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Suzuki Manuals
Motorcycle
XF650 Freewind
User manual
Table Of Contents - Suzuki XF650 User Manual
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:
Service manual
(350 pages)
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
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Table of Contents
Group Index
1
Component Parts And Work To Be Done
2
Symbol
3
General Information
4
Contents
4
Warning/Caution/Note
5
General Precautions
5
Suzuki Xf650V ('97 Model) Overview
7
Serial Number Location
7
Fuel And Oil Recommendation
7
Fuel
7
Brake-In Procedures
8
Brake Fluid
8
Front Fork Oil
8
Information Labels
9
Rh View
9
Lh View
9
Specifications
11
Country Or Area
13
Periodic Maintenance
14
Periodic Maintenance Schedule
15
Periodic Maintenance Chart
15
Lubrication Points
16
Maintenance And Tune-Up Procedures
17
Valve Clearance
17
Spark Plugs
18
Carbon Deposit
18
Spark Plug Gap
18
Electrode's Condition
18
Air Cleaner Element
19
Idle Speed
20
Throttle Cable Play
21
Carburetor Synchronization
21
Fuel Line
22
Clutch
22
Engine Oil And Oil Filter
23
Necessary Amount Of Engine Oil
23
Drive Chain
24
Checking
24
Adjusting
24
Cleaning And Lubricating
25
Brake Fluid Level
26
Brake Pads
26
Brake Pedal Height
26
Air Bleeding The Brake Fluid Circuit
27
Tires
28
Steering
28
Tire Tread Condition
28
Tire Pressure
28
Front Forks
29
Rear Suspension
29
Exhaust Pipe And Muffler Bolts
29
Chassis Bolts And Nuts
30
Compression Pressure Check
32
Compression Test Procedure
32
Compression Pressure Specification
32
Oil Pressure Check
33
Oil Pressure Test Procedure
33
Low Oil Pressure
33
High Oil Pressure
33
Engine
34
Engine Components Removable With The Engine In Place
35
Engine Removal
36
Engine Reinstallation
40
Engine Disassembly
43
Engine Reassembly
51
Oil Seals
51
Crankshaft
51
Balancer Shaft
52
Gearshift Mechanism
52
Crankcase
53
Cam Driven Gear
53
Gearshift Shaft
54
Neutral Position Indicator Switch
54
Oil Pump
55
Cam Chain And Primary Drive Gear/Generator And Starter Motor
55
Piston And Cylinder
59
Cylinder Head
60
Camshaft
61
Cylinder Head Cover
62
Cylinder Head Cover/Rocker Arm
64
Cylinder Head Cover Removal
65
Rocker Arm Removal
66
Inspection And Service
67
Rocker Arm Installation
67
Cylinder Head Cover Distortion
67
Rocker Arm Shaft O.d.
67
Cylinder Head Cover Installation
68
Camshaft/Cylinder Head/Valves
70
Camshaft/Cylinder Head Removal
71
Valve Removal
72
Camshaft/Automatic De-Comp. Assembly
72
Camshaft Cam Wear
73
Camshaft Journal Wear
73
Cylinder Head Distortion
74
Valve Face Wear
74
Valve Stem Runout
74
Valve Head Radial Runout
75
Valve Stem Deflection
75
Valve Stem Wear
75
Valve Guide Servicing
76
Valve Seat Width
76
Valve Seat Servicing
77
Valve Stem End Condition
79
Valve Spring
79
Valve Installation
80
Cylinder Head/Camshaft Installation
81
Cylinder/Piston
82
Cylinder/Piston Removal
83
Cylinder Distortion
83
Cylinder Bore
83
Piston-Cylinder Clearance
83
Piston Ring-Groove Clearance
84
Piston Ring Free End Gap And Piston Ring End Gap
84
Piston/Cylinder Installation
85
Piston Pin And Pin Bore
85
Oil Ring
85
Top Ring And 2Nd Ring
85
Starter Motor/Generator Rotor/Gearshift
86
Starter Motor Removal
87
Generator Rotor Removal
87
Gearshift Shaft Removal
88
Starter Clutch
88
Starter Torque Limiter
88
Generator Rotor Installation
89
Gearshift Shaft Installation
89
Starter Motor Installation
89
Clutch Removal
91
Clutch Drive Plate
92
Clutch Driven Plate
92
Clutch Spring Free Length
92
Clutch Installation
93
Clutch Release Bearing
93
Clutch Release Pinion And Rack
93
Gearshift Cam/Transmission
94
Gearshift Cam/Transmission Removal
95
Gearshift Fork Groove Clearance
95
2Nd Drive Gear Disassembly
95
Transmission/Gearshift Cam Installation
96
Balancer Shaft/Crankshaft/Crankcase
98
Balancer Shaft/Crankshaft/Crankcase Removal
99
Balancer Shaft Disassembly
99
Crankshaft Disassembly
99
Conrod Small End I.d.
99
Conrod Deflection And Conrod Big End Side Clearance
100
Crankshaft Runout
100
Crankshaft Assembly
101
Balancer Shaft Assembly
101
Crankcase Bearings
101
Crankcase/Crankshaft/Balancer Shaft Installation
102
Engine Lubrication System
103
Oil Filter
104
Removal And Disassembly
104
Inspection
105
Assembly And Installation
105
Oil Nozzle And Oil Jet Removal
106
Oil Sump Filter
107
Fuel And Lubrication System
108
Fuel System
109
Fuel Valve
110
Fuel Valve Mechanism
110
Fuel Valve/Fuel Filter Removal
110
Inspection And Cleaning
111
Fuel Tank Removal
111
Carburetor
113
Construction
113
I.d. No. Location
114
Slow System
115
Main System
116
Diaphragm And Piston Operation
117
Lower Position Of Piston Valve
117
Upper Position Of Piston Valve
117
Piston Valve Lift Control System
118
Starter System
119
Float System
119
Removal
120
Disassembly
121
Pilot Screw Removal
124
Carburetor Cleaning
125
Needle Valve Inspection
126
Float Height Adjustment
126
Solenoid Valve Inspection
126
V.t.v. Inspection
127
Throttle Position Sensor Inspection
127
Reassembly And Remounting
127
Throttle Position Sensor Positioning
128
Carburetor Clamps
129
Calibrating Each Gauge
130
Lubrication System And Cooling System
132
Engine Lubrication/Cylinder Head Cooling System Chart
133
Oil Pan
133
Oil Cooler
135
Chassis
137
Exterior Parts Construction
138
Frame Cover
141
Remounting
141
Front Wheel
142
Wheel Bearing
144
Front Axle
145
Wheel Rim
145
Spoke Nipple
145
Brake Disc
146
Front Fork
148
Fork Spring
151
Inner Tube And Outer Tube
151
Damper Rod Ring
152
Inner Tube Metal
152
Outer Tube Metal, Oil Seal And Dust Seal
153
Damper Rod Bolt
153
Fork Oil
154
Front Fork Remounting
154
Bearing Races
160
Bearing
160
Stem Nut
160
Handlebars
161
Rear Wheel
162
Wheel Bearing And Sprocket Drum Bearing
165
Rear Axle
166
Rear Sprocket
166
Rear Sprocket Damper
166
Rear Axle Nut
167
Rear Swingarm And Suspension
168
Reassembling Information
169
Swingarm
172
Cushion Lever
172
Shock Absorber
173
Swingarm Pivot Shaft
173
Swingarm Bearing
173
Cushion Lever Bearing
173
Final Inspection And Adjustment
174
Shock Absorber Spring Pre-Load Adjustment
174
Spring Setting Table
174
Shock Absorber Damping Force Adjustment
174
Front Brake
175
Brake Pad Replacement
176
Brake Fluid Replacement
176
Caliper Removal And Disassembly
177
Caliper Inspection
178
Caliper Reassembly And Remounting
178
Brake Disc Inspection
179
Master Cylinder Removal And Disassembly
179
Master Cylinder Inspection
181
Master Cylinder Reassembly And Remounting
181
Rear Brake
182
Caliper And Disc Inspection
185
Lowering The Seat Height
188
Optional Parts Supply
188
Special Tools
188
Rear Shock Absorber
196
Side-Stand
198
Side-Stand Removal And Installation
199
Warning Label
199
Electrical System
200
Cautions In Servicing
201
Connector
201
Coupler
201
Clamp
201
Battery
202
Connecting Battery
202
Wiring Procedure
202
Using Multi Circuit Tester
202
Location Of Electrical Components
203
Charging System
205
Description
205
Troubleshooting
206
Battery Leak Current Inspection
207
Charging Output Inspection
207
Generator Coil Continuity Inspection
208
Generator No-Load Performance Inspection
208
Regulator/Rectifier Inspection
209
Starter System Description
210
Side-Stand/Ignition Interlock System Description
210
Starter Motor Removal And Disassembly
213
Starter Motor Inspection
213
Carbon Brush
213
Starter Motor Reassembly
214
Commutator
214
Armature Coil Inspection
214
Oil Seal Inspection
214
Starter Relay Inspection
215
Side-Stand/Ignition Interlock System Inspection
216
Starter Relay Circuit Diagram
216
Diode
216
Neutral Switch
217
Side-Stand Switch
217
Side-Stand/Ignition Interlock Relay
218
Clutch Lever Position Switch
218
Ignition System
219
Ignition Coil Primary Peak Voltage
221
Ignition Coil (Checking With Electro Tester)
222
Ignition Coil Resistance
222
Power Source Coil And Pick-Up Coil
223
Combination Meter
225
Speedometer Inspection
227
Speed Sensor Inspection
227
Fuel Meter Inspection
228
Fuel Level Gauge Removal/Installation
228
Fuel Level Gauge Inspection
229
Lamps
229
Headlight And Position Light
229
Bulb Replacement
230
Tail/Brake Light, Turn Signal Light And License Plate Light
231
Turn Signal Relay
232
Switches
233
Battery Specifications
234
Initial Charging
234
Recharging Operation
236
Servicing Information
237
Engine Troubleshooting
238
Carburetor Troubleshooting
241
Chassis Troubleshooting
241
Brake Troubleshooting
242
Electrical Troubleshooting
243
Battery Troubleshooting
244
Wiring Diagram For Australia
245
Wiring Diagram For The Other Market
246
Wire Routing
247
Cable Routing
251
Carburetor And Air Cleaner Hose Routing
253
Pair (Air Supply) System Hose Routing
254
Front Brake Hose Routing
255
Rear Brake Hose Routing
256
Fuel Tank Water Drain Hose Routing
257
Oil Hose Routing
258
Fairing Set-Up
259
Fuel Tank Cover Set-Up
259
Protector And Heat Shield Adhering
260
Side Stand Spring Set-Up
261
Tightening Torque
265
Tightening Torque Chart
267
Service Data
268
Xf650W/Uw/X/Ux ('98, '99-Models)
276
Oil Pump (From X-Model)
287
Xf650Y (2000-Model)
288
General Specifications
290
Inspection And Service Clutch
297
Clutch Drive Plates
297
Clutch Driven Plates
297
Wiring Diagram
307
Xf650K1 ('01-Model)
319
R30 Harness
328
Dual Sports Harness
329
Shock Absorber Manual
330
Set-Up & Adjustment
332
Spring Preload
332
Adjusting The Damping
333
The Ideal Setting
334
Adjustment Guidelines
334
Maintenance
335
After Each Race
335
After A Longer Period Of Time
335
Workshop
335
Workshop Spring
336
Dismantling The Spring
336
Draining The Oil
337
Removing Nitrogen Pressure
337
Dismantling The Spindle
338
Fitting The Spindle
338
Refilling The Oil
339
Bleeding
340
Dismantling The Cc Mechanism
340
Assembly
341
Refilling The Nitrogen
341
Checking The Shock Absorber
341
Previous
Page
1
...
347
348
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Table of Contents
Troubleshooting
Troubleshooting
206
Engine Troubleshooting
238
Carburetor Troubleshooting
241
Brake Troubleshooting
242
Electrical Troubleshooting
243
Battery Troubleshooting
244
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