Suzuki SFV650 Manuals

Manuals and User Guides for Suzuki SFV650. We have 1 Suzuki SFV650 manual available for free PDF download: Service Manual

Suzuki SFV650 Service Manual (573 pages)

Brand: Suzuki | Category: Motorcycle | Size: 44.36 MB

Section 1 Engine

59
- General Information
  13
- Fuel and Oil Recommendation
  16
- Vehicle Identification Number
  16
- Vehicle Side View
  16
- Cylinder Identification
  17
- Maintenance and Lubrication
  27
- Scheduled Maintenance
  27
- Lubrication Points
  28
- Table of Contents
  59
- Engine General Information and Diagnosis
  64
- Fi System Wiring Diagram
  68
- Fi System Parts Location
  70
- Engine Symptom Diagnosis
  72
- Engine General Information and
  
  77
  - Show Data When Trouble
    78
  - Malfunction Code and Defective Condition
    88
    
    Malfunction
    88
    
    DTC "C13" (P1750) or "C17" (P0105): IAP Sensor Circuit Malfunction
    93
    
    DTC "C14" (P0120-H/L): TP Sensor Circuit
    99
    
    DTC "C15" (P0115-H/L): ECT Sensor Circuit
    110
    
    DTC "C21" (P0110-H/L): IAT Sensor Circuit
    116
    
    DTC "C23" (P1651-H/L): to Sensor Circuit
    122
    
    DTC "C24" (P0351) or "C25" (P0352): Ignition System Malfunction
    130
    
    DTC "C28" (P1655): Secondary Throttle Valve Actuator (STVA) Malfunction
    130
    
    DTC "C29" (P1654-H/L): Secondary Throttle Position Sensor (STPS) Circuit Malfunction
    136
    
    DTC "C31" (P0705): GP Switch Circuit Malfunction
    147
    
    Troubleshooting
    147
    
    DTC "C32" (P0201), "C33" (P0202): Fuel Injector Circuit Malfunction
    151
    
    DTC "C40" (P0505 / P0506 / P0507): ISC Valve Circuit Malfunction
    154
    
    DTC "C41" (P0230-H/L): FP Relay Circuit Malfunction
    156
    
    DTC "C42" (P1650): IG Switch Circuit
    160
    
    DTC "C44" (P0130 / P0135): HO2 Sensor (HO2S) Circuit Malfunction
    160
    
    DTC "C60" (P0480): Cooling Fan Relay Circuit Malfunction
    167
- Specifications
  
  173
  - Service Data
    173
  - Special Tool
    174
- 1B-1 Emission Control Devices
  
  176
- Precautions
  
  176
  - Precautions for Emission Control Devices
    176
- General Description
  
  176
- Repair Instructions
  
  178
- Specifications
  
  180
  - Service Data
    180
- Engine Electrical Devices
  
  181
- Precautions
  
  181
  - Precautions for Engine Electrical Device
    181
- Component Location
  
  181
  - Engine Electrical Components Location
    181
  - ECM Removal and Installation
    181
  - CKP Sensor Inspection
    181
  - CKP Sensor Removal and Installation
    182
  - IAP Sensor Inspection
    182
  - IAP Sensor Removal and Installation
    182
  - TP Sensor Inspection
    182
  - TP Sensor Removal and Installation
    182
  - TP Sensor Adjustment
    182
  - IAT Sensor Removal and Installation
    183
  - IAT Sensor Inspection
    183
  - ECT Sensor Removal and Installation
    183
  - ECT Sensor Inspection
    184
  - TO Sensor Removal and Installation
    185
  - TO Sensor Inspection
    185
  - STP Sensor Inspection
    185
  - STP Sensor Adjustment
    185
  - STP Sensor Removal and Installation
    186
  - STV Actuator Inspection
    187
  - STV Actuator Removal and Installation
    187
  - ISC Valve Inspection
    187
  - ISC Learned Value Reset and Opening Initialization
    187
  - HO2 Sensor Inspection
    188
  - HO2 Sensor Removal and Installation
    188
  - GP Switch Inspection
    188
  - GP Switch Removal and Installation
    188
- Specifications
  
  188
  - Service Data
    188
  - Tightening Torque Specifications
    189
- Special Tools and Equipment
  
  189
  - Recommended Service Material
    189
  - Special Tool
    189
- Engine Mechanical
  
  190
- General Description
  
  190
  - ISC Valve System Description
    190
- Schematic and Routing Diagram
  
  190
  - Camshaft and Sprocket Assembly Diagram
    190
  - Throttle Cable Routing Diagram
    191
- Diagnostic Information and Procedures
  
  192
  - Engine Mechanical Symptom Diagnosis
    192
  - Compression Pressure Check
    192
- Repair Instructions
  
  193
  - Engine Components Removable with the Engine in Place
    193
  - Air Cleaner Element Removal and Installation
    195
  - Air Cleaner Element Inspection and Cleaning
    195
  - Air Cleaner Box Removal and Installation
    195
  - Throttle Body Components
    196
  - Throttle Body Construction
    197
  - Throttle Body Removal and Installation
    199
  - Throttle Body Disassembly and Assembly
    200
  - Throttle Body Inspection and Cleaning
    204
  - Throttle Valve Synchronization
    204
  - ISC Learned Value Reset
    206
  - Engine Assembly Removal
    207
  - Engine Assembly Installation
    211
  - Engine Top Side Disassembly
    214
  - Engine Top Side Assembly
    220
  - Valve Clearance Inspection and Adjustment
    232
  - Camshaft Inspection
    233
  - Cam Chain Tension Adjuster Inspection
    234
  - Cam Chain Guide Inspection
    235
  - Cam Chain Tensioner Inspection
    235
  - Cylinder Head Disassembly and Assembly
    235
  - Cylinder Head Related Parts Inspection
    238
  - Valve Guide Replacement
    241
  - Valve Seat Repair
    242
  - Cylinder Inspection
    243
  - Piston Ring Removal and Installation
    244
  - Piston and Piston Ring Inspection
    245
  - Engine Bottom Side Disassembly
    247
  - Engine Bottom Side Assembly
    254
  - Conrod Removal and Installation
    268
  - Conrod / Crankshaft Inspection
    269
  - Conrod Crank Pin Bearing Inspection and Selection
    270
  - Crankshaft Journal Bearing Inspection and Selection
    272
- Specifications
  
  273
  - Service Data
    273
  - Tightening Torque Specifications
    275
- Special Tools and Equipment
  
  276
  - Recommended Service Material
    276
- Engine Lubrication System
  
  280
- Precautions
  
  280
  - Precautions for Engine Oil
    280
- Schematic and Routing Diagram
  
  281
  - Engine Lubrication System Chart Diagram
    281
  - Oil Pan
    281
  - Engine Lubrication Circuit Diagram
    282
- Diagnostic Information and Procedures
  
  284
  - Engine Lubrication Symptom Diagnosis
    284
  - Oil Pressure Check
    284
- Repair Instructions
  
  285
- Specifications
  
  293
  - Service Data
    293
  - Tightening Torque Specifications
    293
- Special Tools and Equipment
  
  294
  - Recommended Service Material
    294
  - Special Tool
    294
- Engine Cooling System
  
  295
- Precautions
  
  295
  - Precautions for Engine Cooling System
    295
  - Precautions for Engine Coolant
    295
- General Description
  
  295
  - Engine Coolant Description
    295
- Schematic and Routing Diagram
  
  296
  - Cooling Circuit Diagram
    296
  - Water Hose Routing Diagram
    297
- Diagnostic Information and Procedures
  
  298
  - Engine Cooling Symptom Diagnosis
    298
- Repair Instructions
  
  298
  - Cooling Circuit Inspection
    298
  - Radiator Cap Inspection
    299
  - Radiator Inspection and Cleaning
    299
  - Radiator / Cooling Fan Motor Removal and Installation
    299
  - Water Hose Inspection
    301
  - Water Hose Removal and Installation
    301
  - Radiator Reservoir Tank Inspection
    301
  - Radiator Reservoir Tank Removal and Installation
    302
  - Cooling Fan Inspection
    302
  - Cooling Fan Relay Inspection
    303
  - ECT Sensor Removal and Installation
    303
  - ECT Sensor Inspection
    303
  - Engine Coolant Temperature Indicator Inspection
    303
  - Thermostat Removal and Installation
    303
  - Battery Inspection
    303
  - Thermostat Inspection
    304
  - Water Pump Components
    305
  - Water Pump Removal and Installation
    306
  - Water Pump Disassembly and Assembly
    307
  - Water Pump Related Parts Inspection
    310
- Specifications
  
  311
  - Service Data
    311
  - Tightening Torque Specifications
    311
- Special Tools and Equipment
  
  312
  - Recommended Service Material
    312
  - Special Tool
    312
- Fuel System
  
  313
- Precautions
  
  313
  - Precautions for Fuel System
    313
- General Description
  
  314
  - Fuel System Description
    314
- Schematic and Routing Diagram
  
  315
  - Fuel Tank Drain Hose and Breather Hose Routing Diagram
    315
- Diagnostic Information and Procedures
  
  316
  - Fuel System Diagnosis
    316
- Repair Instructions
  
  317
  - Fuel Pressure Inspection
    317
  - Fuel Pump Inspection
    318
  - Fuel Discharge Amount Inspection
    318
  - Fuel Pump Relay Inspection
    318
  - Fuel Hose Inspection
    319
  - Fuel Hose Removal and Installation
    319
  - Fuel Level Gauge Inspection
    319
  - Fuel Tank Removal and Installation
    319
  - Fuel Pump Components
    321
  - Fuel Pump Assembly Removal and Installation
    322
  - Fuel Level Gauge Inspection
    322
  - Fuel Pump Disassembly and Assembly
    322
  - Fuel Mesh Filter Inspection and Cleaning
    324
  - Fuel Injector / Fuel Delivery Pipe Removal and Installation
    324
  - Fuel Injector Inspection and Cleaning
    326
- Specifications
  
  326
  - Service Data
    326
  - Tightening Torque Specifications
    326
- Special Tools and Equipment
  
  327
  - Recommended Service Material
    327
  - Special Tool
    327
- Ignition System
  
  328
- Schematic and Routing Diagram
  
  328
  - Ignition System Diagram
    328
- Component Location
  
  329
  - Ignition System Components Location
    329
- Diagnostic Information and Procedures
  
  329
  - Ignition System Symptom Diagnosis
    329
  - No Spark or Poor Spark
    330
- Repair Instructions
  
  331
- Specifications
  
  337
  - Service Data
    337
  - Tightening Torque Specifications
    337
- Special Tools and Equipment
  
  338
  - Recommended Service Material
    338
  - Special Tool
    338
- Starting System
  
  339
- Schematic and Routing Diagram
  
  339
  - Starting System Diagram
    339
- Component Location
  
  339
  - Starting System Components Location
    339
- Diagnostic Information and Procedures
  
  339
- Repair Instructions
  
  341
- Specifications
  
  351
  - Service Data
    351
  - Tightening Torque Specifications
    351
- Special Tools and Equipment
  
  352
  - Recommended Service Material
    352
- Charging System
  
  353
- Schematic and Routing Diagram
  
  353
  - Charging System Diagram
    353
- Component Location
  
  353
  - Charging System Components Location
    353
- Diagnostic Information and Procedures
  
  353
  - Charging System Symptom Diagnosis
    353
  - Battery Runs down Quickly
    354
- Repair Instructions
  
  355
  - Battery Current Leakage Inspection
    355
  - Regulated Voltage Inspection
    355
  - Generator Inspection
    356
  - Generator Removal and Installation
    356
  - Regulator / Rectifier Construction
    360
  - Regulator / Rectifier Inspection
    360
  - Regulator / Rectifier Removal and Installation
    361
  - Battery Components
    362
  - Battery Charging
    362
  - Battery Removal and Installation
    364
  - Battery Visual Inspection
    365
- Specifications
  
  365
  - Service Data
    365
  - Tightening Torque Specifications
    365
- Special Tools and Equipment
  
  366
  - Recommended Service Material
    366
  - Special Tool
    366
- Exhaust System
  
  367
- Precautions
  
  367
  - Precautions for Exhaust System
    367
- Diagnostic Information and Procedures
  
  367
  - Engine Symptom Diagnosis
    367
- Repair Instructions
  
  368
- Specifications
  
  374
Section 2 Suspension

375
- Precautions
  
  376
  - Precautions for Suspension
    376
- Diagnostic Information and Procedures
  
  377
  - Suspension and Wheel Symptom Diagnosis
    377
- Suspension General Diagnosis
  
  377
- Repair Instructions
  
  378
  - Front Fork Components
    378
  - Front Fork Removal and Installation
    379
  - Front Fork Inspection
    380
  - Front Fork Adjustment
    380
  - Front Fork Disassembly and Assembly
    381
  - Front Fork Parts Inspection
    386
- Front Suspension
  
  378
- Specifications
  
  386
  - Service Data
    386
  - Tightening Torque Specifications
    387
- Special Tools and Equipment
  
  387
  - Recommended Service Material
    387
    
    Special Tool
    387
- Rear Suspension
  
  388
- Repair Instructions
  
  388
- Specifications
  
  399
  - Service Data
    399
  - Tightening Torque Specifications
    399
- Special Tools and Equipment
  
  400
  - Recommended Service Material
    400
  - Special Tool
    400
- Wheels and Tires
  
  401
- Precautions
  
  401
  - Precautions for Wheel and Tire
    401
- Repair Instructions
  
  402
- Specifications
  
  418
  - Service Data
    418
  - Tightening Torque Specifications
    418
- Special Tools and Equipment
  
  419
  - Recommended Service Material
    419
  - Special Tool
    419
Section 3 Driveline / Axle

421
- Precautions
  
  422
  - Precautions for Driveline / Axle
    422
- Diagnostic Information and Procedures
  
  423
  - Drive Chain and Sprocket Symptom Diagnosis
    423
- Drive Chain / Drive Train / Drive Shaft
  
  423
- Repair Instructions
  
  423
- Specifications
  
  432
  - Service Data
    432
  - Tightening Torque Specifications
    432
- Special Tools and Equipment
  
  433
  - Recommended Service Material
    433
  - Special Tool
    433
Section 4 Brake

435
- Precautions
  
  436
  - Precautions for Brake System
    436
  - Brake Fluid Information
    436
- Brake Control System and Diagnosis
  
  437
- Schematic and Routing Diagram
  
  437
  - Front Brake Hose Routing Diagram
    437
  - Rear Brake Hose Routing Diagram
    438
- Diagnostic Information and Procedures
  
  439
  - Brake Symptom Diagnosis
    439
- Repair Instructions
  
  440
- Specifications
  
  452
  - Service Data
    452
  - Tightening Torque Specifications
    453
- Special Tools and Equipment
  
  453
  - Recommended Service Material
    453
  - Special Tool
    453
- Repair Instructions
  
  454
- Front Brakes
  
  454
- Specifications
  
  461
  - Service Data
    461
  - Tightening Torque Specifications
    461
- Special Tools and Equipment
  
  462
  - Recommended Service Material
    462
  - Special Tool
    462
- Rear Brakes
  
  463
- Repair Instructions
  
  463
  - Rear Brake Components
    463
  - Rear Brake Pad Inspection
    463
  - Rear Brake Pad Replacement
    464
  - Rear Brake Caliper Removal and Installation
    465
  - Rear Brake Caliper Disassembly and Assembly
    466
  - Rear Brake Caliper Parts Inspection
    467
  - Rear Brake Disc Removal and Installation
    468
  - Rear Brake Disc Inspection
    469
- Specifications
  
  470
  - Service Data
    470
  - Tightening Torque Specifications
    470
- Special Tools and Equipment
  
  471
  - Recommended Service Material
    471
  - Special Tool
    471
Section 5 Transmission / Transaxle

473
- Precautions
  
  474
  - Precautions for Transmission / Transaxle
    474
- Diagnostic Information and Procedures
  
  475
  - Manual Transmission Symptom Diagnosis
    475
- Manual Transmission
  
  475
- Repair Instructions
  
  476
- Specifications
  
  492
  - Service Data
    492
  - Tightening Torque Specifications
    492
- Special Tools and Equipment
  
  493
  - Recommended Service Material
    493
  - Special Tool
    493
- Diagnostic Information and Procedures
  
  494
  - Clutch System Symptom Diagnosis
    494
- Precautions
  
  494
  - Precautions for Clutch System
    494
- Clutch
  
  494
- Repair Instructions
  
  495
- Specifications
  
  509
  - Service Data
    509
  - Tightening Torque Specifications
    510
- Special Tools and Equipment
  
  510
  - Recommended Service Material
    510
  - Special Tool
    510
Section 6 Steering

511
- Precautions
  
  512
  - Precautions for Steering
    512
- Steering General Diagnosis
  
  513
- Diagnostic Information and Procedures
  
  513
  - Steering Symptom Diagnosis
    513
- Repair Instructions
  
  514
  - Handlebars Components
    514
  - Handlebar Construction
    515
  - Handlebars Removal and Installation
    516
  - Handlebars Inspection
    517
  - Steering Components
    518
  - Steering Removal and Installation
    518
  - Steering Related Parts Inspection
    521
  - Steering System Inspection
    521
  - Steering Stem Bearing Removal and Installation
    521
  - Steering Tension Adjustment
    522
- Steering / Handlebar
  
  514
- Specifications
  
  523
  - Tightening Torque Specifications
    523
- Special Tools and Equipment
  
  523
  - Recommended Service Material
    523
  - Special Tool
    524
Section 9 Body and Accessories

525
- Precautions
  
  527
  - Precautions for Electrical System
    527
- Component Location
  
  527
  - Electrical Components Location
    527
- Schematic and Routing Diagram
  
  528
  - Wiring Diagram
    528
  - Wiring Harness Routing Diagram
    532
- Wiring Systems
  
  528
- Specifications
  
  536
  - Service Data
    536
  - Tightening Torque Specifications
    536
- Repair Instructions
  
  537
- Lighting Systems
  
  537
- Specifications
  
  551
  - Service Data
    551
  - Special Tool
    551
- General Description
  
  553
  - Combination Meter System Description
    553
- Combination Meter / Fuel Meter / Horn
  
  553
- Repair Instructions
  
  554
- Special Tools and Equipment
  
  561
- Specifications
  
  561
  - Service Data
    561
- Exterior Parts
  
  562
- Schematic and Routing Diagram
  
  562
  - Seat Lock Cable Routing Diagram
    562
- Repair Instructions
  
  563
  - Frame Cover Construction
    563
  - Rear Fender Construction
    564
  - Fastener Removal and Installation
    565
  - Exterior Parts Removal and Installation
    565
- Special Tools and Equipment
  
  568
  - Recommended Service Material
    568
- Body Structure
  
  569
- Repair Instructions
  
  569
  - Body Frame Construction
    569
  - Front Footrest Construction
    570
    
    Side-Stand Construction
    571
- Specifications
  
  571
  - Tightening Torque Specifications
    571
- Special Tools and Equipment
  
  571
  - Recommended Service Material
    571

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Suzuki SFV650 Manuals

Suzuki SFV650 Service Manual (573 pages)

Table of Contents

Section 1 Engine

Engine General Information and

Specifications

1B-1 Emission Control Devices

Precautions

General Description

Repair Instructions

Specifications

Engine Electrical Devices

Precautions

Component Location

Specifications

Special Tools and Equipment

Engine Mechanical

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Lubrication System

Precautions

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Engine Cooling System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Fuel System

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Ignition System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Starting System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Charging System

Schematic and Routing Diagram

Component Location

Diagnostic Information and Procedures

Repair Instructions

Specifications

Special Tools and Equipment

Exhaust System

Precautions

Diagnostic Information and Procedures

Repair Instructions

Specifications

Section 2 Suspension

Precautions

Diagnostic Information and Procedures

Suspension General Diagnosis

Repair Instructions

Front Suspension

Specifications

Special Tools and Equipment