2000-2018 Suzuki SV650 Problems: 3 Known Issues

Recall 06V013 / Suzuki 2086 concerns California-specification E-33 SV650/S motorcycles: all 2003–2005 and certain 2006 models. Repeated vibration can crack the tank at the internal liquid/vapor-separator bracket weld, allowing a fuel leak and fire in the presence of ignition. NHTSA lists 4,841 motorcycles in the campaign, including the SV1000/S. These are campaign populations, not observed failures; non-California models are outside this campaign.

On early-production Suzuki SV650 motorcycles (built July 1 to December 31, 1999, sold as 2000 models), the crankcase design lets air pockets form near the oil pump inlet when oil sloshes during riding. If the pump draws air, lubrication to the 645cc V-twin drops, which can cause severe engine damage and sudden engine seizure. A seized engine can lock the rear wheel and cause a loss of control. NHTSA campaign 00V009 covered 1,458 bikes. SV riders have linked the same sump design to oil starvation during wheelies and hard acceleration. Suzuki's fix was a plate in the oil sump that makes this less likely on first-generation bikes.

On the 2016-on SV650, the front brake uses two-piston sliding calipers that ride on slider pins behind rubber boots. On bikes used through winter or in salt, the pins corrode and seize in their bores, so the caliper can no longer float. The result is uneven pad wear (the inboard pad wears out while the outboard is barely touched), a pad that stays in contact and drags on the disc, reduced braking feel and, in the worst case, a warped disc and a hot wheel. Reviewers of the 2016-on bike single this out as a reputation item: the sliders stick if the bike is used in winter and not kept clean. It is preventable with routine caliper maintenance.