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. SFV650 SERVICE MANUAL 9 9 5 0 0 - 3 6 1 9 0 - 0 1 E. FOREWORD This manual contains an introductory description on the SUZUKI SFV650 and procedures for its inspection/ser- vice and overhaul of its main components. Other information considered as generally known is not included.

Service Manual. When torque values are given in this Service Manual, use them. Either too little or too. Flywheel Puller, M12 × 1.75: 57001-252. Free Suzuki Motorcycle Service Manuals for download. Lots of people charge for motorcycle service and workshop manuals online which is a bit cheeky I reckon as they are freely available all over the internet. £5 each online or download your Suzuki manual here for free!!

Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its maintenance. Use this section as well as other sections to use as a guide for proper inspection and service. TABLE OF CONTENTS Precautions. 00-i Precautions.00-1 General Information. 0-i General Information.0A-1 Maintenance and Lubrication.

0B-1 Service Data.0C-1 Engine. 1-i Precautions. 1-1 Engine General Information and Diagnosis. 1A-1 Emission Control Devices.1B-1 Engine Electrical Devices.1C-1 Engine Mechanical.1D-1 Engine Lubrication System. Table of Contents 00- i Section 00 Precautions CONTENTS Precautions.00-1 General Precautions.

00-1 Precautions for Electrical Circuit Service. 00-2 Precautions.00-1 Warning / Caution / Note.00-1. CAUTION special meanings. Pay special attention to the messages highlighted by these signal words. If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or WARNING their equivalent.

Indicates a potential hazard that could result. When removing parts that are to be reused, in death or injury.

Precautions: 00-2. Use a torque wrench to tighten fasteners. Before refitting the sealed coupler, make sure its seal to the specified torque. Wipe off grease rubber is positioned properly. The seal rubber may and oil if a thread is smeared with them. Possibly come off the position during disconnecting work and if the coupler is refitted with the seal rubber.

00-3 Precautions:. Check the male connector for bend and female Fuse connector for excessive opening. Also check the. When a fuse blows, always investigate the cause to coupler for locking (looseness), corrosion, dust, etc. Correct it and then replace the fuse. Precautions: 00-4.

When disconnecting and connecting the coupler,. Before measuring voltage at each terminal, check to make sure to turn OFF the ignition switch, or make sure that battery voltage is 11 V or higher. Electronic parts may get damaged. Terminal voltage check with a low battery voltage will lead to erroneous diagnosis. 00-5 Precautions: 1) Disconnect the negative (–) cable from the battery. Continuity check 2) Check each connector/coupler at both ends of the 1) Measure resistance across coupler “B” (between “A” circuit being checked for loose connection.

Also and “C” in figure). Check for condition of the coupler lock if equipped. Precautions: 00-6 3) Also, if measured values are as listed following, a 3) Measure resistance between terminal at one end of resistance (abnormality) exists which causes the circuit (“A” terminal in figure) and body ground.

If voltage drop in the circuit between terminals “A” and continuity is indicated, there is a short circuit to “B”. 00-7 Precautions: Using The Multi-Circuit Testers NOTE. Use the Suzuki multi-circuit tester set. When connecting the multi-circuit tester,. Use well-charged batteries in the tester. Use the needle pointed probe to the back side of the lead wire coupler and connect.

Table of Contents 0- i Section 0 General Information CONTENTS General Information. 0A-1 Exhaust Pipe Bolts and Muffler Bolts Inspection.0B-4 General Description.0A-1 Valve Clearance Inspection and Adjustment.0B-4 Symbols. 0A-1 Spark Plug Replacement.0B-9 Abbreviations.0A-2 Spark Plug Inspection and Cleaning.0B-9 Vehicle Side View. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1:1).

Apply SUZUKI SUPER GREASE “A” or equivalent. 0 Apply SUZUKI MOLY PASTE or equivalent. 0 Apply SUZUKI SILICONE GREASE or equivalent. BBDC: Before Bottom Dead Center ROM: Read Only Memory BTDC: Before Top Dead Center B+: Battery Positive Voltage SAE: Society of Automotive Engineers SDS: Suzuki Diagnosis System CKP Sensor: Crankshaft Position Sensor (CKPS) STC System: Secondary Throttle Control System CKT: Circuit (STCS). PERFORMANCE 4 MOTOR OIL or an equivalent engine oil. Use of SF/SG or SH/SJ in API with MA in JASO.

Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select and alternative according to the chart. 1 850 ml (2.0/1.6 US/Imp qt) oil.

Use of SF/SG or SH/SJ in API with MA in JASO. Suzuki recommends the use of SAE 10W-40 engine oil.

For engine coolant mixture information, refer to “Engine If SAE 10W-40 engine oil is not available, select an Coolant Description in Section 1F (Page 1F-1)”. Country and Area Codes B99 The following codes stand for the applicable country(-ies) and area(-s). Code Country or Area Effective Frame No.

SFV650 K9 (E-02) U.K. JS1CX01 – SFV650 K9 (E-03) U.S.A (Except for California) JS1VP55A 92100001 – SFV650 K9 (E-19) E.U.

Warning, Caution and Information Labels Location B91 7, 8, 9 2, 3 1, 10 11, 12 5, 6 I9-02 SFV650 SFV650U 1. Noise label For E-03, 24, 33 For E-24 2. Information label For E-03, 28, 33 — 3.

Vacuum hose routing label For E-33 —. 0A-7 General Information: Component Location Electrical Components Location B91 I9-04 1. IAP sensor (#1) 7.

ECT sensor 13. Starter motor 2. IAP sensor (#2) 8. Ignition coil (#2) 14. Oil pressure switch 3. IAT sensor 9. Ignition coil (#1) 15.

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Cooling fan 4. General Information: 0A-8 I9-04 17. Fuel injector (#1) 23.

TO sensor 29. CKP sensor 18. Fuel injector (#2) 24. Turn signal/Side-stand relay 30.

Speed sensor 19. Fuel pump/Fuel level gauge 25. GP switch 20. Starter relay/main fuse 26.

0A-9 General Information: Specifications Specifications B91 NOTE These specifications are subject to change without notice. Dimensions and curb mass Item Specification Remark Overall length 2 130 mm (83.9 in) Overall width 760 mm (29.9 in) Overall height 1 090 mm (42.9 in) Wheelbase 1 445 mm (56.9 in) Ground clearance. General Information: 0A-10 Chassis Item Specification Remark Front suspension Telescopic, coil spring, oil damped Rear suspension Link type, coil spring, oil damped Front suspension stroke 125 mm (4.9 in) Rear wheel travel 130 mm (5.1 in) Caster 25° Trail 106 mm (4.17 in) Steering angle 33°.

Plastigauge Plastigauge Small bore gauge (18 Multi circuit tester set Needle pointed probe – 35 mm) 0 0 1 1 1 TP Sensor test lead SUZUKI Diagnostic Universal clamp Oil seal remover Journal bearing system set wrench installer & holder. General Information: 0A-12 0 0 1 2 0 Bearing installer set Oil filter wrench Compression gauge Compression gauge Oil pressure gauge (10 – 75) attachment attachment 1 1 1 0 2 Adapter hose Oil pressure gauge Valve lapper set Valve lifter Valve lifter attachment (1000 kPa) 0. 0A-13 General Information: 0 0 0 3 0 Torx bit holder Torx wrench (5 mm) Rotor remover bolt Flywheel rotor holder Rotor holder 0 1 0 1 1 Mode selection switch Steering stem nut T type handle Front fork assembling Fuel pressure gauge socket wrench attachment (A). Maintenance and Lubrication: 0B-1 Maintenance and Lubrication General Information Precautions Precautions for Maintenance B91 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in terms of kilometers, miles and months for your convenience. 0B-2 Maintenance and Lubrication: Interval 1 000 6 000 12 000 18 000 24 000 Item miles 4 000 7 500 11 000 14 500 months Rear suspension — — — Chassis bolts and nuts Lubrication Points B92 Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.

Service manual for 2015 harley deuce. Major lubrication points are indicated as follows. Maintenance and Lubrication: 0B-3 Repair Instructions Air Cleaner Element Replacement CAUTION B91 Always apply compressed air to the inside of Replace air cleaner element the air cleaner element. If compressed air is Every 18 000 km (11 000 miles, 36 months) applied to the outside, dirt will be forced into Refer to “Air Cleaner Element Removal and Installation the pores of the air cleaner element. 0B-4 Maintenance and Lubrication: Exhaust Pipe Bolts and Muffler Bolts Inspection Valve Clearance Inspection and Adjustment B93 B96 Tighten exhaust pipe bolts, muffler bolts and nut Inspect valve clearance Initially at 1 000 km (600 miles, 2 months) and every Every 24 000 km (14 500 miles, 48 months) thereafter 12 000 km (7 500 miles, 24 months) thereafter Inspection.

Maintenance and Lubrication: 0B-5 NOTE. The tappet clearance should be taken when each cylinder is at Top Dead Center (TDC) of compression stroke. The cams (IN. & EX.) on the front cylinder at position “A” show the front cylinder at TDC of compression stroke. 0B-6 Maintenance and Lubrication: 7) Turn the crankshaft 270 degrees (3/4 turns) to set 2) Remove the tappet (1) and shim (2) by fingers or the #2 (Rear) cylinder at TDC of compression stroke. Magnetic hand.

(Align the “ R” line on the generator rotor to the center of timing inspection hole and also bring the camshafts to the position “B”. Maintenance and Lubrication: 0B-7 (INTAKE SIDE) I9-01. 0B-8 Maintenance and Lubrication: (EXHAUST SIDE) I9-01. Maintenance and Lubrication: 0B-9 6) Install the intake or exhaust cam chain tension Spark Plug Gap adjuster.

Refer to “Engine Top Side Assembly in 1) Remove the spark plugs. Refer to “Spark Plug Cap Section 1D (Page 1D-31)”. And Spark Plug Removal and Installation in Section 7) Rotate the engine so that the tappet is depressed 1H (Page 1H-5)”.

0B-10 Maintenance and Lubrication: Fuel Line Inspection Engine Oil Replacement B97 1) Keep the motorcycle upright. Inspect fuel line 2) Place an oil pan below the engine, and drain engine Every 6 000 km (4 000 miles, 12 months) oil by removing the oil drain plug (1) and filler cap (2). Also, do not use a genuine Suzuki 3) Turn off the engine and wait about three minutes, automobile oil filter on this motorcycle.

0B-12 Maintenance and Lubrication: Throttle Cable Play Inspection and Adjustment Throttle Valve Synchronization B99 B90 Inspect throttle cable play Inspect throttle valve synchronization Initially at 1 000 km (6 000 miles, 2 months) and Initially 1 000 km (600 miles, 2 months) (E-33 only) every 6 000 km (4 000 miles, 12 months) thereafter and every 12 000 km (7 500 miles, 24 months) Inspect and adjust the throttle cable play “a”. Maintenance and Lubrication: 0B-13 WARNING Do not open the radiator cap when the engine is hot, as you may be injured by escaping hot liquid or vapor. Engine coolant may be harmful if swallowed or if it comes in contact with skin or eyes. 0B-14 Maintenance and Lubrication: 10) Reinstall the removed parts. 3) From that position, turn out the release screw (2) 1 turn and tighten the lock-nut (1) securely by holding Radiator Hose Inspection the release screw (2). Check the radiator hoses for crack, damage or engine Clutch release screw coolant leakage.

Maintenance and Lubrication: 0B-15 Drive Chain Inspection and Adjustment 4) Count out 21 pins (20 pitches) on the chain and B96 measure the distance between the two points. If the distance exceeds the service limit, the chain must be Inspect drive chain replaced.

Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings.

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The standard drive chain is a DID520VM2. SUZUKI recommends to use this standard drive chain as a replacement. I9-01 I9-01 I9-01.

Maintenance and Lubrication: 0B-17 Brake Pads Check The extent of brake pad wear can be checked by observing the grooved limit line “A” on the pad. When the wear exceeds the grooved limit line, replace the pads with new ones. Refer to “Front Brake Pad Replacement in Section 4B (Page 4B-2)”.

0B-18 Maintenance and Lubrication: Brake Fluid Replacement Tire Pressure If the tire pressure is too high or too low, steering will be Replace brake fluid adversely affected and tire wear increased. Therefore, Every 2 years maintain the correct tire pressure for good roadability or Refer to “Brake Fluid Replacement in Section 4A shorter tire life will result. Maintenance and Lubrication: 0B-19 2) Support the motorcycle so that the front wheel is off the ground, with the wheel facing straight ahead, grasp the lower fork tubes near the axle and pull forward. If play is found, readjust the steering. Refer to “Steering Tension Adjustment in Section 6B (Page 6B-9)”. 0B-20 Maintenance and Lubrication: I9-01 I9-02 Front brake hose union bolt 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) Rear axle nut 100 N⋅m (10.0 kgf-m, 72.5 lbf-ft) Front brake master cylinder mounting bolt 10 N⋅m (1.0 kgf-m, Rear sprocket nut 60 N⋅m (6.0 kgf-m, 43.5 lbf-ft) 7.0 lbf-ft) I9-01 I9-01.

Maintenance and Lubrication: 0B-21 Compression Pressure Check B94 Refer to “Compression Pressure Check in Section 1D (Page 1D-3)”. Oil Pressure Check B95 Refer to “Oil Pressure Check in Section 1E (Page 1E- 5)”.

SDS Check B96 Refer to “SDS Check in Section 1A (Page 1A-18)”. I9-02 Rear shock absorber mounting bolt (Lower) 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft). 0B-22 Maintenance and Lubrication: Special Tools and Equipment Recommended Service Material B91 Material SUZUKI recommended product or Specification Note Brake fluid DOT 4 — (Page 0B-16) NOTE Required service material is also described in the following. “Lubrication Points (Page 0B-2)”. Service Data: 0C-1 Service Data General Information Specifications Service Data B91 Valve + Guide Unit: mm (in) Item Standard Limit 31 (1.22) — Valve diam.

25.5 (1.00) — 0.10 – 0.20 (0.004 – 0.008) — Valve clearance (when cold) 0.20 – 0.30 (0.008 – 0.012) —. 0C-2 Service Data: Cylinder + Piston + Piston Ring Unit: mm (in) Item Standard Limit 1 300 – 1 700 kPa 1 100 kPa Compression pressure (13.0 – 17.0 kgf/cm, 185 – 242 psi) (11.0 kgf/cm, 156 psi) 200 kPa Compression pressure difference —. Service Data: 0C-3 Transmission + Drive Chain Unit: mm (in) Except ratio Item Standard Limit Primary reduction ratio 2.088 (71/34) — Final reduction ratio 3.066 (46/15) — 2.461 (32/13) — 1.777 (32/18) — 1.380 (29/21) — Gear ratios 1.125 (27/24) —. 0C-4 Service Data: FI Sensors + Secondary Throttle Valve Actuator Item Standard/Specification Note 160 – 240 Ω CKP sensor resistance CKP sensor peak voltage 4.6 V and more When cranking IAP sensor (#1 & #2) input voltage 4.5 – 5.5 V IAP sensor (#1 &. Service Data: 0C-5 Electrical Unit: mm (in) Item Specification Note 1 ⋅ 2 Firing order NGK: CR8EIA-9 Type Spark plug DENSO: IU24D 0.8 – 0.9 (0.031 – 0.035) Spark performance Over 8 (0.3) at 1 atm. 160 – 240 Ω CKP sensor resistance CKP sensor peak voltage 4.6 V and more.

Front fork oil level (Without spring, 96 (3.78) — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL SS-08 or an equivalent fork oil — Front fork oil capacity (Each leg) 517 ml (17.5/18.2 US/Imp oz) — Front fork spring adjuster 3th groove from top —. Service Data: 0C-7 Fuel + Oil Item Specification Note Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2). Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less E-03, 28, 33 Fuel type than 10% ethanol, or less than 5% methanol with appropriate cosolvents and corrosion inhibitor is permissible.

0C-8 Service Data: Item N⋅m kgf-m lbf-ft Gear position switch mounting bolt 0.65 Oil pressure switch 10.0 Oil pressure switch lead wire bolt 0.15 M6 Crankcase bolt M8 19.0 (Cylinder head) M6 M6 Oil gallery plug M8 13.0 M12 15.0 M16 25.5 Oil drain plug. Service Data: 0C-9 Chassis Item N⋅m kgf-m lbf-ft Steering stem head nut 65.0 Tighten 45 N⋅m (4.5 kgf-m, 32.5 lbf-ft) then turn back 1/2 Steering stem nut – 1/4. Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 16.5. 0C-10 Service Data: Tightening Torque Chart For other bolts and nuts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt “a” (mm) N⋅m kgf-m lbf-ft N⋅m kgf-m lbf-ft 0.15 0.23 0.45 0.55. Table of Contents 1- i Section 1 Engine CONTENTS Precautions.1-1 DTC “C31” (P0705): GP Switch Circuit Malfunction.1A-84 Precautions. 1-1 DTC “C32” (P0201), “C33” (P0202): Fuel Precautions for Engine. 1-1 Injector Circuit Malfunction.1A-88 Engine General Information and DTC “C40” (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction.1A-91 Diagnosis.

1-ii Table of Contents Engine Symptom Diagnosis.1C-1 Engine Top Side Disassembly.1D-25 Engine Top Side Assembly.1D-31 Repair Instructions.1C-1 Valve Clearance Inspection and Adjustment.1D-43 ECM Removal and Installation.1C-1 Camshaft Inspection.1D-44 CKP Sensor Inspection.1C-1 Cam Chain Tension Adjuster Inspection.1D-45 CKP Sensor Removal and Installation.1C-2 Cam Chain Guide Inspection.1D-46 IAP Sensor Inspection.1C-2. Table of Contents 1-iii Special Tool.1E-15 Fuel Hose Removal and Installation.1G-7 Fuel Level Gauge Inspection.1G-7 Engine Cooling System.1F-1 Fuel Tank Removal and Installation.1G-7 Fuel Pump Components.1G-9 Precautions.1F-1 Fuel Pump Assembly Removal and Precautions for Engine Cooling System. 1-iv Table of Contents Starter Motor Disassembly and Assembly. 1I-4 Generator Removal and Installation.1J-4 Starter Motor Related Parts Inspection.1I-6 Regulator / Rectifier Construction. 1J-8 Starter Relay Removal and Installation.1I-6 Regulator / Rectifier Inspection.1J-8 Starter Relay Inspection.

Precautions: Precautions Engine Precautions Precautions for Engine B91 Refer to “General Precautions in Section 00 (Page 00-1)” and “Precautions for Electrical Circuit Service in Section 00 (Page 00-2)”. 1A-1 Engine General Information and Diagnosis: Engine General Information and Diagnosis Engine General Description Injection Timing Description B91 Injection Time (Injection Volume) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the intake air pressure, engine speed and throttle opening angle, and various compensations.

Engine General Information and Diagnosis: 1A-2 Compensation of Injection Time (Volume) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Signal Descriptions ENGINE COOLANT TEMPERATURE SENSOR When engine coolant temperature is low, injection time (volume) SIGNAL is increased. 1A-3 Engine General Information and Diagnosis: Self-Diagnosis Function B92 The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the LCD (DISPLAY) panel and LED (FI indicator light). To check the function of the individual FI system devices, the dealer mode is provided. Engine General Information and Diagnosis: 1A-4 Dealer Mode The defective function is memorized in the computer.

Use the special tool’s coupler to connect to the mode select switch. The memorized malfunction code is displayed on LCD (DISPLAY) panel.

Malfunction means that the ECM does not receive signal from the devices. 1A-5 Engine General Information and Diagnosis: Schematic and Routing Diagram FI System Wiring Diagram B91 Combination meter Cooling fan motor Cooling fan relay 15 A Br/B CKPS 31 36 Fuel injector Fuel Pump O/Bl Gr/W Gr/B FP relay 10 A Engine stop B/Br switch.

Engine General Information and Diagnosis: 1A-6 Terminal Alignment of ECM Coupler B92 I9-01 TERMINAL NO. CIRCUIT TERMINAL NO. CIRCUIT GP switch signal (GP) CKP sensor signal (CKP+) IAT sensor signal (IAT) — IAP sensor signal #1 (IAP.F) — STP sensor signal (STP) —.