Segment:
Sportbike/Naked Bike.
Target Audience:
Enthusiasts seeking a sporty, reliable, and relatively affordable V-twin motorcycle, suitable for commuting, spirited riding, and light touring. Appeals to both DIY mechanics and professional technicians.
Competitors:
Ducati Monster series, Kawasaki ER-5, Honda CB500/CB600 Hornet, Yamaha FZS600 Fazer (depending on regional availability and specific model comparisons).
Engine Layout:
Unique 90-degree V-twin architecture offering a distinctive character and sound.
Design Philosophy:
Emphasis on a balance of performance, usability, and value. The SV650 became renowned for its friendly power delivery and agile handling.
Engine:
V-twin, 90-degree, liquid-cooled, DOHC, 4-valve per cylinder. Includes disassembly, assembly, inspection, and repair of engine internals (pistons, rings, cylinders, crankshaft, connecting rods, camshafts, valves), lubrication system, cooling system, and fuel system (carburetors).
Transmission:
6-speed constant mesh. Covers clutch operation, transmission disassembly and assembly, gear shifting mechanisms, and related lubrication.
Chassis And Suspension:
Front telescopic fork (conventional or inverted depending on model variant), rear monoshock swingarm. Includes fork oil changes, seal replacement, shock absorber inspection and replacement, swingarm maintenance, and bearing checks.
Brakes:
Front dual discs with opposed piston calipers, rear single disc. Covers brake fluid replacement, caliper overhaul, master cylinder inspection, pad replacement, and bleeding procedures.
Electrical System:
Ignition system (CDI), charging system (alternator, regulator/rectifier), starter system, lighting, instrumentation, and wiring diagrams. Includes troubleshooting for electrical faults, component testing, and replacement.
Fuel System:
For these years, the SV650 utilized carburetors (typically Mikuni CV). The manual covers carburetor cleaning, adjustment, synchronization, jetting considerations, and fuel tank/petcock maintenance.
Exhaust System:
Covers inspection, removal, and installation of the exhaust system components, including mufflers and headers.
Cooling System:
Liquid cooling with radiator, fan, and coolant reservoir. Details coolant type, capacity, bleeding procedures, and component inspection.
Bodywork And Trim:
Includes procedures for removing and installing body panels, fairings (for 'S' models), seats, and fuel tank. Also covers minor bodywork repairs.
Maintenance:
Routine maintenance tasks such as oil and filter changes, chain adjustment and lubrication, air filter replacement, spark plug replacement, brake fluid flush, coolant flush, and general inspection. Includes periodic maintenance schedules.
Troubleshooting:
Systematic diagnostic procedures for common problems, including hard starting, poor performance, electrical issues, braking problems, and suspension anomalies. Provides symptom-based troubleshooting charts.
Repair And Rebuild:
Detailed step-by-step instructions for engine disassembly, component inspection and measurement, reassembly, transmission overhaul, carburetor rebuilding, suspension fork servicing, and brake system repair.
Installation And Removal:
Comprehensive guidance on removing and installing virtually all components and systems of the motorcycle, from minor parts to major assemblies.
Adjustments:
Instructions for clutch cable adjustment, throttle cable adjustment, idle speed adjustment, carburetor synchronization, chain slack adjustment, and suspension pre-load adjustments.
Depth:
Highly comprehensive, covering everything from basic owner maintenance to full engine rebuilds and advanced diagnostics. Includes factory specifications, tolerances, and wear limits.
Diagrams And Illustrations:
Abundant step-by-step procedures, exploded diagrams, detailed drawings, and photographs illustrating each service and repair operation, including the usage of special service tools.
Special Tools:
References specific Suzuki special service tools (SSTs) required for certain operations, often with illustrations showing their application.
Type:
90-degree V-twin, 4-stroke, DOHC, 4 valves per cylinder, liquid-cooled.
Displacement:
645cc (exact bore and stroke would be detailed in the manual).
Bore X Stroke:
Detailed in manual, but typically around 81 mm x 62.6 mm.
Compression Ratio:
Typically around 11.5:1. Specific values in manual.
Horsepower:
Approximately 70-75 HP at the crank (specific dyno figures vary). Manual will provide OEM specs.
Torque:
Around 45-50 lb-ft at the crank. Manual will provide OEM specs.
Carburetor Type:
Mikuni CV (Constant Velocity) carburetors, typically 39mm twin.
Fuel Delivery:
Carbureted with accelerator pump for improved throttle response.
Type:
CDI (Capacitor Discharge Ignition).
Oil Change:
Typically every 4,000-6,000 km (2,500-3,700 miles) or annually. Manual will specify exact interval.
Air Filter:
Inspect at 6,000 km (3,700 miles), replace as needed. Manual provides detailed inspection and replacement procedures.
Spark Plugs:
Replace typically every 12,000-16,000 km (7,500-10,000 miles). Manual lists recommended spark plug types and gap.
Valve Clearance:
Check at higher mileage intervals (e.g., 24,000 km or 15,000 miles). Manual provides precise checking and adjustment procedures.
Engine Oil:
API SG or higher, JASO MA rated 10W-40 viscosity recommended. Manual will specify exact Suzuki-approved oil and capacity (typically around 3.4 L with filter change).
Coolant:
Mixture of antifreeze and distilled water (50/50 ratio). Manual will specify type and capacity.
Brake Fluid:
DOT 4 recommended for brake and clutch systems. Manual will specify exact type and replacement intervals.
Fork Oil:
Specific viscosity and quantity detailed in manual, often SAE 10W or similar.
Common Complaints:
Some owners report occasional issues with regulator/rectifier failure (heat-related), stator output degradation over time, and potential carb synchronization drift. Early models might have had minor fit and finish critiques compared to later iterations. Manual aids in diagnosing and rectifying these.
Wear And Tear Items:
Chain and sprockets, brake pads, tires, fork seals are common wear items that require periodic inspection and replacement as outlined in the manual's maintenance schedule.
