SV650 K6S wiring diagram required.

[Duke]

This last weekend I spent chasing wiring faults.

The initial issue was that the indicators stopped working but the hazard lights were OK. This led me to the handlebar switch loom connectors under the headstock. These were very corroded and needed cleaning and some soldering of links across the worst joints. The ignition switch (green) connector was fine.
Once disturbing the connectors more faults appeared – no headlights and front brake switch. – more inspection and cleaning.
The final fault was – Starter circuit failure, when pressing the starter button the headlights go out and the engine does not turn.
This was traced to the clutch interlock, the relevant female socket in the LHS connector had corroded so much that the “spring” part had gone completely. So, I cut the wires off the connector the loom side and soldered them together, shorting out the clutch interlock.
All now sorted!

The wiring diagram I have is from the 2003 Service manual, but my K6S is different in some areas. So far, I have discovered that I have a 10-way connector on the RHS handlebar switch rather than an 8 way and my bike has two fuel level sensors, rather than one. Also, some wire colours are different.

Is there a UK model K6S wiring diagram available, this would be really useful?

I would like to fix the fuel level indicators that stopped working correctly some miles ago, it just flashes very quickly on low, where it used to flash slowly first, then some miles later flash very quickly. I have previously had the fuel pump out of the tank and confirmed that the fault is not in the tank sensors, so the fault must be in the loom or connectors, but I stopped hunting for the fault due to lack wiring diagram.

This is an everyday commuter ride, come sun, rain or snow, now with 50K miles on the clock.



Thanks


Duke

[R1ffR4ff]

This should help but you need to use Chrome Browser with the Photobucket extension fix thanks to,"Atomic Goose"

http://cx500forum.com/forum/general-discussion/88177-fix-broken-photobucket-images-browser-extension.html

http://www.svrider.com/forum/showthread.php?t=120691


There are also Google Images,

https://www.google.co.uk/search?q=SV650+wiring+diagram&newwindow=1&hl=en&tbm=isch&tbo=u&source=univ&sa=X&ved=0ahUKEwjz48mqj8jYAhUDDcAKHXU5CQIQsAQIKA&biw=1152&bih=535

HTH :)

[Craig380]

PM me an email address and I can send you the K7 service manual PDF if that's any good ....

[Duke]

Thanks for the replies

Riffraff,
That photo bucket link fix is great- I was pulling my hair out last week trying to solve that. Very useful.
Although the photos on the link do not seem to show for me – I get a brief picture of a cat with “picture not found” across the top, then it disappears.
The link seems to offer a diagram for “SV650 S + Naked K3, K4, K5 and K6 (2003-2004-2005-2006)”, but one diagram cannot cover K3 to K6 as I know my K6 is different to the K3 diagram I have.
I have spent some time trying to goggle for the diagram but have not found it.

Craig,
I have the K7 supplement, but this includes ABS which I don’t have. The K7 diagram is more complicated and I don’t know if the bits I need for the K6 are correct on this diagram.
The K7 supplement states “Use this manual with SV650/S service manual (99500-36123-01E)” and this would seem to be manual that would cover the K6.
There are some (dodgy looking) sites that suggest that they have this manual – but I have not had the confidence to attempt a download, I don’t want a PC virus.

Does anyone have a copy of the service manual 99500-36123-01E, or know of a “safe” way to download it?

Thanks

[R1ffR4ff]

There's more manuals here,

http://www.svrider.com/forum/showthread.php?t=78213

https://www.carlsalter.com/suzuki-service-manuals.asp

[Stilo]

I can scan the diagram in my Haynes manual if you want?

[shiftin_gear98]

I have a scan of my Haynes manual, the file is currently too big to load. About 2KB.
My missus hopefully will have a go later today to try to reduce it. (Graphic Designer)
Hopefully it's still readable at 250mb, who knows.


Duke, if it can't be done I'm happy to PM it to you. However it would be good to have on here.

[Duke]

Riffraff, I have searched all the normal places for manuals but can’t find one to cover the K6. I am willing to purchase on CD or download, paper I find a bit clumsy and expensive. Your SVrider link offers a link on this site that no longer exists.

This manual should also cover my bike, but I can only find it in paper form, “99500-36126-03E 2003-2009 Suzuki SV650 Motorcycle Service Manual”.


Stilo and Shiftin_gear, yes a Haynes diagram would be great if it covers the SV605S K6 UK bike. It needs to show two fuel tank sensors (4 pin connector) and no ABS.

[R1ffR4ff]

Does this Haynes one from Halfords cover it?

http://www.halfords.com/motoring/motorcycling/motorcycle-parts-manuals/haynes-suzuki-sv650-99-08

[Duke]

It does suggest that it covers the K6.
I have had several Haynes manuals, they tend to be more generalised, I prefer the original motorcycle manufactures workshop manual as they tend to be more specific and accurate. I remember once trying to split a crankcase when Haynes said, “remove the 12 bolts” only to find after some hitting with a soft mallet, that it was 13 bolts. I now am more careful and clean all the casing and remove any covers and sensors before the hitting starts.
I am using the 2003 Suzuki which has been good but clearly does not cover the K6.
I will probably find out something new if a had the correct manual!
I have ridden one bike for some years with tyre pressures at 42psi front and rear as listed in the original workshop manual for the year previous to my bike, only one day to find the Supplement covering my year which gave 33/36. This bike rode very differently with the lower pressures – I could not get used to it, so I now ride it on a compromised pressure setting!

I will see if Stilo or Shiftin_gear come back with confirmation of the wiring diagram covering the area I need.

[R1ffR4ff]

Found this?

http://dpippin.com/dl/SV650%20Service%20Manual.pdf

But I think you already have it or similar :/


And an oline one,

https://www.emanualonline.com/Motorbikes/Suzuki/SV650/Suzuki-SV650-%25252F-SV650S-2003_2012-Factory-Workshop-Manual.html?currency=USD&gclid=Cj0KCQiA7dHSBRDEARIsAJhAHwg4ysTK7AFS-kmRvQSiLEjOO2uGYHQqb-aMLe4Oj_WVCxnj4ahEFaUaAkkFEALw_wcB

[shiftin_gear98]

My wife managed to knock it down to 138KB, which alas is still too big. Plus you can't read any of it now.
Duke PM me your email and I'll send it over.


Edit: And yes two fuel sensors no ABS.


SV650K5, K6, SK5 and SK6 European Models

[R1ffR4ff]

138k too big?

If I need to send/transfer large files I use a Free Boxnet Account,

https://www.box.com/en-gb/personal

10 gig free space.

Then upload the file to it and send the link to the recipient if that helps?

Also what size did your original scan come out at if you,"Zipped" it?

[shiftin_gear98]

Too big to add to here file size must be less than 125kb to attach to a comment - or something similar.
Thanks for the link R1ffR4ff, However I can't be arsed with setting up ****e like that.


I don't have the patience.


Original scan 1.21 gigawatts. :)

[DarrenSV650S]

The forum upload thing is borked just now FYI

[shiftin_gear98]

Hello Duke - Hopefully on it's way now.

[Duke]

Thanks Shiftin,

The diagram looks great, all in colour also.
It states that it covers the SV650K5, K6, SK6 & SK6 European models.

As far as the fuel sensor signal is concerned, as I have already checked the tank sensors and resistor pack, that leaves the three electrical connections (at the fuel pump and sensors, resistor pack or the LCD/instrument cluster) or a possible faulty LCD /instrument cluster.
I will check when I next have a chance.

As far as the problems I had with the left and right handle bar electrical connections, all seems to be fixed now.
I have purchased replacement 10Way connectors from Kojaykat to keep in my spares box for next time!

10 Way HM Connector Unsealed
http://kojaycat.co.uk/epages/950000457.sf/en_GB/?ObjectID=961760

(http://kojaycat.co.uk/epages/950000457.sf/en_GB/?ObjectID=961760)
Duke