2 Front brake hose tighten the clamp bolt.
  • Page 137 SV650K7/SK7/AK7/SAK7 (’07-MODEL) FRONT BRAKE HOSE ROUTING (For SV650A) 14˚ *7 Pass through the throttle cables in front of the 1 ABS control unit/HU brake hose. Pass through the brake pipes inside of the fuel 2 Clamp tank drain hose and breather hose. *1 Pass through the brake hose A under the B.
  • Page 138 SV650K7/SK7/AK7/SAK7 (’07-MODEL) FRONT BRAKE HOSE ROUTING (For SV650SA) 1 ABS control unit/HU *8 Clamp ends should face backward. 2 Clamp *9 Clamp ends should face forward. *1 Pass through the brake hose A under *10 Pass through the brake pipes inside of the fuel tank the B.
  • Page 139 SV650K7/SK7/AK7/SAK7 (’07-MODEL) REAR BRAKE HOSE ROUTING (For SV650/S) 35 ˚ 28 ˚ 1 Brake hose No contact with reservoir tank and seat rail. After the brake hose union has contacted the stopper, 2 Brake hose guide tighten the union bolt.
  • Page 140 SV650K7/SK7/AK7/SAK7 (’07-MODEL) REAR BRAKE HOSE ROUTING (For SV650A/SA) Parallel Parallel 1 Guide *4 White paint 2 Wheel speed sensor lead *5 Clamp sleeve of brake hose to guide. 3 Screw *6 No contact with reservoir tank and seat rail. 4 Washer *7 Clamp sleeve of brake hose.

  • Page 141: Cooling System Hose Routing

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) COOLING SYSTEM HOSE ROUTING VIEW B Make Clearance VIEW A Inserting the radiator hose to the union. *1 Clamp bolt head must face downward. Clamp ends should face forward. *2 Clamp bolt head must face left side. Marking mark (White) *3 Clamp ends should face downward.
  • Page 142 SV650K7/SK7/AK7/SAK7 (’07-MODEL) VIEW A 13 N . m 1.3 kgf . m 9.5 lb-ft 1 Reservoir tank 9 Oil filter 2 Reservoir tank over flow hose 0 Water pump drain hose 3 Fuel tank breather hose *1 The clamp bolt head must face downward. 4 Thermostat *2 Matching mark (Yellow) 5 Reservoir tank inlet hose...
  • Page 143 SV650K7/SK7/AK7/SAK7 (’07-MODEL) PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING Approx. 20˚ 1 Air cleaner Matching mark (Yellow) 2 Fuel hose Be careful not to touch the air cleaner and fuel hose. Pass through the hose between head cover and 3 PAIR valve intake pipe.
  • Page 144 SV650K7/SK7/AK7/SAK7 (’07-MODEL) FRONT WHEEL SPEED SENSOR INSTALLATION (For SV650A) *1, *2 60 mm (2.4 in) 50 mm (2.0 in) Pass the wheel speed sensor lead wire and speed sensor lead wire in front of the brake *7 Into headlight housing hose.
  • Page 145 SV650K7/SK7/AK7/SAK7 (’07-MODEL) FRONT WHEEL SPEED SENSOR INSTALLATION (For SV650SA) *2, *3 Clamp the sensor lead wire to wiring harness Clamp the sensor lead wire to brake hose at with speed sensor lead wire at yellow marking. sleeve. Pass the wheel speed sensor lead wire and Clamp at front side of brake hose.
  • Page 146 SV650K7/SK7/AK7/SAK7 (’07-MODEL) REAR WHEEL SPEED SENSOR INSTALLATION (For SV650A/SA) 1 Guide 7 Wheel speed sensor *1 Check the clearance between clamp and swin- 2 Brake hose garm. 3 Wheel speed sensor lead wire *2 Cut excess tip. Clamp the sensor lead wire at white painted 4 Washer line.

  • Page 147: Throttle Body Installation

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) THROTTLE BODY INSTALLATION 18 N . m 1.8 kgf 13.0 lb-ft Tighten temporarily in order to 1 to 5. Tighten in order to 1 to 6 with torque wrench 10 N . m (1.0 kgf-m 7.0 lb-ft) 25˚ 35 –...

  • Page 148: Rear Fender Installation

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) REAR FENDER INSTALLATION 1 Battery holder 4 Rear rear fender 2 Seat rail 5 Front rear fender 3 Clamp...

  • Page 149: Heat Shield Installation

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) HEAT SHIELD INSTALLATION 1 Sheet bracket 4 Battery holder 2 Heat shield rubber sheet 5 ABS control unit/HU holder 3 ABS control unit/HU *1 Set both side to rear fender front firmly.

  • Page 150: Ignition Coil Installation

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) IGNITION COIL INSTALLATION 1 Frame Front ignition coil Rear ignition coil...

  • Page 151: Emission Control System

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) The exhaust emission control system is composed of the PAIR system and CATALYST system. The fresh air is drawn into the exhaust port with the PAIR solenoid valve and PAIR reed valve. The PAIR solenoid valve is operated by the ECM, and the fresh air flow is controlled according to the TPS, ECTS, IATS, IAPS and CKPS.

  • Page 152: Pair (Air Supply) System Inspection

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) PAIR (AIR SUPPLY) SYSTEM INSPECTION HOSES #SV650/SK3 10-6 PAIR REED VALVE #SV650/SK3 10-6 PAIR CONTROL SOLENOID VALVE #Page 48 HEATED OXYGEN SENSOR (HO2S) INSPECTION (For E-02, 19, 24, 33) #Page 44...

  • Page 153: Special Tools

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) SPECIAL TOOLS 09900-20803 09900-25008 09900-25009 09900-28630 09900-20806 Multi-circuit tester Needle pointed TPS test wire har- 09904-41010 Thickness gauge probe set ness SDS set tool 09913-10130 09917-47011 09930-10121 Carburetor adjuster Vacuum pump Spark plug socket 09930-11950 09930-82710 driver gauge wrench set Torx wrench Mode select switch...

  • Page 154: Service Data (Sv650/S)

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) SERVICE DATA (SV650/S) VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ---- (1.2) 25.5 ---- (1.0) Valve clearance (when cold) 0.1 – 0.2 ---- (0.004 – 0.008) 0.2 – 0.3 ---- (0.008 – 0.012) Valve guide to valve stem 0.020 –...
  • Page 155 SV650K7/SK7/AK7/SAK7 (’07-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.060 – 36.105 35.76 (1.4196 – 1.4214) (1.408) 34.680 – 34.725 34.38 (1.3654 – 1.3671) (1.354) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.0013 –...
  • Page 156 SV650K7/SK7/AK7/SAK7 (’07-MODEL) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 100 kPa 1 500 kPa (11 kgf/cm (15 kgf/cm , 213 psi) 156 psi) Compression pressure 200 kPa difference ---- (2 kgf/cm 28 psi) Piston to cylinder clearance 0.055 –...

  • Page 157: Oil Pump

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD 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 (0.0067 – 0.0126) (0.02) Conrod big end width 20.95 – 21.00 ---- (0.825 –...
  • Page 158 SV650K7/SK7/AK7/SAK7 (’07-MODEL) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.088 (71/34) ---- Final reduction ratio SV650 3.000 (45/15) ---- SV650S * 3.000 (45/15) ---- Gear ratios 2.461 (32/13) ---- 1.777 (32/18) ---- 1.380 (29/21)
  • Page 159 SV650K7/SK7/AK7/SAK7 (’07-MODEL) THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD NOTE Thermostat valve opening * Approx. 76.5 °C (170 °F) ---- temperature Thermostat valve lift * Over 8.0 mm (0.31 in) at 90 °C (194 °F) ---- Engine coolant temperature sensor 20 °C Approx.
  • Page 160 SV650K7/SK7/AK7/SAK7 (’07-MODEL) FI SENSORS ITEM SPECIFICATION NOTE 130 – 240 Ω CKP sensor resistance CKP sensor peak voltage 3.7 V (When cranking) and more IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage * Approx. 2.5 V at idle speed TP sensor input voltage 4.5 –...
  • Page 161 14.0 – 15.5 V at 5 000 r/min. 3 – 6 Ω Starter relay resistance Battery Type designation YTX12-BS Capacity 12 V 36.0 kC (10 Ah)/10 HR Fuze size SV650 10 A SV650S 15 A Headlight SV650 10 A SV650S 15 A...
  • Page 162 SV650K7/SK7/AK7/SAK7 (’07-MODEL) WATTAGE Unit: W SPECIFICATION ITEM SV650 SV650S E-03, 24, 28, 33 Others ← Headlight 60 × 2 ← 55 × 2 Parking or position light 5 × 2 ← ← Brake light/Taillight ← ← Turn signal light ←...
  • Page 163 SV650K7/SK7/AK7/SAK7 (’07-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height SV650 50 – 60 (1.97 – 2.36) ---- SV650S 60 – 70 (2.36 – 2.76) Brake disc thickness Front (0.18) (0.16) Rear (0.20) (0.18) Brake disc runout ---- (0.012)
  • Page 164 SV650S 94 (3.70) Front fork spring adjuster 3rd groove from Top ---- Front fork oil type SUZUKI FORK OIL SS8 ---- or equivalent fork oil Front fork oil capacity (each leg) 490 ml SV650 ---- (20.2/17.3 US/Imp oz)
  • Page 165 SV650K7/SK7/AK7/SAK7 (’07-MODEL) FUEL + OIL ITEM STD/SPEC. NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

  • Page 166: Service Data (Sv650A/Sa)

    SV650K7/SK7/AK7/SAK7 (’07-MODEL) SERVICE DATA (SV650A/SA) VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. ---- (1.2) 25.5 ---- (1.0) Valve clearance (when cold) 0.1 – 0.2 ---- (0.004 – 0.008) 0.2 – 0.3 ---- (0.008 – 0.012) Valve guide to valve stem 0.020 –...
  • Page 167 SV650K7/SK7/AK7/SAK7 (’07-MODEL) CAMSHAFT + CYLINDER HEAD Unit: mm (in) ITEM STANDARD LIMIT Cam height 36.060 – 36.105 35.76 (1.4196 – 1.4214) (1.408) 34.680 – 34.725 34.38 (1.3654 – 1.3671) (1.354) Camshaft journal oil clearance 0.032 – 0.066 0.150 IN. & EX. (0.0013 –...
  • Page 168 SV650K7/SK7/AK7/SAK7 (’07-MODEL) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 1 100 kPa 1 500 kPa (11 kgf/cm (15 kgf/cm , 213 psi) 156 psi) Compression pressure 200 kPa difference ---- (2 kgf/cm 28 psi) Piston to cylinder clearance 0.055 –...
  • Page 169 SV650K7/SK7/AK7/SAK7 (’07-MODEL) CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD 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 (0.0067 – 0.0126) (0.02) Conrod big end width 20.95 – 21.00 ---- (0.825 –...
  • Page 170 SV650K7/SK7/AK7/SAK7 (’07-MODEL) TRANSMISSION + DRIVE CHAIN Unit: mm (in) Except ratio ITEM STANDARD LIMIT Primary reduction ratio 2.088 (71/34) ---- Final reduction ratio SV650A 3.000 (45/15) ---- SV650SA 3.000 (45/15) ---- Gear ratios 2.461 (32/13) ---- 1.777 (32/18) ---- 1.380 (29/21) ---- 1.125 (27/24) ----...
  • Page 171 SV650K7/SK7/AK7/SAK7 (’07-MODEL) THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD NOTE Thermostat valve opening Approx. 76.5 °C (170 °F) ---- temperature Thermostat valve lift Over 8.0 mm (0.31 in) at 90 °C (194 °F) ---- Engine coolant temperature sensor 20 °C Approx.
  • Page 172 SV650K7/SK7/AK7/SAK7 (’07-MODEL) FI SENSORS ITEM SPECIFICATION NOTE 130 – 240 Ω CKP sensor resistance CKP sensor peak voltage 3.7 V (When cranking) and more IAP sensor input voltage 4.5 – 5.5 V IAP sensor output voltage Approx. 2.5 V at idle speed TP sensor input voltage 4.5 –...
  • Page 173 SV650K7/SK7/AK7/SAK7 (’07-MODEL) ELECTRICAL Unit: mm (in) ITEM SPECIFICATION NOTE Firing order Spark plug NGK: CR8E Type DENSO: U24ESR-N 0.7 – 0.8 mm (0.028 – 0.031 in) Spark performance Over 8 mm (0.3 in) at 1 atm. 130 – 240 Ω Crankshaft position sensor resistance BI –...
  • Page 174 SV650K7/SK7/AK7/SAK7 (’07-MODEL) WATTAGE Unit: W SPECIFICATION ITEM SV650A SV650SA E-03, 24, 28, 33 Others ← Headlight 60 × 2 ← 55 × 2 Parking or position light 5 × 2 ← ← Brake light/Taillight ← ← Turn signal light ← ←...
  • Page 175 SV650K7/SK7/AK7/SAK7 (’07-MODEL) BRAKE + WHEEL Unit: mm (in) ITEM STANDARD LIMIT Rear brake pedal height SV650 50 – 60 (1.97 – 2.36) ---- SV650S 60 – 70 (2.36 – 2.76) Brake disc thickness Front (0.18) (0.16) Rear (0.20) (0.18) Brake disc runout ---- (0.012)
  • Page 176 SV650SA 94 (3.70) Front fork spring adjuster 3rd groove from Top ---- Front fork oil type SUZUKI FORK OIL SS8 ---- or equivalent fork oil Front fork oil capacity (each leg) 490 ml SV650A ---- (20.2/17.3 US/Imp oz)
  • Page 177 SV650K7/SK7/AK7/SAK7 (’07-MODEL) FUEL + OIL ITEM STD/SPEC. NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91 octane or higher rated by the research method. Gasoline containing MTBE (Methyl Tertiary Butyl E-03, 28, 33 Ether), less than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

  • Page 178: Wiring Diagram

    WIRING DIAGRAM SV650K7 (For E-02, 19, 24, 33) Wiring diagrams wire color, refer to SV650/S service manual section “WIRE COLOR”. HANDLEBAR SWITCH (R) ENGINE HAZARD : TURN SIGNAL INDICATOR LIGHT (R) STOP FRONT BRAKE STARTER SWITCH SWITCH : TURN SIGNAL INDICATOR LIGHT (L)
  • Page 179 SV650K7 (For E-03, 28) HANDLEBAR SWITCH (R) ENGINE HAZARD : TURN SIGNAL INDICATOR LIGHT (R) STOP STARTER FRONT BRAKE SWITCH : TURN SIGNAL INDICATOR LIGHT (L) SWITCH BUTTON SWITCH SENSOR REAR BRAKE : HI-BEAM INDICATOR LIGHT OIL PRESSURE SWITCH PUSH SPEEDOMETER SWITCH : FUEL INDICATOR LIGHT...
  • Page 180 SV650SK7 (For E-02, 19, 24, 33) HANDLEBAR SWITCH (R) ENGINE HAZARD : TURN SIGNAL INDICATOR LIGHT (R) STOP STARTER FRONT BRAKE SWITCH : TURN SIGNAL INDICATOR LIGHT (L) SWITCH BUTTON SWITCH SENSOR REAR BRAKE : HI-BEAM INDICATOR LIGHT OIL PRESSURE SWITCH PUSH SPEEDOMETER...
  • Page 181 SV650SK7 (For E-03, 28) HANDLEBAR SWITCH (R) ENGINE HAZARD : TURN SIGNAL INDICATOR LIGHT (R) STOP STARTER FRONT BRAKE SWITCH : TURN SIGNAL INDICATOR LIGHT (L) SWITCH BUTTON SWITCH SENSOR REAR BRAKE : HI-BEAM INDICATOR LIGHT OIL PRESSURE SWITCH PUSH SPEEDOMETER SWITCH : FUEL INDICATOR LIGHT...
  • Page 182 SV650AK7 (For E-02, 19, 24, 33) HANDLEBAR SWITCH (R) ENGINE HAZARD : TURN SIGNAL INDICATOR LIGHT (R) STOP STARTER FRONT BRAKE SWITCH : TURN SIGNAL INDICATOR LIGHT (L) SWITCH BUTTON SWITCH SENSOR REAR BRAKE : HI-BEAM INDICATOR LIGHT OIL PRESSURE SWITCH PUSH SPEEDOMETER...
  • Page 183 SV650AK7 (For E-03, 28) HANDLEBAR SWITCH (R) ENGINE HAZARD : TURN SIGNAL INDICATOR LIGHT (R) STOP STARTER FRONT BRAKE SWITCH : TURN SIGNAL INDICATOR LIGHT (L) SWITCH BUTTON SWITCH SENSOR REAR BRAKE : HI-BEAM INDICATOR LIGHT OIL PRESSURE SWITCH PUSH SPEEDOMETER SWITCH : FUEL INDICATOR LIGHT...
  • Page 184 SV650SAK7 (For E-02, 19, 24, 33) HANDLEBAR SWITCH (R) ENGINE HAZARD : TURN SIGNAL INDICATOR LIGHT (R) STOP FRONT BRAKE STARTER SWITCH SWITCH : TURN SIGNAL INDICATOR LIGHT (L) BUTTON SWITCH SENSOR REAR BRAKE : HI-BEAM INDICATOR LIGHT OIL PRESSURE PUSH SWITCH SPEEDOMETER...
  • Page 185 SV650SAK7 (For E-03, 28) HANDLEBAR SWITCH (R) ENGINE HAZARD : TURN SIGNAL INDICATOR LIGHT (R) STOP FRONT BRAKE STARTER SWITCH SWITCH SWITCH : TURN SIGNAL INDICATOR LIGHT (L) BUTTON SENSOR REAR BRAKE : HI-BEAM INDICATOR LIGHT OIL PRESSURE SWITCH PUSH SPEEDOMETER SWITCH : FUEL INDICATOR LIGHT...
  • Page 186 Prepared by October, 2006 Part No. 99501-36140-01E Printed in Japan...
  • Page 187 Printed in Japan...

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