Suzuki SVF650K9 User guide

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.

1
PREPARATION
WORKSHOP

A: Packed motorcycle
B: Working space
SELF PROTECTION

UNCRATING THE MOTORCYCLE
Remove the carton.

A: Crate
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 and safety shoes as shown in the
illustration when handling metal crates.
Metal crates may have sharp edges and may
cause injury.

2
Remove the bolts of the bracket.
A: Bolt
Remove the bolts from 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 requires two operators.
Be careful not to damage the motorcycle.

3
LOCATION OF PARTS
Check all the components which have been removed from the base of the crate.
Parts listed above are installed respectively into the positions as follows.
Item Part Name Q’ty Remarks
A
Handlebars assembly 1
Clamp 2
Allen bolt 4 8 × 25 mm
Burring washer 4 OD:13.0 ID:8.5
Plastic cap 4
OD:11.0
For handlebar
clamp bolt
Clutch lever cover 1
Screw 1 5 × 45 mm
For left switch
Screw 1 5 × 25 mm
For left switch
Screw 1
5 × 30 mm
For throttle
assembly
Strap 2 L:140
BHolder 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 cushion 1 L:15.0
Spacer nut 1 6 mm
D Rear view mirror 2 Right and Left
E Washer 2 OD:20.0 ID:6.5
FBattery electrolyte
container 1
GOwner’smanualset 1
H Warning label 7 For
E-19 CC selection
I Warning label 4 For
E-19 CD selection
OD : Outside diameter (mm)
ID : Inside diameter (mm)
L : Length (mm)
T : Thickness (mm)
TL
OD ID
NOTE:
The parts shown as Item E, H and I in the above table are supplied for limited markets.
Use washers of Item E for mounting the license plate.
A
DD
B
C

4
The photograph shown 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
HH
II
FFGG
EE
CC
BB
DD
AA

5
Before assembling the motorcycle, thoroughly
understand the “Safety Check Out” described on
page 32.
After completion of assembly, carefully check the
motorcycle referring to the “Safety Check Out”,
then deliver the motorcycle to the customer.
ASSEMBLY
REMOVING THE BRACKET
Remove the 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: Bolt
Keep the position of front brake master cylinder
with its cap facing upwards until it is installed.
NOTE:
The bolt is no longer needed and this may be
discarded.
Be careful not to damage the fuel tank.
NOTE:
The bracket and bolts are no longer needed
and these may be discarded.

6
HANDLEBARS
Loosen the throttle housing retaining screws.
Insert the throttle assembly onto the handlebars.
A: Throttle assembly
B: Handlebars
Install the handlebars assembly with the two clamps,
four Allen bolts and washers.
A: Clamp
B: 8 × 25 mm Allen bolt
C: Burring washer OD:13.0 mm ID:8.5 mm
D: Punch mark
E: Dot mark
F: Plastic cap OD:11.0 mm
Tighten the handlebar clamp bolts to the specified
torque.
Handlebar clamp bolt: 23 N·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 direction as
shown in the illustration.
Install each clamp with the punch mark facing
front.
Align the dot mark on the handlebars with the
mating surface of the front side of left clamp.
NOTE:
To install the clamps correctly, first tighten the
bolt Aof the front side with specified torque
and then tighten the bolt Bof the rear side.
Make sure that the clamp has no clearance at
the front side as shown in the illustration.
FRONT

7

A: Front brake hose
B: Throttle cables
C: Right switch wiring harness
D: Clutch cable
E: Left switch wiring harness
THROTTLE
Insert the boss of throttle housing into the hole on the
handlebars.
Install the throttle assembly with two screws.

A: Boss
B: Hole
C: 5 × 30 mm screw
FRONT BRAKE MASTER CYLINDER
Install the front brake master cylinder onto the handle-
bars.
Align the dot mark on the handlebars with the master
cylinder-to-holder fitting 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 flange bolt
D: 6 × 22 mm flange bolt
E: Dot mark
The line drawings on page 29, 30 and 31 show
the proper routing of the control cables, hose
and wirings.
Refer to them in addition to following the
instructions carefully.
Check to ensure that the throttle operates freely
and closes automatically.
NOTE:
To install the holder correctly, first tighten the
bolt Cof the upper side with specified torque
and then tighten the bolt Dof the lower side.

8

A: Bolt
B: Holder
C: Front brake master cylinder
D: Handlebars
Connect the lead wires coupler to the front brake light
switch.
A: Front brake light switch
B: Lead wire coupler
LEFT SWITCH
Insert the boss of left switch 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
mark “UP”.
Make sure that the holder has no clearance at
the upper side as shown.
Check for brake fluid leakage.
Check to ensure that the holder is set the cor-
rect position.
Be careful not to pinch the wiring harness.

9
Connect the lead wire coupler to the clutch lever posi-
tion switch.
A: Clutch lever position switch
B: Lead wire coupler
CLUTCH CABLE
Pass the clutch cable through the lever cover.
A: Clutch cable
B: Lever cover
Turn the clutch 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 adjuster.
Do not adjust at this time.
Adjustment will be covered in the SERVICING section.
Install the lever cover.
A: Clutch cable
B: Adjuster
C: Lock nut
D: Cable end
E: Lever cover
NOTE:
Before installing the cable, grease the cable
end.