Suzuki SVF650K9 User guide

December ’08 Printed in Japan (TK) 19

99505-01149-01E

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.

PREPARATION

WORKSHOP



A: Packed motorcycle

B: Working space

SELF PROTECTION



UNCRATING THE MOTORCYCLE

Remove the carton.



A: Crate

The workshop where the machine is assembled

should be clean, spacious, and have a level

floor.

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.

Metal crates may have sharp edges and may

cause injury.

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.





A: Steel frame

B: Crate base

Handling crates requires two operators.

Be careful not to damage the motorcycle.

LOCATION OF PARTS

Check all the components which have been removed from the base of the crate.

Parts listed above are installed respectively into the positions as follows.

Item Part Name Q’ty Remarks

Handlebars assembly 1

Clamp 2

Allen bolt 4 8 × 25 mm

Burring washer 4 OD:13.0 ID:8.5

Plastic cap 4

OD:11.0

For handlebar

clamp bolt

Clutch lever cover 1

Screw 1 5 × 45 mm

For left switch

Screw 1 5 × 25 mm

For left switch

Screw 1

5 × 30 mm

For throttle

assembly

Strap 2 L:140

BHolder 1 For front brake

master cylinder

Flange bolt 2 6 × 22 mm

Item Part Name Q’ty Remarks

Handlebar balancer

weight 1 Right

Screw 1 6 × 65 mm

Rubber cushion 1 L:15.0

Spacer 1 L:15.0

Rubber cushion 1 L:15.0

Spacer nut 1 6 mm

D Rear view mirror 2 Right and Left

E Washer 2 OD:20.0 ID:6.5

FBattery electrolyte

container 1

GOwner’smanualset 1

H Warning label 7 For

E-19 CC selection

I Warning label 4 For

E-19 CD selection

OD : Outside diameter (mm)

ID : Inside diameter (mm)

L : Length (mm)

T : Thickness (mm)

OD ID

NOTE:

The parts shown as Item E, H and I in the above table are supplied for limited markets.

Use washers of Item E for mounting the license plate.

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

FFGG

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.



A: Front brake master cylinder

B: Bolt

C: Bracket

Remove the bolts to take off the bracket from the han-

dlebar holder.



A: Bracket

B: Bolt

Keep the position of front brake master cylinder

with its cap facing upwards until it is installed.

NOTE:

The bolt is no longer needed and this may be

discarded.

Be careful not to damage the fuel tank.

NOTE:

The bracket and bolts are no longer needed

and these may be discarded.

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.

A: Clamp

B: 8 × 25 mm Allen bolt

C: Burring washer OD:13.0 mm ID:8.5 mm

D: Punch mark

E: Dot mark

F: Plastic cap OD:11.0 mm

Tighten the handlebar clamp bolts to the specified

torque.

Handlebar clamp bolt: 23 N·m (2.3 kgf-m)



After installing the handlebars, fit the plastic cap on the

head of each bolt.

A: 8 × 25 mm Allen bolt

B: 8 × 25 mm Allen bolt

C: Plastic cap OD:11.0 mm

NOTE:

Install the burring washer in the direction as

shown in the illustration.

Install each clamp with the punch mark facing

front.

Align the dot mark on the handlebars with the

mating surface of the front side of left clamp.

NOTE:

To install the clamps correctly, first tighten the

bolt Aof the front side with specified torque

and then tighten the bolt Bof the rear side.

Make sure that the clamp has no clearance at

the front side as shown in the illustration.

FRONT



A: Front brake hose

B: Throttle cables

C: Right switch wiring harness

D: Clutch cable

E: Left switch wiring harness

THROTTLE

Insert the boss of throttle housing into the hole on the

handlebars.

Install the throttle assembly with two screws.



A: Boss

B: Hole

C: 5 × 30 mm screw

FRONT BRAKE MASTER CYLINDER

Install the front brake master cylinder onto the handle-

bars.

Align the dot mark on the handlebars with the master

cylinder-to-holder fitting surface.

Tighten the front brake master cylinder mounting bolts

to the specified torque.

Front brake master cylinder mounting bolt:

10 N·m (1.0 kgf-m)

A: Holder

B: Front brake master cylinder

C: 6 × 22 mm flange bolt

D: 6 × 22 mm flange bolt

E: Dot mark

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.

Check to ensure that the throttle operates freely

and closes automatically.

NOTE:

To install the holder correctly, first tighten the

bolt Cof the upper side with specified torque

and then tighten the bolt Dof the lower side.



A: Bolt

B: Holder

C: Front brake master cylinder

D: Handlebars

Connect the lead wires coupler to the front brake light

switch.

A: Front brake light switch

B: Lead wire coupler

LEFT SWITCH

Insert the boss of left switch housing into the hole on

the handlebars.

Install the left switch assembly with two screws.



A: Boss

B: Hole

C: Holder

D: 5 × 45 mm screw

E: 5 × 25 mm screw

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.

Check to ensure that the holder is set the cor-

rect position.

Be careful not to pinch the wiring harness.

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.

Insert the inner cable end into the recess in the clutch

lever, then pull on the outer cable housing and insert it

into the adjuster.

Do not adjust at this time.

Adjustment will be covered in the SERVICING section.

Install the lever cover.

A: Clutch cable

B: Adjuster

C: Lock nut

D: Cable end

E: Lever cover

NOTE:

Before installing the cable, grease the cable

end.

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