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Suzuki SVF650K9 User Manual

Suzuki SVF650K9
33 pages
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K9
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.
Question and Answer IconNeed help?

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Suzuki SVF650K9 Specifications

General IconGeneral
Bore x Stroke81.0 mm x 62.6 mm
Compression Ratio11.5:1
Fuel SystemFuel Injection
IgnitionElectronic ignition (transistorized)
Transmission6-speed constant mesh
Final DriveChain
Front SuspensionTelescopic, coil spring, oil damped
Rear SuspensionLink type, coil spring, oil damped
Front BrakesDual hydraulic disc
Rear BrakesSingle hydraulic disc
Front Tire120/70ZR17M/C (58W), tubeless
Rear Tire160/60ZR17M/C (69W), tubeless
StarterElectric
Engine Type4-stroke, liquid-cooled, DOHC, 90-degree V-twin
Overall Length2130 mm
Overall Width760 mm
Overall Height1085 mm (42.7 in)
Seat Height785 mm
Wheelbase1445 mm

Summary

FOREWORD

Safety Warning

Indicates a potential hazard that could result in death or injury.

Preparation and Uncrating

Self Protection Measures

Technician should wear protective clothing like gloves, long sleeve shirt, eye protection, and safety shoes.

Assembly Procedures

Throttle and Brake Master Cylinder Installation

Handlebar Balancer and Hoisting

Battery Servicing

Battery Location and Removal

Location and removal of the battery, including access by removing the seat and prop stay.

Filling Electrolyte

Procedure for filling the battery with electrolyte, including removing tape and inserting nozzles.

Electrolyte Container Handling

Electrolyte Container Cap Removal

Instructions for removing and using caps from the electrolyte container for sealing battery filler holes.

Inserting Electrolyte Containers

Applying force to break nozzle seals and insert electrolyte containers into battery ports without spillage.

Monitoring Electrolyte Flow

Observing air bubbles to confirm electrolyte flow and letting it settle for 20 minutes.

Battery Finalization and Charging

Battery Electrolyte Finalization

Final steps for battery electrolyte filling, including inserting caps and confirming sealing.

Battery Charging Procedure

Guidance on charging the battery using a suitable charger and precautions during charging.

Battery Installation

Procedure for installing the charged battery back into the motorcycle, observing polarity.

Brake Fluid Checks

Brake Air Bleeding

Front Brake Air Bleeding

Procedure for bleeding air from the front brake fluid circuit using a hose and container.

Rear Brake Air Bleeding

Specific instructions for bleeding air from the rear brake caliper.

Lever and Pedal Adjustments

Cable and Pedal Adjustments

Chain and Suspension Settings

Suspension, Tire Pressure, and Headlights

Engine Coolant Level Check

Engine Oil Level and Specifications

Engine Oil Level Check

Checking engine oil level through the inspection window after running the engine.

Adding Engine Oil

Procedure for adding engine oil if the level is below the 'LOWER' mark or above 'FULL'.

Oil Warnings and Speedometer

Tightening Torque Specifications

Front Fork Torques

Torque specifications for handlebar clamp, steering stem, and front fork bracket bolts.

Brake System Torques

Torque specifications for brake master cylinder, caliper, and bleeder valves.

Axle and Suspension Torques

Torque specifications for front axle, rear axle nut, and shock absorber mounting.

General Bolt Torques

Torque specifications for various bolt diameters based on marking and type.

Harness Routing

Cable Routing Procedures

Safety Check Out

Engine and Transmission Checks

Checklists for engine oil, fuel tank, throttle cable, idle speed, exhaust, and coolant.

Electricals Checks

Checklists for lights, indicators, switches, and instrument panel functions.

Chassis Checks

Checklists for brakes, cables, chain, forks, shocks, and wiring.

Road Test Inspection

Items to check during a road test, including engine, transmission, brakes, and suspension.

Cold Inflation Tire Pressure

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