Suzuki SVF650K9 Setup Manual Download Page 30

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HARNESS ROUTING

Clamp

Pass the ignition coil lead wire
over the regulator/rectifier.

Front brake hose

Clutch cable

Clamp

Throttle cable

To the horn and cooling fan.

Pass the wiring harness under the starter relay.

Wiring harness

Rear brake switch lead wire

Starter motor lead wire

sensor lead wire

Side stand switch lead wire

sensor lead wire

Side stand switch lead wire

Fuel pump lead wire coupler

Generator lead wire

Neutral switch lead wire

Speed sensor lead wire

Handlebar switch wiring harness (L)

Handlebar switch wiring harness (R)

Front brake hose

Starter relay

Pass the fuel injector lead wire between
the intake air pressure sensor vacuum hose
and purge hose.

Summary of Contents for SVF650K9

Page 1: ...e 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 g...

Page 2: ...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 an...

Page 3: ...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...

Page 4: ...140 B Holder 1 For front brake master cylinder Flange bolt 2 6 22 mm Item Part Name Q ty Remarks C Handlebar balancer weight 1 Right Screw 1 6 65 mm Rubber cushion 1 L 15 0 Spacer 1 L 15 0 Rubber cush...

Page 5: ...n 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 H H I I F F G G...

Page 6: ...he 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 Bol...

Page 7: ...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 direc...

Page 8: ...g 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 fla...

Page 9: ...ch 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...

Page 10: ...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 adjust...

Page 11: ...e the handlebar balancer parts as shown A 6 65 mm screw B Balancer weight C Rubber cushion L 15 0 mm D Spacer L 15 0 mm E Rubber cushion L 15 0 mm F 6 mm spacer nut With the screw not tightened insert...

Page 12: ...motorcycle by using a hoist 2 Raise the rear of motorcycle 3 Pull the crate base forward then balance the motorcycle Place the motorcycle on the side stand then remove the hoist hook NOTE Lift the mot...

Page 13: ...ot REMOVING THE WRAP FILM Remove the wrap film from the muffler A Muffler B Wrap film FRONT REAR BRAKE DISC To prevent brake squeaking and pad contamination carefully clean the front and rear brake di...

Page 14: ...A Washer OD 20 0 mm ID 6 5 mm B Rear fender C License plate 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...

Page 15: ...at 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...

Page 16: ...Unhook the hook A Battery holder B Screw C Hook Unhook the hook and remove the battery holder Remove the battery from the motorcycle A Battery holder B Hook Battery box C Battery box D Hook Battery h...

Page 17: ...precaution not to allow any of the fluid to spill A Electrolyte containers Make sure air bubbles are coming up in each electro lyte container and leave in this position for about 20 minutes A Air bub...

Page 18: ...use anything except the specified battery electrolyte Once the sealing cap has been installed in the battery do not remove the sealing cap For charging the battery make sure to use the charger special...

Page 19: ...boot D Battery holder E Prop stay FRONT REAR BRAKE FLUID Keep the motorcycle upright and place the handlebars straight Check the brake fluid level in both the front and rear master cylinder reservoirs...

Page 20: ...ervicing 3 Close the valve pump and squeeze the lever and open the valve while squeezing brake lever 4 Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles 5...

Page 21: ...ay at the throttle grip Throttle cable play 2 0 4 0 mm If adjustment is necessary carry out the following pro cedure 1 Shift the rubber boot E 2 Loosen the throttle cable adjuster lock nut C 3 Turn th...

Page 22: ...holding the adjuster B 5 Minor adjustments can now be made with the clutch lever adjuster D 6 Tighten the lock nut C while holding the adjuster D 7 Place the lever cover E REAR BRAKE PEDAL Check the r...

Page 23: ...e nut to the specified torque Rear axle nut 100 N m 10 0 kgf m A Axle nut B Adjuster bolt C Reference marks FRONT SUSPENSION Checking spring setting Make sure the spring setting of the front suspensio...

Page 24: ...D INFLATION TIRE PRESSURE LEFT RIGHT HEADLIGHT BEAM ADJUSTMENT The headlight beam can be adjusted both horizontally and vertically if necessary To adjust the beam vertically Turn the adjuster A clockw...

Page 25: ...ve the prop stay Remove the frame covers A Frame cover B Fastener C Stepped Allen screw D Stepped Allen screw E Boss F Velcro fastening G Boss 1 Remove the fuel tank fitting bolt 2 Lift the front end...

Page 26: ...d vertically on level ground 1 Start the engine and allow it to run for a few minutes at idling speed 2 Turn off the engine and wait about three minutes then check the oil level through the inspection...

Page 27: ...o select engine oils for 4 stroke motorcycle and ATV engines Motorcycle and ATV engines lubricate clutch and transmission gears with engine oil JASO T903 specifies performance requirements for motorcy...

Page 28: ...he display Select km h or mph properly to comply with traffic reg ulations Check km h and mph display after adjusting the instru ment panel display A ADJ button B SEL button C Speedometer display km h...

Page 29: ...kgf m J Rear brake push rod lock nut 18 1 8 K Brake caliper air bleeder valve Front 7 5 0 75 L Brake caliper air bleeder valve Rear 6 0 0 60 AXLE M Front axle 65 6 5 N Rear axle nut 100 10 0 ABSORBER...

Page 30: ...switch lead wire Starter motor lead wire Starter motor lead wire Starter motor lead wire HO2 sensor lead wire Side stand switch lead wire Side stand switch lead wire HO2 sensor lead wire HO2 sensor l...

Page 31: ...ead wire Battery lead wire Wiring harness Wiring harness Wiring harness Wiring harness Generator lead wire Front ignition coil lead wire Ignition switch lead wire Ignition switch lead wire Rear brake...

Page 32: ...able left side of the frame head pipe Pass the throttle cables right side of the frame head pipe Pass the clutch cable over the wiring harness Pass the clutch cable under the radiator inlet hose Pass...

Page 33: ...ll nuts and bolts Torque those listed in this manual Cotter pins circlip and fasteners Check Paint and chrome Inspect Wash and polish Warning label For E 19 Select Stick SOLO RIDING DUAL RIDING FRONT...

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