BATTERY

The battery is located under thefront seat . This battery is a sealedtype and requires no maintenance .Have your dealer check thebattery's state of charge periodi-cally.

The standard charging rate in1 .2A x 5 - 10 hours and the maxi-mum rate is 5.OA x 1 hour.

A WARNINGBattery posts terminals, and re-lated accessories contain leadand lead compounds.

Wash hands after handling .

A WARNINGHydrogen gas produced by bat-teries can explode if exposed toflames or sparks .

Keep flames and sparks awayfrom the battery. Never smokewhen working near the battery .

A CAUTIONExceeding the maximum charg-ing rate for the battery canshorten its life .

Never exceed the maximumcharging rate .

A CAUTIONReversing the battery lead wirescan damage the charging sys-tem and the battery.

The red lead must go to the posi-tive (+) terminal and the black (orblack with white tracer) leadmust go to the negative (-) ter-minal .

AIR CLEANERThe air cleaner element must bekept clean to provide good enginepower and gas mileage . If you useyour motorcycle under normal low-stress conditions, you should ser-vice the air cleaner at the intervalsspecified . If you ride in dusty, wet,or muddy conditions, you will needto inspect the air cleaner elementmuch more frequently. Use the fol-lowing procedure to remove theelement and inspect it.

A WARNINGOperating the engine withoutthe air cleaner element in placecould allow a flame to spit backfrom the engine to the aircleaner, or could allow dirt toenter the engine . This couldcause a fire or severe enginedamage.

Never run the engine without theair cleaner element properly in-stalled .

A CAUTIONClean or replace the air cleanerelement frequently if the motor-cycle is used in dusty, wet ormuddy conditions . The aircleaner element will clog underthese conditions, and this maycause engine damage, poor per-formance, and poor fueleconomy.

Clean the air cleaner case andelement immediately if watergets in the air cleaner box .

Air Cleaner Element Removal1 . Place the motorcycle on the

side stand .2. Remove the front seat by refer-

ring to the SEAT LOCK ANDHELMET HOLDERS section .

Nil

I`

3. Remove the fuel tank fittingbolts) .

4 . Take the prop stay 02 off .

5 . Lift the front end of the fuel tankand prop it up as shown above .Insert the crank end of the propstand into the hole of the steer-ing shaft .

6. Remove the four screws (1 .7. Remove the air cleaner element®.

Air Cleaner Element Cleaning

Carefully use an air hose to blowthe dust from the air cleaner ele-ment.

NOTE: Always apply air pressure tothe outside of the air cleaner ele-ment only. If you apply air pressureto the inside, dirt will be forced intothe pores of the element, restrict-ing the air flow through the element.

InstallationReinstall the air cleaner element inthe reverse order of the removal .

A CAUTIONA torn air cleaner element willallow dirt to enter the engine andcan damage the engine .

Carefully examine the air cleanerelement for tears during clean-ing. Replace it with a new one ifit is torn .

ACAUTIONFailure to position the aircleaner element properly canallow dirt to bypass the aircleaner element . This will causeengine damage.

Be sure to properly install the aircleaner element.

Air Cleaner Drain Plug

Remove the plugs and drain waterand oil at the periodic maintenanceinterval . The air cleaner drain plugis located beneath the air cleanerbox .

SPARK PLUGYour motorcycle comes equippedwith NGK CR8E or DENSOU24ESR-N spark plugs. To deter-mine if the standard spark plug isright for your usage, check the colorof the plug's porcelain center elec-trode insulator after motorcycleoperation . A light brown color indi-cates that the plug is correct . Awhite or dark insulator indicatesthat the engine may need adjust-ment, or another plug type may beneeded . Consult your Suzukidealer or qualified mechanic if yourplug insulator is not a light browncolor .

A CAUTIONAn improper spark plug mayhave an incorrect fit or heatrange for your engine .This maycause severe engine damagewhich will not be covered underwarranty.

Use one of the spark plugslisted below or equivalent. Con-sult your Suzuki dealer or quali-fied mechanic if you are not surewhich spark plug is correct fortype of usage .

Plug Replacement Guide

NOTE.- If the above-named plugsare not availale, consult yourSuzuki dealer.

SPARK PLUG REMOVALTo remove the spark plugs, followthe procedure below :

Front Side

1 . (Only for SV650S) Remove thescrews t0 (right and left) andunhook the hook 02 (right andleft) .

2. Remove the bolt OO and the horn®.

3. Remove the radiator mountingbolt © and move the radiatorforward .

NOTE: Do not extract the radiatorhose.

4. Extract the spark plug, cap .

NGK DENSO REMARKS

CR8E U24ESR-N Standard

CR9E U27ESR-N

If the standardplug is apt tooverheat,replace withthis plug .

5 . Remove the spark plug with thespark plug wrench provided inthe tool kit .

NOTE: Be careful not to damagethe radiator fins.

A WARNINGA hot radiator and hot enginecan burn you .

Wait until the radiator and en-gine are cool enough to touchwith bare hands before startingthis work .

Xi

Rear Side1 . Lift the fuel tank by referring to

the AIR CLEANER section .

2. Remove the spark plug with thespark plug wrench provided inthe tool kit .

A CAUTIONDirt can damage your engine ifit enters an open spark plughole .

Cover the spark plug hole when-ever spark plug is removed.

Spark Plug Cleaning

To maintain a hot, strong spark,keep the plug free from carbon .Remove carbon deposits from theplug with a wire or pin, and adjustthe gap to 0 .7 - 0.8 mm (0.028 -0.031 in) for good ignition . Use athickness (feeler) gauge to checkthe gap .

InstallationTo install a spark plug, turn it in asfar as possible with your fingers,then tighten it with a wrench .

A CAUTIONA crossthreaded or overtight-ened spark plug will damage thealuminum threads of the cylin-der head .

Carefully turn the spark plug byhand into the threads until it is fin-ger tight. If the spark plug is new,tighten it with a wrench about 1 /2turn past finger tight . If you are re-using the old spark plug, tighten itwith a wrench about 1/8 turn pastfinger tight .

NOTE: When installing the sparkplug caps, point the arrow marks]on the spark plug caps to the ex-haust side to fit the cover properly.

ENGINE OILEngine life depends on oil amountand quality. Daily oil level checksand periodic changes are two of themost important maintenance itemsto be performed .

Engine Oil Level CheckCheck the engine oil level as fol-lows :1 . Place the motorcycle on level

ground on the side stand .2. Start the engine and allow it to

idle for a few minutes .3. Stop the engine and wait for

three minute.

4. Hold the motorcycle verticallyand check the oil level throughthe oil level inspection windowon the right side of the engine .The engine oil level should bebetween "L' (low) and "F" (full)lines .

A CAUTIONThe engine oil level must be be-tween the "L" (Low) line and "F"(Full) line, or engine damagemay occur.

Check the oil level, through theinspection window, with themotorcycle held vertically onlevel ground before each use ofthe motorcycle .

Engine Oil and Filter ChangeChange the engine oil and oil filterat the scheduled times . The engineshould always be warm when theoil is changed so the oil will draineasily. The procedure is as follows :

1 . Place the motorcycle on theside stand .

2 . Remove the oil filler cap O .

3. Remove the drain plug 2 fromthe bottom of the engine anddrain the engine oil into a drainpan .

A WARNINGEngine oil and exhaust pipescan be hot enough to burn you .

Wait until the oil drain plug andexhaust pipes are cool enoughto touch with bare hands beforedraining oil .

A WARNINGNew and used oil and solventcan be hazardous. Children andpets may be harmed by swallow-ing new or used oil or solvent .Continuous contact with usedengine oil has been found tocause skin cancer in laboratoryanimals. Brief contact with usedoil or solvent may irritate skin .

•

Keep new and used oil andsolvent away from childrenand pets.

•

Wear a long-sleeve shirt andwaterproof gloves .

•

Wash with soap if oil or sol-vent contacts your skin .

NOTE: Recycle or properly disposeof used oil and solvent.

4 . Reinstall the drain plug and gas-ket. Tighten the plug securelywith a wrench .

Oil filter wrench(Part No. 09915-40610)

5 . Turn the oil filter 0 counter-clockwise with a Suzuki "captype" oil filter wrench or a "straptype" filter wrench of propersize .

6 . Wipe off the mounting surface® on the engine where the newfilter will be seated with a cleanrag .

7. Smear a little engine oil aroundthe rubber gasket ($ of the newoil filter .

8. Screw on the new filter by handuntil the filter gasket contactsthe mounting surface (a smallresistance will be felt) .

AL CAUTIONUsing an oil filter with the wrongdesign or thread specificationscan cause oil leaks or enginedamage.

Use a genuine SUZUKI oil filteror an equivalent designed foryour motorcycle .

NOTE: To tighten the oil filter prop-erly, it is important to accuratelyidentify the position at which the fil-ter gasket first contacts the mount-ing surface .

Oil filter wre

In the position atwhich the filtergasket first contactsthe mountingsurface .

9. Mark the top dead center posi-tion on the "cap type" filterwrench or on the oil filter. Usean oil filter wrench to tighten thefilter 2 turns .

10.Reinstall the drain plug andtighten it securely. Pour about2400 ml (2.5 US qt) of the speci-fied engine oil in the filler hole .(See FUEL, ENGINE OIL ANDCOOLANT RECOMMENDA-TION section .)

CLUTCH

At each maintenance interval, ad-just the clutch cable play with theclutch cable adjuster . The cableplay should be 10 - 15 mm (0 .4 -0.6 in) as measured at the clutchlever end before the clutch beginsto disengage . If you find the play ofclutch incorrect, adjust it in the fol-lowing way:

1 . Loosen the lock nut 90 .2. Turn clutch lever adjuster 2

clockwise as far as it will go .

3. Remove the engine sproketcover .

4. Loosen cable adjuster lock nutO, and turn cable adjusterto obtain approximately 10-15mm (0.4 - 0.6 in) of free play atthe clutch lever end as indi-cated .

5. Minor adjustment can now bemade with the adjuster 2.

6. Tighten the lock nuts, O and O3 ,after finishing adjustment .

NOTE: Any maintenance of theclutch other than the clutch cableplay should be performed by yourSuzuki dealer.

ENGINE COOLANTCOOLANT LEVEL

The engine coolant solution shouldbe between "F" (full) and "L' (low)level lines on the engine coolantreservoir. If the level is lower than"L' (low) level line, bring it up to "F"(full) level by adding 50 :50 mixtureof distilled water and engine cool-ant.

To add mixed coolant :1 . Remove the front seat by refer-

ring to the SEAT LOCK ANDHELMET HOLDERS section .

2. Lift the fuel tank by referring tothe AIR CLEANER section .

3. Remove the filler cap and addmixed coolant through the fillerhole .

A WARNINGEngine coolant is harmful ifswallowed or if it comes in con-tact with your skin or eyes .

Keep engine coolant away fromchildren and pets. Call yourphysicion immediately if enginecoolant is swallowed, and in-duce vomiting . Flush eyes orskin with water if engine cool-ant gets In eyes or comes in con-tact with skin .

NOTE: Adding only water will dilute_the engine coolant and reduce 8 \effectiveness. Add 50:50 mixtu a ofengine coolant and water.

DRIVE CHAINThis motorcycle has an endlessdrive chain constructed from spe-cial materials . It does not use amaster link . The drive chain hasspecial "0" rings that permanentlyseal grease inside. We recommendthat you take your motorcycle to anauthorized Suzuki dealer if thedrive chain needs replacing .

The condition and adjustment ofthe drive chain should be checkedbefore each use of the motorcycle .Always follow the guidelines belowfor inspecting and servicing thechain .

A WARNINGRiding with the chain in poorcondition or improperly ad-justed can lead to an accident .

Inspect, adjust, and maintain thechain properly before each ride,according to this section .

Inspecting the Drive ChainWhen inspecting the chain, look forthe following :•

Loose pins•

Damaged rollers•

Dry or rusted links•

Kinked or binding links•

Excessive wear•

Improper chain adjustment

If you find anything wrong with thedrive chain condition or adjustment,correct the problem if you knowhow. If necessary, consult your au-thorized Suzuki dealer .

Damage to the drive chain meansthat the sprockets may also bedamaged . Inspect the sprockets forthe following :

-

Good Worn

•

Excessively worn teeth•

Broken or damaged teeth•

Loose sprocket mounting nuts

If you find any of these problemswith your sprocket, consult yourSuzuki dealer.

A WARNINGImproperly installing a replace-ment chain, or using a joint-cliptype chain, can be hazardous .An incompletely riveted masterlink, or a joint-clip type masterlink, may come apart and causean accident or severe enginedamage .

Do not use a joint-clip typechain . Chain replacement re-quires a special riveting tool anda high-quality, non-joint-cliptype chain. Ask an authorizedSUZUKI dealer or qualified me-chanic to perform this work .

Drive Chain Cleaning andOilingClean and oil the chain as follows :1 . Wash the chain with kerosene .

Kerosene will lubricate andclean the chain .

A WARNINGKerosene can be hazardous .Kerosene is flammable. Childrenor pets may be harmed fromcontact with kerosene .

Keep flames and smoking ma-terials away from kerosene .Keep children and pets awayfrom kerosene. If swallowed, donot induce vomiting . Call physi-cian immediately. Dispose ofused kerosene properly .

A CAUTIONCleaning the chain with gasolineor commercial cleaning solventscan damage 0-rings and ruinthe chain .

Clean the drive chain with kero-sene only.

2, Allow the chain to dry, then lu-bricate the links with Suzukichain lube or an equivalent .

AL CAUTIONSome drive chain lubricantscontain solvents and additiveswhich could damage the "0"rings in your chain .

Use Suzuki chain lube or anequivalent that is specificallyintended for use with "0" ringchains.

Drive Chain Adjustment

20-30 mm(0 .8-1 .2 in)

Inspect the drive chain slack beforeeach use of the motorcycle . Placethe motorcycle on the side stand .The drive chain should be adjustedfor 20 - 30 mm (0.8 - 1 .2 in) ofslack, as shown .

A WARNINGToo much chain slack can causethe chain to come off the sprock-ets, resulting in an accident orserious damage to the motor-cycle .

Inspect and adjust the drivechain slack before each use .

To adjust the drive chain, follow theprocedure below :

1 . Place the motorcycle on theside stand .

2 . Remove the cotter pin t0 andloosen the axle nut OO .

A WARNINGA hot muffler can burn you . Themuffler will be hot enough toburn you for some time afterstopping the engine .

Wait until the muffler cools toavoid burns .

3. Turn the right and left adjusterbolts (O until the chain has20 - 30 mm (0.8 - 1 .2 in) ofslack halfway between the en-gine sprocket and rear sprocket .

4. At the same time that the chainis being adjusted, the rearsprocket must be kept in perfectalignment with the frontsprocket. To assist you in per-forming this procedure, thereare reference marks ® on theswing arm and each chain ad-

juster which are to be alignedwith each other and to be usedas a reference from one side tothe other.

5. Tighten the axle nut OO securely.Replace the cotter pin D with anew one .

6. Recheck the chain slack aftertightening and readjust if nec-essary.

Rear axle nut tightening torque :65 N .m (6.5 kgf-m, 47.0 lb-ft)

I BRAKESThis motorcycle has front and rear

I disk brakes .

A WARNINGFailure to inspect and properlymaintain the brakes increasesyour chance of having an acci-dent .

Inspect the brake system beforeeach use according to the IN-SPECTION BEFORE RIDINGsection . Follow the MAINTE-NANCE SCHEDULE section tomaintain your brake system .

I NOTE:Operating in mud, water,sand or other extreme conditionscan cause accelerated brake wear.If you operate your motorcycle un-

E der these conditions, the brakesmust be inspected more often thanrecommended in the MAINTE-NANCE SCHEDULE

Brake Fluid

FRONT

SV650S

REAR

Check the brake fluid level in bothfront and rear brake fluid reservoirs .Inspect for brake pad wear andleaks .

A WARNINGBrake fluid can be hazardous tohumans and pets. Brake fluid isharmful or fatal if swallowed,and harmful if it comes in con-tact with skin or eyes.

Keep brake fluid away from chil-dren and pets. Call your doctorimmediately if brake fluid isswallowed, and induce vomiting .Flush eyes or skin with water ifbrake fluid gets in eyes orcomes in contact with skin .

A WARNINGFailure to keep the brake fluidreservoir full with proper brakefluid can be hazardous. Thebrakes may not work correctlywithout the proper amount andtype of brake fluid . This couldlead to an accident .

Inspect the brake fluid level be-fore each use. Use only DOT4brake fluid from a sealed con-tainer. Never use or mix differ-ent types of brake fluid . If thereis frequent loss of fluid, takeyour motorcycle to a SUZUKIdealer or qualified mechanic forinspection .

A CAUTIONSpilled brake fluid can damagepainted surfaces and plasticparts.

Avoid spilling any fluid when fill-ing the reservoir. Wipe up spillsimmediately.

Brake Pads

i

FRONT

REAR

FRONT

~%

s0.010.

REAR

Inspect the front and rear brakepads to see if they are worn downto the grooved wear limit line O . Ifa pad is worn to the grooved wearlimit line, it must be replaced with anew one. After replacing either thefront or rear brake pads, the brakelever or pedal must be pumpedseveral times . This will extend thepads to their proper position .

A WARNINGRiding with worn brake pads willreduce braking performanceand will increase your chance ofhaving an accident.

Inspect brake pad wear beforeeach use . Ask your SUZUKIdealer or qualified mechanic toreplace brake pads if any pad isworn to the limit.

A WARNINGFailure to extend brake pads af-ter repair or replacement cancause poor braking perfor-mance and may result in an ac-cident .

Before riding, "pump" the brakerepeatedly until brake pads arepressed against the brake disksand proper lever/pedal strokeand firm feel are restored .

NOTE.-Do not squeeze/depressthe brake lever/pedal when thepads are not in their positions . It isdifficult to push the pistons backinto position .

Rear Brake AdjustmentThe rear brake pedal must be ad-justed to set the clearance betweenthe pedal and the footrest . Adjustthe brake pedal as follows :

a: 0

1 . Loosen the lock nut 10, and turnthe push rod OO to locate thepedal 55 - 65 mm (2 .2 - 2.6 in)below the top face of the footrest .

2. Retighten the lock nut 10 to lockthe push rod OO in the properposition .

AL CAUTIONAn incorrectly adjusted brakepedal may force brake pads torub against the disk at all times,causing damage to the pads anddisk .

Follow the steps in this sectionto adjust the brake pedal prop-erly.

Rear Brake Light Switch

To adjust the brake light switch,hold the switch body and turn theadjuster so that the brake light willcome on just before a pressure riseis felt when the brake pedal is de-pressed .

TIRES

A WARNINGFailure to follow these warningsmay result in an accident due totire failure . The tires on yourmotorcycle form the crucial linkbetween your motorcycle andthe road .

Follow these instructions :•

Check tire condition and pres-sure, and adjust pressure be-fore each ride .

•

Avoid overloading your motor-cycle .

• Replace a tire when worn tothe specified limit, or if youfind damage such as cuts orcracks.

• Always use the size and typeof tires specified in thisowner's manual .

•

Balance the wheel after tireinstallation .

•

Read this section of owner'smanual carefully .

A WARNINGFailure to perform break-in ofthe tires could cause tire slipand loss of control .

Use extra care when riding onnew tires. Perform proper break-in of the tires referring to theBREAK-IN section and avoidhard acceleration, hard corner-ing, and hard braking for the first160 km (100 miles).

Tire Pressure and LoadingProper tire pressure and proper tireloading are important factors . Over-loading your tires can lead to tirefailure and loss of motorcycle con-trol .

Check tire pressure each day be-fore you ride, according to the tablebelow.Tire pressure should only bechecked and adjusted beforeriding, since riding will heat up thetires and lead to higher inflationpressure readings .

Under-inflated tires make smoothcornering difficult, and can resultin rapid tire wear. Over-inflated tireshave a smaller amount of tire incontact with the road, which cancontribute to skidding and loss ofcontrol .

NOTE: When you detect drops intire pressure, check the tire for nailsor other punctures, or a damagedwheel rim. Tubeless tires some-times lose pressure gradually whenpunctured.

Tire Condition and TypeTire condition and tire type affectmotorcycle performance . Cuts orcracks in the tires can lead to tirefailure and loss of motorcycle con-trol . Worn tires are susceptible topuncture failures and subsequentloss of motorcycle control . Tirewear also affects the tire profile,changing motorcycle handlingcharacteristics .

Check tire condition each day be-fore you ride . Replace tires if tiresshow visual evidence of damage,such as cracks or cuts, or if treaddepth is less than 1 .6 mm (0.06 in)front, 2 .0 mm (0.08 in) rear.

0

T I

The "TWI" mark indicates the placewhere the wear bars are moldedinto the tire . When the wear barscontact the road, it indicates thatthe tire wear limit has beenreached .

Whenever you replace a tire, usea tire of the size and type listed be-low. If you use a different size ortype of tire, motorcycle handlingmay be adversely affected, possi-bly resulting in loss of motorcyclecontrol .

Always balance the wheel after re-pairing a puncture or replacing thetire. Proper wheel balance is impor-tant to avoid variable wheel-to-roadcontact, and to avoid uneven tirewear.

A WARNINGAn improperly repaired, in-stalled, or balanced tire cancause loss of control or shortentire life .

•

Ask your SUZUKI dealer orqualified mechanic to performtire repair, replacement, andbalancing because propertools and experience are re-quired .

•

Install tires according to therotation direction shown byarrows on the sidewall of eachtire .

LOAD

TIRE

SOLORIDING

TWO-UPRIDING

FRONT225 kPa

2.25 kgf/cm233 psi

225 kPa2.25 kgf/cm 2

33 psi

REAR250 kPa

2.50 kgf/cm 236 psi

250 kPa2.50 kgf/cm 2

36 psi

\ FRONT REAR

SIZE 120/60 ZR17(55W)

160/60 ZR17(69W)

TYPEMETZELERMEZ4 Front

METZELERMEZ4

A WARNINGFailure to follow these instruc-tions about tubeless tires mayresult in an accident due to tirefailure .Tubeless tires require dif-ferent service procedures thantube tires .

• Tubeless tires require an air-tight seal between the tirebead and wheel rim. Specialtire irons and rim protectors ora specialized tire mountingmachine must be used for re-moving and installing tires toprevent tire or rim damagewhich could result in an airleak.

• Repair puncture in tubelesstires by removing the tire andapplying an internal patch .

• Do not use an external repairplug to repair a puncture sincethe plug may work loose as aresult of the cornering forcesexperienced in a motorcycletire .

• After repairing a tire, do notexceed 80 km/h (50 mph) forthe first 24 hours, 130 km/h (80mph) thereafter . This is toavoid excessive heat build-upwhich could result in a tire re-pair failure and tire deflation .

• Replace the tire if it is punc-tured in the sidewall area, or ifa puncture in the tread area islarger than 6 mm (3/16in) .These punctures cannot be re-paired adequately.

NOTE: The wheel has arrow marksshowing the rotating direction. Thearrow marks on the tire and on thewheel should be in the same direc-tion .

SIDE STAND/IGNITIONINTERLOCK SYSTEM

*010) APzIN II

spCheck the side stand/ignition inter-lock system for proper operation asfollows :1 . Sit on the motorcycle in the nor-

mal riding position, with the sidestand up .

2. Shift into first gear, hold theclutch in, and start the engine .

3. While continuing to hold theclutch in, move the side standto the down position .

If the engine stops running whenthe side stand is moved to the downposition, then the side stand/igni-tion interlock system is workingproperly. If the engine continues torun with the side stand down andthe transmission in gear, then theside stand/ignition interlock systemis not working properly. Have yourmotorcycle inspected by an autho-rized Suzuki dealer or some otherqualified service mechanic .

A WARNINGIf the side stand/ignition inter-lock system is not working prop-erly, it is possible to ride themotorcycle with the side standin the down position. This mayinterfere with rider control dur-ing a left turn .

Check the side stand/ignitioninterlock system for proper op-eration before riding. Check thatthe side stand is returned to itsfull up position before startingoff.

FRONT WHEEL REMOVAL1 . Place the motorcycle on the

side stand .

2. Remove both brake calipersfrom the front forks by remov-ing two mounting bolts O oneach caliper.

NOTE: Never squeeze the frontbrake lever with the caliper re-moved. It is very difficult to forcethe pads back into the caliper as-sembly and brake fluid leakagemay result.

0 0

00

0

0

00'J~ 0o

Jo y

00

A CAUTIONImproper jacking may causedamage to the oil filter.

Do not apply the jack head to theoil filter when jacking up themotorcycle .

7. Turn the axle counterclockwiseand draw it out .

3. Loosen the two axle holder boltsO2 on the right front fork .

4. Loosen the axle OO temporarily.5. Place an accessory service

stand or equivalent under theswing arm to help stabilize therear end .

6. Carefully position a jack under 8. Slide the front wheel forward .the engine and raise until thefront wheel is slightly off theground .

OO

O0

0 O

000

G

C

3 ~a p

0

00000

J

0

0

9. To reinstall the wheel assembly,reverse the sequence as de-scribed . Fit the slot of speedom-eter gearbox to the projectionsof the wheel hub .

10. After installing the wheel, ap-ply the brake several times torestore the proper lever stroke .

A WARNINGFailure to extend brake pads af-ter installing the wheel cancause poor braking perfor-mance and may result in an ac-cident.

Before riding, "pump" the brakerepeatedly until brake pads Orepressed against the brake disksand proper lever/pedal strokeand firm feel are restored. Alsocheck that the wheel rotatesfreely.

WARNINGInstalling the front wheel in thereverse direction can be hazard-ous.The tire for this motorcycleis directional. Therefore, themotorcycle may have unusalhandling if the wheel is installedincorrectly.

Install the front wheel in a speci-fied direction, as indicated bythe arrow on the sidewall of thetire .

WARNINGFailure to torque bolts and nutsproperly could lead to an acci-dent.

Torque bolts and nuts to theproper specifications . If you arenot sure of the proper proce-dure, have your authorizedSUZUKI dealer or qualified me-chanic do this .

Front axle tightening torque :65 N •m (6.5 kgf-m, 47 .0 lb-ft)

Front axle holder bolt tighteningtorque :23 N •m (2 .3 kgf-m, 16.5 lb-ft)

Front brake caliper mounting bolttightening torque :39 N •m (3.9 kgf-m, 28.0 lb-ft)

0REAR WHEEL REMOVAL1 . Place the motorcycle on the

side stand .

2. Remove the caliper bolts t0 .

NOTE: Never depress the rearbrake pedal with the rear wheelremoved. It is very difficult to forcethe pads back into the caliper as-sembly.

3 . Remove the cotter pin 02 .4 . Remove the axle nut 03 .5. Loosen the chain adjusting bolts

® (right and left) .

A WARNINGA hot muffler can burn you. Themuffler will be hot enough toburn you for some time afterstopping the engine .

Wait until the muffler cools toavoid burns .

6. Place an accessory servicestand or equivalent under theswing arm to lift the rear wheelslightly off the ground .

7. Draw out the axle .

I

8. With the wheel moved forward,remove the chain from thesprocket .

9. Pull the rear wheel assemblyrearward .

NOTE: Never depress the rearbrake pedal with the rear wheelremoved. It is very difficult to forcethe pads back into the caliper as-sembly.

10.To replace the wheel, reversethe complete sequence listed .

11 . Replace the cotter pin with anew one .

12.After installing the wheel, applythe brake several times andthen check that the wheel ro-tates freely.

A WARNINGFailure to adjust the drive chainand failure to torque bolts andnuts properly could lead to anaccident .

•

Adjust the drive chain as de-scribed in DRIVE CHAIN AD-JUSTMENT section after in-stalling the rear wheel .• ue bolts and nuts to the

proper specifications . If youare not sure of the proper pro-cedure, have your authorizedSUZUKI dealer or qualifiedmechanic do this .

Rear axle nut tightening torque :65.N .m (6 .5 kgf-m, 47 .0 lb-ft)

A WARNINGFailure to extend brake pads af-ter installing the wheel cancause poor braking perfor-mance and may result in an ac-cident .

Before riding, "pump" the brakerepeatedly until brake pads arepressed against the brake disksand proper lever/pedal strokeand firm feel are restored . Alsocheck that the wheel rotatesfreely.

LIGHT BULB REPLACEMENTThe wattage rating of each bulb isshown in the following chart . Whenreplacing a burned out bulb, alwaysuse the same wattage rating .

A CAUTION

Using a light bulb with the wrongwattage rating can cause elec-trical system damage or shortenbulb life .

Always use the specified lightbulb .

HeadlightTo replace the headlight bulb, per-form the following steps :

(SV650)

1 . Remove the screws 10 (rightand left) from the headlightouter ring .

2. Disconnect the socket 02 andremove the rubber cap (1 .

3. Unhook the bulb holder spring® and pull out the bulb 05 .

A CAUTION

Oil from your skin may damagethe headlight bulb or shorten itslife .

Grasp the new bulb with a cleancloth .

1 . Disconnect the socket 10 fromthe headlight and remove therubber cap 02 .

2. Unhook the bulb holder springO3 and pull out the bulb ® .

Headlight SV650 12V 60/55W

SV650S 12V 45/45W x 2Position light(SV650S)

12V 5W

Turn signal light 12V 21 WBrake light/Taillight 12V 21/5W x 2

License plate light 12V 5W

I Right Side

1 . Disconnect the socket t® fromthe headlight and remove therubber cap (Z .

. 2 . Unhook the bulb holder springO3 and pull out the bulb ® .

3. (Except for UK, Canada andAustralia) Pull off the bulb (5from the socket © .

A CAUTION

Oil from your skin may damagethe headlight bulb or shorten itslife .

Grasp the new bulb with a cleancloth .

Headlight Beam AdjustmentThe headlight beam can be ad-justed both horizontally and verti-cally if necessary.

(SV650)

To adjust the beam horizontally :Turn the adjuster 10 clockwise orcounterclockwise .

To adjust the beam vertically :Turn the adjuster OO clockwise orcounterclockwise .

NOTE: To adjust the headlightbeam, adjust the beam horizontallyfirst, then adjust vertically.

(SV650S)

To adjust the beamhorizontally :Turn the adjuster ® clockwise orcounterclockwise .

To adjust the beam vertically :Turn the adjuster ©2 clockwise orcounterclockwise .

NOTE: To adjust the headlightbeam, adjust the beam horizontallyfirst, then adjust vertically.

Position LightTo replace the position light bulb fol-low the procedure below .

1 . Remove the two screws 0) andremove the panel O2 .

2 . Pull off the bulb (3) .

i Turn Signal Light: Tb replace the turn signal light bulb,I follow these directions .

1 . Remove screw and take off thelens .

2. Turn the socket counterclock-wise and remove it .

3. Push in on the bulb, turn it tothe left, and pull it out .

A CAUTION

Overtightening the screws maycause the lens to crack .

Tighten the screws only untilthey are sung .

Brake Light/TaillightTo change the brake light/taillightbulb, perform the following steps :

1 . Remove the lens by removingthe screws t0 .

2. Push in the bulb, turn it to theleft and ull it off.

License Plate LightTo change the license plate lightbulb, perform the following steps :

WWI

1 . Remove the lens by removingthe screws t0 .

2. Pull off the bulb .

FUSES

The main fuse is located behind theright frame cover . Remove theframe cover by referring to theSEAT LOCK AND HELMET HOLD-ERS section . One 30A spare fuseis located inside the fuse box .

The fuses are located under the in-strument panel . One 1 OA and one15A spare fuses are provided in-side the fuse box .

They are designed to open when acircuit overload exists in individualelectrical system circuits . If anyelectrical system fails to operate,then the fuses must be checked .

A CAUTIONInstalling a fuse of incorrect rat-ing or using aluminum foil orwire instead of a fuse may seri-ously damage the electrical sys-tem .

Always replace a blown fusewith a fuse of the same type andrating. If the new fuse blows in ashort time, consult your Suzukidealer or qualified mechanicimmediately.

FUSE LIST•

30A MAIN fuse protects all elec-trical circuits .

•

15A HEAD-HI fuse protects theheadlight high beam and highbeam indicator light .

•

15A HEAD-LO fuse protects theheadlight low beam .

•

10A IGNITION fuse protectsignition coil and cooling fanmotor .

•

15A SIGNAL fuse protects thefuel level indicator light, the oilpressure indicator light, neutralindicator light, horn, brake light,speedometer light .

•

10A METER fuse protects theinstrument panel .

TROUBLESHOOTING

This troubleshooting guide is pro-vided to help you find the cause ofsome common complaints .

A CAUTIONFailure to troubleshoot a prob-lem correctly can damage yourmotorcycle. Improper repairs oradjustments may damage themotorcycle instead of fixing it .Such damage may not be cov-ered under warranty.

If you are not sure about theproper action, consult yourSuzuki dealer about the prob-lem .

COMPLAINT: Engine is hard tostart or does not start at all .

Ignition System Check1 . Remove the spark plugs and

reattach them to the spark plugleads .

2. Put the engine stop switch in the"0" position and ignition switchin the "ON" position . While hold-ing a spark plug with its basefirmly against the engine, pushthe electric starter button . If theignition system is operatingproperly, a blue spark shouldjump across the spark plug gap .

3 . If there is no spark, clean thespark plug . Replace it if neces-sary. Retry the above procedurewith the cleaned spark plug ornew one .

4. If there is still no spark, takeyour machine to your authorizedSuzuki dealer.

A WARNINGPerforming the spark test im-properly can cause a high volt-age electrical shock or an explo-sion .

Avoid performing this check ifyou are not familiar with this pro-cedure, or if you have a heartcondition or wear a pacemaker.Keep the spark plug away fromthe spark plug hole during thistest .

COMPLAINT: Engine Stalls1 . Make sure there is enough fuel

in the fuel tank .2. Check the ignition system for

intermittent spark.3. Check the idle speed . If neces-

sary, adjust it using a tachom-eter. The correct idle speed is1200 - 1400 r/min .

STORAGE PROCEDURE

If your motorcycle is to be left un-used for an extended period oftime, it needs special servicing re-quiring appropriate materials,equipment and skill . For this rea-son, Suzuki recommends that youtrust this maintenance work to yourSuzuki dealer. If you wish to ser-vice the machine for storage your-self, follow the general guidelinesbelow:

MOTORCYCLEClean the entire motorcycle . Placethe motorcycle on the side standon a firm, flat surface where it willnot fall over. Turn the handlebarsall the way to the left and lock thesteering, and remove the ignitionkey.

FUEL1 . Fill the fuel tank to the top with

fuel mixed with the amount ofgasoline stabilizer recom-mended by the stabilizer manu-facturer .

2. Run the engine for a few min-utes until the stabilized gasolinefills the carburators .

ENGINE1 . Pour one tablespoon of motor

oil into each spark plug hole .Reinstall the spark plugs andcrank the engine a few times .

2. Drain the engine oil thoroughlyand refill the crankcase withfresh engine oil all the way upto the filler hole .

3. Cover the air cleaner intake andthe muffler outlet with oily ragsto prevent humidity from enter-ing .

BATTERY1 . Remove the battery from the

motorcycle .2 . Clean the outside of the battery

with mild soap and remove cor-rosion from the terminals andwiring harness .

3 . Store the battery inabove freezing .

a room

TIRESInflate tires to the normal pressure .

EXTERNAL•

Sprayalll vinyl and rubber partswith rubber protectant .

•

Spray unpainted surfaces withrust preventative .

•

Coat painted surfaces with carwax .

MAINTENANCE DURINGSTORAGEOnce a month, recharge the bat-tery. The standard charging rate is1 .2Ax5-10 hour.

PROCEDURE FORRETURNING TO SERVICE1 . Clean the entire motorcycle .2 . Remove the oily rags from the

air cleaner intake and muffleroutlet.

3. Drain all the engine oil . Install anew oil filter and fill the enginewith fresh oil as outlined in thismanual .

4 . Remove the spark plugs . Turnthe engine a few times . Reinstallthe spark plugs .

5 . Reinstall the battery.6. Make sure that the motorcycle

is properly lubricated .7. Perform the INSPECTION BE-

FORE RIDING as listed in thismanual .

8. Start the motorcycle as outlinedin this manual .

APPEARANCE CARE

CORROSION PREVENTIONIt is important to take good care ofyour motorcycle to protect it fromcorrosion and keep it looking newfor years to come .

Important Information AboutCorrosionCommon causes of corrosion•

Accumulation of road salt, dirt,moisture, or chemicals in hard-to-reach areas .

• Chipping, scratches, and anydamage to treated or paintedmetal surfaces resulting fromminor accidents or impacts fromstones and gravel .

Road salt, sea air, industrial pollu-tion, and high humidity will all con-tribute to corrosion .

How to Help Prevent Corrosion•

Wash your motorcycle fre-quently, at least once a month .Keep your motorcycle as cleanand dry as possible .

•

Remove foreign material depos-its . Foreign material such asroad salt, chemicals, road oil ortar, tree sap, bird droppings andindustrial fall-out may damageyour motorcycle's finish . Re-move these types of deposits asquickly as possible . If these de-posits are difficult to wash off,an additional cleaner may berequired .

Follow

themanufacturer's directions whenusing these special cleaners .

•

Repair finish damage as soonas possible . Carefully examineyour motorcycle for damage tothe painted surfaces. Shouldyou find any chips or scratchesin the paint, touch them up im-mediately to prevent corrosionfrom starting . If the chips orscratches have gone through tothe bare metal, have a Suzukidealer make the repair .

•

Store your motorcycle in a dry,well-ventilated area . If you oftenwash your motorcycle in thegarage or if you frequently parkit inside when wet, your garagemay be damp. The high humid-ity may cause or accelerate cor-rosion. A wet motorcycle maycorrode even in a heated ga-rage if the ventilation is poor .

•

Cover your motorcycle. Expo-sure to mid-day sun can causethe colors in paint, plastic parts,and instrument faces to fade .Covering your motorcycle witha high-quality, "breathable" mo-torcycle cover can help protectthe finish from the harmful UVrays in sunlight, and can reducethe amount of dust and air pol-lution reaching the surface .YourSuzuki dealer can help you se-lect the right cover for your mo-torcycle .

MOTORCYCLE CLEANINGWashing the MotorcycleWhen washing the motorcycle, fol-low the instructions below :1 . Remove dirt and mud from the

motorcycle with running water .You may use a soft sponge orbrush . Do not use hard materi-als which can scratch the paint .

2. Wash the entire motorcycle withmild detergent or car wash soapusing a sponge or soft cloth . Thesponge or cloth should be fre-quently soaked in the soap so-lution .

A CAUTIONRadiator fins can be damagedby spraying high pressure wa-ter on them .

Do not spray high pressure wa-ter on the radiator fins .

NOTE: Avoid spraying or allowingwater to flow over the following

s:•

Ignition switch•

Spark plugs•

Fuel tank cap•

Fuel injection system•

Brake master cylinders

3. Once the dirt has been com-pletely removed, rinse off thedetergent with running water .

4. After rinsing, wipe off the mo-torcycle with a wet chamois orcloth and allow it to dry in theshade .

5. Check carefully for damage topainted surfaces . If there is anydamage, obtain "touch-up" paintand "touch-up" the damage .

Windshield CleaningClean the windshield with a softcloth and warm water with milddetergent . If scratched, polish witha commercially available plasticpolish . Replace the windshield if itbecomes scratched or discoloredso as to obstruct view . When re-placing the windshield, use Suzukireplacement windshield .

AL CAUTIONCleaning with any alkaline orstrong acid cleaner, gasoline,brake fluid, or any other solventwill damage the windshield .

Clean only with a soft cloth andwarm water with a mild deter-gent.

Waxing the MotorcycleAfter washing the motorcycle, wax-ing is recommended to further pro-tect and beautify the paint . Observethe precautions specified by thewax manufacturer.

INSPECTION AFTERCLEANINGFor extended life of your motor-cycle, lubricate according to "GEN-ERAL LUBRICATION" section .

A WARNINGWet brakes can cause poorbraking performance and maylead to an accident.

Avoid a possible accident byexpecting longer stopping dis-tances after washing your mo-torcycle. Apply brakes severaltimes to let heat dry the brakepads or shoes .

Follow the procedures in the "IN-SPECTION BEFORE RIDING"section to check your motorcyclefor any problems that may havearisen during your last ride .

CONSUMERINFORMATION

EMISSION CONTROLWARRANTYSuzuki Motor Corporation warrantsto the ultimate purchaser and eachsubsequent purchaser that thisvehicle is designed, built, andequipped so as to conform at thetime of sale with all U .S. emissionstandards applicable at the time ofmanufacture, and that it is free fromdefects in materials and workman-ship which would cause it not tomeet these standards within itsuseful life . Useful life is defined foreach class of motorcycle as 5 yearsor the corresponding number of ki-lometers (miles) shown in the chartbelow, whichever occurs first .

Failures, other than those resultingfrom defects in material or work-manship, which arise solely as aresult of owner abuse and/or lackof proper maintenance are not cov-ered by the warranty .

REPORTING SAFETY

DEFECTSIf you believe that your vehicle hasa defect which could cause a crashor could cause injury or death, youshould immediately inform the Na-tional Highway Traffic Safety Ad-ministration (NHTSA) in addition tonotifying American Suzuki MotorCorp .

If NHTSA receives similar com-plaints, it may open an investiga-tion, and if it finds that a safety de-fect exists in a group of vehicles, itmay order a recall and remedycampaign. However, NHTSA can-not become involved in individualproblems between you, yourdealer, or American Suzuki MotorCorp .

To contact NHTSA, you may eithercall the Auto Safety Hotline toll-freeat 1-800-424-9393 (or 366-0123 inWashington, D.C. area) or write to :NHTSA, U.S. Department of Trans-portation, Washington, D.C. 20590 .You can also obtain other informa-tion about motor vehicle safety fromthe Hotline .

To contact American Suzuki, own-ers in the continental United Statescan call toll-free 1-800-444-5077,or write to : American Suzuki MotorCorporation Motorcycle CustomerService PO. Box 1100, Brea, CA92822-1100 .

For owners outside the continentalUnited States, please refer to thedistributor's address listed on yourWarranty Information brochure .

TAMPERING WITH NOISE

CONTROL SYSTEMPROHIBITEDFederal law prohibits the followingacts or the causing thereof ;1 . The removal or rendering inop-

erative by any person other thanfor purposes of maintenance,repair, or replacement, of anydevice or element of design in-corporated into any new vehiclefor the purpose of noise controlprior to its sale or delivery to theultimate purchaser or while it isin use, or

2. The use of the vehicle after suchdevice or element of design hasbeen removed or rendered in-operative by any person .

Among those acts presumed toconstitute tampering are the actslisted below :•

Removing or puncturing themuffler, baffles, header pipes,screen type spark arrester (ifequipped) or any other compo-nent which conducts exhaustgases .

•

Replacing the exhaust systemor muffler with a system or muf-fler not marked with the samemodel specific code as the codelisted on the Motorcycle NoiseEmission Control Informationlabel, and certified to appropri-ate EPA noise standards .

VehicleClass

EngineDisplacement

Useful LifeDistance

Class 1 50 to 169 cc 12000 km(7456 miles)

Class II 170 to 279 cc 18000 km(11185 miles)

Class 111 280 cc andOver

30000 km(18641 miles)

• Removing or puncturing the aircleaner case, air cleaner cover,baffles, or any other componentwhich conducts intake air .

Whenever replacing parts on yourmotorcycle, Suzuki recommendsthat you use genuine Suzuki re-placement parts or their equivalent .

SERIAL NUMBER LOCATIONYou need to know the frame andengine serial numbers to get titledocuments for your motorcycle.Youalso need these numbers to helpyour dealer when you order parts .

W11

The frame number 9@ is stampedon the steering head as shown inthe illustration. The engine serialnumber (2 is stamped on the rightside of the crankcase assembly.

Write down the serial numbers herefor your future reference .

Frame No . :

Engine No . :

SPECIFICATIONS (SV650)

DIMENSIONS AND DRY MASSOverall lengthOverall widthOverall heightWheelbaseGround clearanceSeat heightDry mass

ENGINEType

Number of cylindersBoreStrokeDisplacementCompression ratioCarburetorAir cleanerStarter systemLubrication system

TRANSMISSIONClutchTransmissionGearshift patternPrimary reduction ratioGear ratios, Low

2nd3rd4th5thTop

Final reduction ratioDrive chain

CHASSISFront suspensionRear suspension

CasterTrailSteering angleTurning radiusFront brakeRear brakeFront tire sizeRear tire size

2070 mm (81 .5 in)750 mm (29 .5 in)

1060 mm (41 .7 in)1430 mm (56 .3 in)140 mm (5 .5 in)805 mm (31 .7 in)165 kg (363 Ibs)

Four-stroke, liquid-cooled, DOHC, TSCC,90° degree V-twin281 .0 mm (3 .189 in)62 .6 mm (2 .465 in)645 cm 3 (39 .4 cu . in)11 .5 :1MIKUNI BDSR39Non-woven fabric elementElectricWet sump

Wet multi-plate type6-speed constant mesh1-down, 5-up2.088 (71/34)2 .461 (32/13)1 .777 (32/18)1 .380 (29/21)1 .125 (27/24)0 .961 (25/26)0 .851 (23/27)3 .000 (45/15)D .I .D. 525V8, 110 links

Telescopic, coil spring, oil dampedLink type, coil spring, gas/oil damped, springpre-load 7 way adjustable25°100 mm (3 .94 in)33° (right and left)2 .9 m (9 .5 ft)Disk brakeDisk brake120/60 ZR17 (55W), tubeless160/60 ZR17 (69W), tubeless

ELECTRICALIgnition typeSpark plugBatteryGeneratorFuseHeadlightTurn signal lightBrake light/TaillightLicense plate lightSpeedometer lightTurn signal indicator lightHigh beam indicator lightNeutral indicator lightOil pressure indicator light

CAPACITIESFuel tank

Engine oil, Without filter changeWith filter change

Engine coolant

Electronic ignition (Transistorized)NGK CR8E or DENSO U24ESR-N12V 36 kC(10 Ah)/10 HRThree-phase A .C . generator30/15/15/15/10/10A12V 60/55W12V 21W12V 21/5W x 212V 5W12V 1 .7W x 212V 1 .7W12V 1 .7W12V 1 .7W12V 1 .7W

16 .0 L (4 .2 US gal)15 .0 L (4 .0 US gal) . . . For California2300 ml (2 .4 US qt)2400 ml (2 .5 US qt)1600 ml (1 .7 US qt)

SPECIFICAHONS (SV650S)

DIMENSIONS AND DRY MASSOverall length 2045 mm (80 .5 in)

2120 mm (83 .5 in)Overall width 740 mm (29 .1 in)Overall height . __

.1130 mm (44 .5 in)Wheelbase 1420 mm (55 .9 in)Ground clearance 140 mm (5 .5 in)Seat height 805 mm (31 .7 in)Dry mass 169 kg (372 Ibs)

ENGINEType

Number of cylindersBoreStrokeDisplacementCompression ratioCarburetorAir cleanerStarter systemLubrication system

TRANSMISSIONClutchTransmissionGearshift patternPrimary reduction ratioGear ratio*, Low

'lied;trd4th6thThp

Final reduction ratioDrive chain

CHASSISFront suspensionRear suspension

11

Caster .TrailSteering anptaTurning radio«Front brakeRear brakeFront tire miss . . . .Rear tire also

,,,,,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

,,,,,,,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-stroke, liquid-cooled, DOHC, TSCC,90° degree V-twin281 .0 mm (3 .189 in)62 .6 mm (2 .465 in)645 cm 3 (39 .4 cu . in)11 .5 :1MIKUNI BDSR39Non-woven fabric elementElectricWet sump

Wet multi-plate type6-speed constant mesh1-down, 5-up2 .088 (71/34)2 .461 (32/13)1 .777 (32/18)1 .380 (29/21)1 .125 (27/24)0 .961 (25/26)0.851 (23/27)2.933 (44/15)D .I .D . 525V9, 108 links

Switzerland and Sweden

Telescopic, coil spring, oil dampedLink type coil spring, gas/oil damped,spring pre-load 7 way adjustable25°100 mm (3.94 in)30° (right and left)3.1 m (9 .5 ft)Disk brakeDisk brake120/60 ZR17 (55W), tubeless160/60 ZR17 (69W), tubeless

ELECTRICALIgnition typeSpark plugBatteryGeneratorFuseHeadlightPosition lightTurn signal lightBrake light/TaillightLicense plate lightSpeedometer lightTurn signal indicator lightHigh beam indicator lightNeutral indicator lightOil pressure indicator light

CAPACITIESFuel tank

Engine oil, without filter changewith filter change

Engine coolant

Electronic ignition (Transistorized)NGK CR8E or DENSO U24ESR-N12V 36 kC(10 Ah)/10 HRThree-phase A .C . generator30/15/15/15/10/10A12V 45/45W x 212V 5W12V 21W12V 21/5W x 212V 5W12V 0 .84W x 312V 3W12V 1 .7W12V 1 .7W12V 1 .7W

16.0 L (4 .2 US gal)15 .0 L (4 .0 US gal) . .. For California2300 ml (2 .4 US qt)2400 ml (2.5 US qt)1600 ml (1 .7 US qt) Prepared by

SUZUKI MOTOR CORPORATION

Motorcycle Service Department

June, 2000Part No. 99011-20F52-03A

Printed in Japan