Suzuki SV650, SV650S (2003-2009) - Repair, Service Manual, Wiring Diagrams and Owners Manual

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SUZUKI SV650 & SV650S (2003-2009) - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - OWNERS

- English Service Manual / Repair Manual, Owners Manual and Wiring Diagrams, for motorcycles Suzuki SV650, SV650S (2003-2009).

 
CONTENTS:


SV650/S SERVICE MANUAL

Foreword
How To Use This Manual
- To Locate What You Are Looking For
- Component Parts And Work To Be Done
- Symbol
- Abbreviations Used In This Manual
- Sae-To-Former Suzuki Term
- Wire Color
01 General Information
- Warning/Caution/Note
- General Precautions
- Suzuki Sv650 (’03-Model)
- Suzuki Sv650s (’03-Model)
- Serial Number Location
- Fuel, Oil And Engine Coolant Recommendation
- Fuel (For Usa And Canada)
- Fuel (For Other Countries)
- Engine Oil (For Usa)
- Engine Oil (For Other Countries)
- Brake Fluid
- Front Fork Oil
- Engine Coolant
- Water For Mixing
- Anti-Freeze/Engine Coolant
- Liquid Amount Of Water/Engine Coolant
- Break-In Procedures
- Cylinder Identification
- Information Labels
- Specifications
- Dimensions And Dry Mass
- Engine
- Drive Train
- Chassis
- Electrical
- Capacities
- Country And Area Codes
02 Periodic Maintenance
- Periodic Maintenance Schedule
- Periodic Maintenance Chart
- Lubrication Points
- Maintenance And Tune-Up Procedures
- Air Cleaner
- Spark Plug
- Tappet Clearance
- Engine Oil And Oil Filter
- Fuel Hose
- Engine Idle Speed
- Throttle Valve Synchronization
- Evaporative Emission Control System (E-33 Only)
- Pair (Air Supply) System
- Throttle Cable Play
- Clutch
- Engine Coolant
- Radiator Hoses
- Drive Chain
- Brake
- Tire
- Steering
- Front Fork
- Rear Suspension
- Exhaust Pipe Bolt And Nut
- Chassis Bolt And Nut
- Compression Pressure Check
- Compression Test Procedure
- Oil Pressure Check
03 Engine
- Engine Components Removable With The Engine In Place
- Engine Removal And Installation
- Engine Removal
- Engine Installation
- Engine Disassembly
- Engine Top Side
- Engine Bottom Side
- Engine Components Inspection And Servicing
- Cylinder Head Cover
- Camshaft/Camshaft Journal
- Cylinder Head And Valve
- Cylinder
- Piston And Piston Ring
- Conrod And Crankshaft
- Crankcase
- Crankshaft Journal Bearing
- Crankcase Bearing And Oil Seal
- Clutch
- Primary Driven Gear Assembly
- Gearshift Shaft/Gearshift Arm
- Transmission
- Starter Clutch
- Generator And Signal Generator
- Oil Pump
- Clutch Release
- Engine Reassembly
- Engine Bottom Side
- Engine Top Side
04 Fi System Diagnosis
- Precautions In Servicing
- Electrical Parts
- Fuse
- Ecm/Various Sensors
- Electrical Circuit Inspection Procedure
- Using Testers
- Fi System Technical Features
- Injection Time (Injection Volume)
- Compensation Of Injection Time (Volume)
- Injection Stop Control
- Fi System Parts Location
- Fi System Wiring Diagram
- Self-Diagnosis Function
- User Mode
- Dealer Mode
- Tps Adjustment
- Fail-Safe Function
- Fi System Troubleshooting
- Customer Complaint Analysis
- Self-Diagnostic Procedures
- Self-Diagnosis Reset Procedure
- Malfunction Code And Defective Condition
- “C12” Ckp Sensor Circuit Malfunction
- “C13” Iap Sensor Circuit Malfunction
- “C14” Tp Sensor Circuit Malfunction
- “C15” Ect Sensor Circuit Malfunction
- “C21” Iat Sensor Circuit Malfunction
- “C23” To Sensor Circuit Malfunction
- “C24” Or “C25” Ignition System Malfunction
- “C28” Stv Actuator Circuit Malfunction
- “C29” Stp Sensor Circuit Malfunction
- “C31” Gear Position (Gp) Switch Circuit Malfunction
- “C32” Or “C33” Fuel Injector Circuit Malfunction
- “C41” Fp Relay Circuit Malfunction
- “C42” Ig Switch Circuit Malfunction
- “C49” Pair Control Solenoid Valve Circuit Malfunction
- Sensors
- Ckp Sensor Inspection
- Ckp Sensor Removal And Installation
- Iap Sensor Inspection
- Iap Sensor Removal And Installation
- Tp Sensor Inspection
- Tp Sensor Removal And Installation
- Tps Adjustment
- Ect Sensor Inspection
- Ect Sensor Removal And Installation
- Iat Sensor Inspection
- Iat Sensor Removal And Installation
- To Sensor Inspection
- To Sensor Removal And Installation
- Stp Sensor Inspection
- Stp Sensor Removal And Installation
- Stp Sensor Adjustment
05 Fuel System And Throttle Body
- Fuel System
- Fuel Delivery System
- Fuel Pump
- Fuel Pressure Regulator
- Fuel Injector
- Fuel Pump Control System
- Fuel Tank Lift-Up
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Pressure Inspection
- Fuel Pump Inspection
- Fuel Pump Relay Inspection
- Fuel Pump And Fuel Filter Removal
- Fuel Mesh Filter Inspection And Cleaning
- Fuel Pump Case Bushing Inspection
- Fuel Level Switch
- Fuel Pump And Fuel Mesh Filter Installation
- Throttle Body And Stv Actuator
- Construction
- Air Cleaner And Throttle Body Removal
- Throttle Body Disassembly
- Throttle Body Cleaning
- Throttle Body Inspection
- Throttle Body Reassembly
- Stv Synchronization
- Throttle Body Installation
- Stp Sensor Adjustment
- Air Cleaner Box Installation
- Tp Sensor Adjustment
- Fast Idle Inspection
- Fast Idle Adjustment
- Throttle Valve Synchronization
06 Cooling And Lubrication System
- Engine Coolant
- Cooling Circuit
- Cooling Circuit Inspection
- Radiator
- Removal
- Inspection And Cleaning
- Installation
- Radiator Cap
- Inspection
- Water Hose
- Inspection
- Cooling Fan
- Inspection
- Removal
- Installation
- Cooling Fan Thermo-Switch
- Removal
- Inspection
- Installation
- Engine Coolant Temperature Sensor
- Removal
- Inspection
- Installation
- Thermostat
- Removal
- Inspection
- Installation
- Water Pump
- Removal And Disassembly
- Inspection
- Reassembly And Installation
- Lubrication System
- Oil Pressure
- Oil Filter
- Oil Pressure Regulator
- Oil Strainer
- Oil Jet
- Oil Pump
- Oil Pressure Switch
- Oil Cooler
- Removal
- Inspection And Cleaning
- Installation
- Engine Lubrication Flow Chart
- Engine Lubrication Circuit
07 Chassis
- Exterior Parts
- Construction
- Removal
- Front Wheel
- Construction
- Removal
- Inspection And Disassembly
- Reassembly And Remounting
- Front Fork
- Construction
- Removal And Disassembly
- Inspection
- Cylinder
- Reassembly And Remounting
- Suspension Setting
- Steering And Handlebar
- Construction
- Removal
- Inspection And Disassembly
- Reassembly And Remounting
- Steering Tension Adjustment
- Rear Wheel
- Construction
- Removal
- Inspection And Disassembly
- Reassembly And Remounting
- Rear Shock Absorber
- Construction
- Removal
- Inspection
- Rear Shock Absorber Disposal
- Remounting
- Suspension Setting
- Rear Swingarm
- Construction
- Removal
- Inspection And Disassembly
- Reassembly
- Remounting
- Final Inspection And Adjustment
- Front Brake
- Construction
- Brake Pad Replacement
- Brake Fluid Replacement
- Caliper Removal And Disassembly
- Caliper Inspection
- Caliper Reassembly And Remounting
- Brake Disc Inspection
- Master Cylinder Removal And Disassembly (Sv650s)
- Master Cylinder Removal And Disassembly (Sv650)
- Master Cylinder Inspection
- Master Cylinder Reassembly And Remounting (Sv650s)
- Master Cylinder Removal And Remounting (Sv650)
- Rear Brake
- Construction
- Brake Pad Replacement
- Brake Fluid Replacement
- Caliper Removal And Disassembly
- Caliper Inspection
- Brake Disc Inspection
- Caliper Reassembly And Remounting
- Master Cylinder Removal And Disassembly
- Master Cylinder Inspection
- Master Cylinder Reassembly And Remounting
- Tire And Wheel
- Tire Removal
- Inspection
- Valve Installation
- Tire Installation
08 Electrical System
- Cautions In Servicing
- Connector
- Coupler
- Clamp
- Fuse
- Semi-Conductor Equipped Part
- Battery
- Connecting The Battery
- Wiring Procedure
- Using The Multi Circuit Tester
- Location Of Electrical Components
- Charging System
- Trouble Shooting
- Inspection
- Starter System And Side-Stand/Ignition Interlock System
- Trouble Shooting
- Starter Motor Removal And Disassembly
- Starter Motor Inspection
- Starter Motor Reassembly
- Starter Relay Inspection
- Side-Stand/Ignition Interlock System Parts Inspection
- Ignition System
- Troubleshooting
- Inspection
- Combination Meter
- Removal
- Inspection
- Engine Coolant Temperature Meter And Indicator
- Speed Sensor
- Removal
- Installation
- Inspection
- Lamps
- Headlight (Sv650)
- Headlight (Sv650s)
- Brake Light/Taillight
- Turn Signal Lights
- Relays
- Turn Signal/Side-Stand Relay
- Starter Relay
- Fuel Pump Relay
- Switches
- Ignition Switch Removal/ Installation
- Inspection
- Battery
- Specifications
- Initial Charging
- Servicing
- Recharging Operation
09 Servicing Information
- Troubleshooting
- Malfunction Code And Defective Condition
- Engine
- Radiator (Cooling System)
- Chassis
- Brakes
- Electrical
- Battery
- Wire Harness, Cable And Hose Routing
- Cable Routing (Sv650)
- Cable Routing (Sv650s)
- Wire Harness Routing
- Wire Harness Routing (Sv650s Only)
- Speed Sensor Lead Wire Routing
- Throttle Body Installation/Hose Routing
- Fuel System Hose Routing
- Battery Cushion Installation
- Cooling System Hose Routing
- Pair System Hose Routing
- Fuel Tank Installation
- Brake Pedal/Footrest Set-Up For Sv650
- For Sv650s
- Side-Stand Set-Up
- Engine Electrical Parts Set-Up
- Seat Lock Cable Routing
- Heat Shield Installation
- Front Brake Hose Routing For Sv650
- Front Brake Hose Routing For Sv650s
- Rear Brake Hose Routing For Sv650
- Rear Brake Hose Routing For Sv650s
- Special Tools
- Tightening Torque
- Engine
- Fi System Parts
- Chassis
- Tightening Torque Chart
- Service Data
10 Emission Control Information
- Emission Control Systems
- Fuel Injection System
- Crankcase Emission Control System
- Exhaust Emission Control System (Pair System)
- Noise Emission Control System
- Evaporative Emission Control System (Only For E-33)
- Pair (Air Supply) System Inspection
- Hoses
- Pair Reed Valve
- Pair Control Solenoid Valve
- Evaporative Emission Control System Inspection (Only For E-33)
- Hoses
- Evap Canister
- Tank Pressure Control Valve
- Evap Canister Hose Routing (Only For E-33)
11 Sv650k4/Sk4 ('04 Model)
- Specifications
- Service Data
- Periodic Maintenance Chart
- Transmission
- Crankshaft Journal Bearing
- Wire Harness Routing
- Brake Pedal/Footrest Setup
- Rear Brake Hose Routing
- Cooling System Hose Routing
- Gear Shift Pedal Setup
12 Sv650/Sk5 ('05 Model)
- Specifications (Sv650k5)
- Specifications (Sv650sk5)
- Service Data
13 Sv650/Sk6 ('06 Model)
- Specifications (Sv650k6)
- Specifications (Sv650sk6)
- Service Data
14 Sv650/S/A/Sak7 (’07-Model)
- Country And Area Codes
- Abbreviations Used In This Manual
- Sae-To-Former Suzuki Term
- Specifications (Sv650k7/Sv650sk7)
- Specifications (Sv650ak7/Sv650sak7)
- Periodic Maintenance Schedule
- Periodic Maintenance Chart
- Maintenance And Tune-Up Procedures
- Spark Plug
- Throttle Valve Synchronization
- Engine Components Inspection And Servicing
- Piston And Piston Ring
- Thermostat
- Fi System Diagnosis
- Fi System Wiring Diagram
- Ecm Terminal
- Fail-Safe Function
- Dtc Table And Defective Condition
- Dtc Troubleshooting
- Throttle Body
- Air Cleaner And Throttle Body Removal
- Throttle Body Disassembly
- Throttle Body Cleaning
- Throttle Body Reassembly
- Air Cleaner Box And Throttle Body Installation
- Stp Sensor Adjustment
- Tp Sensor Adjustment
- Throttle Valve Synchronization
- Isc Valve
- Isc Valve Pre-Set
- Ignition System
- Inspection
- Introduction Of Abs (For Sv650a/Sa)
- Cautions In Servicing
- Abs Components
- Abs Components Location
- Abs Coupler Connection Diagram
- Abs Wiring Diagram
- Abs Unit System Diagram
- Abs Troubleshooting
- Troubleshooting Procedure
- Dtc (Diagnostic Trouble Code) Output
- Dtc Deleting And Abs Operation Check
- Use Of Sds Diagnostic Procedures
- Use Of Sds Diagnosis Reset Procedure
- Dtc Table Of Abs
- Dtc Troubleshooting
- Abs Component Removal, Inspection And Installation
- Wiring Harness, Cable, Hose Routing And Sensor Installation
- Throttle Body Installation
- Rear Fender Installation
- Heat Shield Installation
- Ignition Coil Installation
- Emission Control System
- Exhaust Emission Control System (Pair System)
- Evaporative Emission Control System (Only For E-33)
- Pair (Air Supply) System Inspection
- Heated Oxygen Sensor (Ho2s) Inspection (For E-02, 19, 24, 33)
- Evaporative Emission Control System Inspection (Only For E-33)
- Special Tools
- Tightening Torque
- Service Data (Sv650/S)
- Service Data (Sv650a/Sa)
15 Sv650/S/A/Sak8 (’08 Model)
- Wiring Harness Routing (For Sv650/S)
- Wire Harness Routing (For Sv650a/Sa)
16 Sv650/S/A/Sak9 ('09 Model)
- Specifications (For Sv650k9/Sv650sk9)
- Specifications (For Sv650ak9/Sv650sak9)
17 Wiring Diagram

SV650/S OWNERS MANUAL
SV650A/SA OWNERS MANUAL