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Suzuki Manuals
Motorcycle
SV650 99
Service manual
Table Of Contents - Suzuki SV650 99 Service Manual
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Table Of Contents
483
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483
Contents
Table of Contents
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Table of Contents
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Table of Contents
Group Index
2
To Locate What You Are Looking For
3
Component Parts And Work To Be Done
3
Symbol
4
General Information
5
Warning/Caution/Note
6
General Precautions
6
Right Side
8
Left Side
8
Serial Number Location
8
Fuel
9
Engine Oil
9
Brake Fluid
9
Front Fork Oil
9
Engine Coolant
10
Water For Mixing
10
Anti-Freeze/Engine Coolant
10
Liquid Amount Of Water/Engine Coolant
10
Information Labels
11
Specifications
12
Dimensions And Dry Mass
12
Country And Area Codes
14
Periodic Maintenance
15
Periodic Maintenance Schedule
16
Periodic Maintenance Chart
16
Lubrication Points
17
Maintenance And Tune-Up Procedures
18
Air Cleaner
18
Spark Plug
19
Spark Plug Removal
19
No.2 Spark Plug Removal
20
Heat Range
21
Carbon Deposits
21
Spark Plug Gap
21
Electrode's Condition
21
Tappet Clearance
22
Tappet Clearance Adjustment
24
Intake Side
25
Exhaust Side
26
Engine Oil And Oil Filter
27
Engine Oil Replacement
27
Oil Drain Plug
27
Oil Filter Replacement
28
Oil Filter Wrench
28
Necessary Amount Of Engine Oil
28
Fuel Hose
29
Engine Idle Speed
29
Carburetor Synchronization
29
Pair System
29
Throttle Cable Play
30
Clutch Cable Play
31
Cooling System
32
Engine Coolant Level Check
32
Engine Coolant Change
32
Air Bleeding The Cooling Circuit
33
Radiator Hoses
33
Drive Chain
34
Checking
34
Cleaning And Lubricating
35
Brake
36
Brake Fluid Level Check
36
Brake Pads
37
Brake Pedal Height
37
Brake Light Switch
37
Air Bleeding The Brake Fluid Circuit
38
Tires
39
Tire Tread Condition
39
Tire Pressure
40
Tire Type
40
Steering
40
Cold Inflation
40
Front Fork
41
Rear Suspension
41
Exhaust Pipe Bolt And Nut
41
Chassis Bolt And Nut
42
Compression Pressure Check
44
Compression Pressure Specification
44
Low Compressure Pressure
44
Overhaul The Engine
44
Oil Pressure Check
45
Low Oil Pressure
45
High Oil Pressure
45
Oil Pressure Test Procedure
45
Engine
46
Engine Components Removable With Engine In Place
47
Engine Left Side
47
Engine Right Side
47
Engine Center
47
Engine Removal
48
Engine Installation
58
Engine Disassembly
65
Cylinder Head Cover
66
No.1 Camshafts
66
No.2 Camshafts
68
Front Cylinder Head
70
Front Cylinder
72
Piston
73
Starter Motor
73
Oil Filter
73
Generator Cover
74
Clutch Cover
74
Clutch
75
Oil Pump
77
Gearshift System
78
Oil Pipe
79
Primary Drive Gear
79
Rear Cam Chain
80
Generator Rotor
80
Front Cam Chain
81
Neutral Indicator Light Switch
82
Crankcase
82
Crankshaft
83
Transmission
83
Engine Components Inspection And Service
85
Camshaft Identification
85
Cam Wear
85
Camshaft Journal Wear
86
Camshaft Runout
87
Cam Chain Tension Adjuster
87
Cam Chain Tensioner
87
Cam Chain Guide
87
Cylinder Head And Valve
88
Valve And Valve Spring Disassembly
88
Cylinder Head Distortion
89
Valve Stem Runout
89
Valve Head Radial Runout
89
Valve Face Wear
89
Valve Stem Deflection
90
Valve Stem Wear
90
Valve Guide Servicing
90
Valve Seat Width Inspection
91
Valve Seat Servicing
92
Initial Seat Cut
92
Top Narrowing Cut
93
Bottom Narrowing Cut
93
Final Seat Cut
93
Valve Stem End Condition
95
Valve Spring
95
Valve And Valve Spring Reassembly
96
Intake Pipe
97
Exhaust Pipe
98
Water Union
98
Cylinder Distortion
98
Cylinder Bore
98
Piston Diameter
99
Piston To Cylinder Clearance
99
Piston Ring To Groove Clearance
99
Piston Ring Free End Gap And Piston Ring End Gap
100
Oversize Piston Ring
100
Oversize Oil Ring
100
Piston Ring Reassembly
101
Piston Pins And Pin Bore
102
Conrod And Crankshaft
102
Conrod Small End I.d.
102
Conrod Big End Side Clearance
103
Conrod Removal And Bearing Inspection
103
Conrod-Crank Pin Bearing Selection
104
Conrod I.d.
105
Crank Pin I.d
105
Bearing Thickness
105
Conrod And Bearing Reassembly
105
Crankshaft Journal Bearing
106
Selection
107
Bearing Selection Table
107
Crank Shaft Journal I.d.
107
Crankshaft Thrust Bearing
112
Bearing And Oil Seal
113
Bearing Remover Attachment
114
Bearing Installer Attachment
114
Oil Pressure Switch
115
Oil Pressure Regulator
116
Oil Strainer Cleaning
116
Oil Plate
117
Oil Jet
118
Gearshift Arm Stopper
119
Clutch Drive Plates
120
Clutch Driven Plates
120
Clutch Spring
120
Clutch Bearing Inspection
121
Primary Driven Gear Assembly
121
Gearshift Shaft
122
Gearshift Arm
122
Countershaft Disassembly
123
Driveshaft Disassembly
124
Gearshift Fork To Groove Clearance
128
Gearshift Fork Groove Width
128
Gearshift Fork Thickness
128
Starter Clutch
129
Generator And Signal Generator
130
Engine Reassembly
132
Engine Serial Number
135
Cam Chain Drive Sprocket
137
Camchain Tension Adjuster
160
Fuel And Lubrication System
165
Fuel System
166
Fuel Pump Operation
167
Intake Process
167
Discharge Process
167
Control Of Fuel Pressure
167
Fuel Tank Lift-Up
168
Fuel Tank Removal
169
Vacuum Fuel Valve
170
Fuel Level Indicator Light Switch
172
Fuel Pump Removal
173
Carburetor Construction
175
Carburetor Specifications
176
I.d. No. Location
177
Diaphragm And Piston Operation
178
Slow System
179
Transient Enrichment System
179
Main System
180
Starter System
181
Float System
181
Carburetor Removal
182
Carburetor Cleaning
191
Carburetor Inspection
191
Needle Valve Inspection
191
Fuel Filter Inspeciton
192
Float Height Adjustment
192
Throttle Position Sensor Inspection
192
Carburetor Heater Inspection
193
Carburetor Thermo-Switch Inspection
193
Carburetor Heater
194
Coasting Valve
195
Funnel
195
Pilot Screw
195
Carburetor Top Cap
195
Throttle Position Sensor Positioning
197
Carburetor Clamps
198
Calibrating Each Gauge
199
Fuel Level Adjustment
202
Fuel Level Gauge
202
Fuel Level
202
Lubrication System
203
Oil Strainer
203
Engine Lubrication System Chart
204
Engine Lubrication System
205
Rear Cylinder
206
Cooling Circuit
209
Cooling Circuit Inspection
209
Radiator And Water Hoses
210
Radiator Removal
210
Radiator Cap Inspection
211
Radiator Inspection And Cleaning
211
Water Hose Inspection
211
Radiator Remounting
212
Cooling Fan Removal
212
Cooling Fan Inspection
212
Cooling Fan Installation
212
Cooling Fan Thermo-Switch
213
Engine Coolant Temperature Switch
214
Thermostat
215
Water Pump Removal And Disassembly
218
Bearing Inspection
221
Mechanical Seal
221
Oil Seal
222
Seal Washer
222
Chassis
227
Exterior Parts Construction
228
Rear Seat
229
Frame Side Cover
229
Front Seat
229
Front Fender
229
Seat Tail Cover
230
Front Wheel Construction
231
Speed Sensor
234
Wheel Bearings
234
Front Wheel
234
Front Axle
234
Brake Disc
235
Wheel Bearing
235
Inner And Outer Tubes
240
Fork Spring
240
Steering Construction
245
Handlebars
246
Steering Removal
249
Steering Inspection And Disassembly
250
Steering Installation
252
Steering Tension Adjustment
254
Rear Wheel
255
Wheel Damper
258
Sprocket
259
Rear Suspension Construction
263
Rear Shock Absorber And Cushion Rod
265
Spacer
265
Bearing
265
Rear Shock Absorber
266
Swingarm
267
Chain Buffer
269
Bearing Installer
269
Suspension Setting
271
Spring Pre-Load Adjustment
271
Front Brake Construction
272
Brake Fluid Replacement
273
Brake Pad Replacement
274
Front Brake Caliper
274
Brake Caliper Inspection
275
Brake Caliper Piston Inspection
275
Front Master Cylinder
277
Rear Brake
281
Tire And Wheel
290
Tire Removal
290
Wheel Inspection
290
Tire Inspection
290
Valve Inspection
291
Valve Installation
291
Tire Installation
291
Cold Inflation Tire Pressure
292
Electrical System
293
Cautions In Servicing
294
Connector
294
Coupler
294
Clamps
294
Battery
295
Connecting Battery
295
Wiring Procedure
295
Using Multi Circuit Tester
295
Location Of Electrical Components
296
Charging System
299
Function Of Regulator
299
Battery Runs Down Quickly
301
Battery Current Leak Inspection
302
Charging Output Inspection
302
Generator Coil Resistance Inspection
303
Generator No-Load Performance Inspection
303
Regulator/Rectifier Inspection
303
Starter System Description
304
Side-Stand/Ignition Interlock System Description
304
Side-Stand
305
Starter Motor Will Not Run
306
Starter Motor Removal And Disassembly
307
Starter Motor Inspection
307
Carbon Brushes
307
Commutator
308
Armature Coil Inspection
308
Oil Seal Inspection
308
Starter Motor Reassembly
308
Starter Relay Inspection
311
Side-Stand/Ignition Interlock System Part Ispection
312
Neutral Switch
312
Side-Stand Switch
313
Turn Signal/Side-Stand Relay
313
Side-Stand Relay Inspection
313
Diode Inspection
314
Ignition System
315
No Spark Or Poor Spark
316
Ignition Coil Primary Peak Voltage
317
Ignition Coil Resistance
318
Signal Generator Peak Voltage
319
Signal Generator
320
Speedometer Removal
321
Bulb Replacement
322
Electrical System Construction
323
Fuel Level Indicator Light Inspection
325
Oil Pressure Indicator Light Inspection
326
Water Temperature Indicator Light Inspection
326
Speed Sensor Inspection
327
Relays
328
Starter Relay
328
Turn Signal Side-Stand Relay
328
Lamps
329
Headlight
329
Brake Light/Taillight
331
Turn Signal Lights
331
Switches
332
Ignition Switch
332
Lighting Switch
332
Starter Button
332
Ignition Switch Removal
333
Battery Specifications
334
Initial Charging
334
Filling Electrolyte
334
Recharging Operation
336
Recharging Time
336
Servicing Information
337
Compression Too Low
338
Plugs Not Sparking
338
No Fuel Reaching The Carburetors
338
Excessive Valve Chatter
338
Noise Seems To Come From Crankshaft
339
Noise Seems To Come From Transmission
339
Noise Seems To Come From Water Pump
339
Radiator
341
Wiring Diagram
346
Wiring Harness Routing
349
Wire Harness Routing
350
Speed Sensor Lead Wire Routing
351
Cable Routing
352
Fuel System Hose Routing
353
Cooling System Hose Routing
355
Front Brake Hose Routing
356
Rear Brake Hose Routing
357
Pair System Hose Routing
358
Fuel Tank Set-Up
359
Special Tools
360
Tightening Torque
363
Tightening Torque Chart
366
Service Data
367
Valve + Guide
367
Camshaft + Cylinder Head
368
Conrod + Crankshaft
369
Transmission + Drive Chain
370
Themrostat + Radiator + Fan + Coolant
370
Sv650Y
376
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