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Suzuki freewind manual available for free PDF download: Service Manual
Suzuki freewind Service Manual (350 pages)
CCM 644 Engine
Brand:
Suzuki
| Category:
Motorcycle
| Size: 13.34 MB
Table of Contents
Index
2
Symbols
4
General Information
5
Precautions
6
Vehicle View
8
Serial Number Location
8
Fuel and Oil Recommendation
8
Brake Fluid
9
Front Fork Oil
9
Break-In Procedures
9
Information Labels
10
Specifications
12
Dimensions and Dry Mass
12
Engine Specifications
12
Transmission Specifications
12
Chassis Specifications
13
Electrical Specifications
13
Capacities
13
Country or Area - Series of Symbols
14
Periodic Maintenance
15
Periodic Maintenance Chart
16
Lubrication Points
17
Maintenance and Tune-Up Procedures
18
Valve Clearance
18
Spark Plugs
19
Carbon Deposit Check
19
Spark Plug Gap
19
Electrode's Condition
19
Air Cleaner Element
20
Idle Speed
21
Throttle Cable Play
22
Carburetor Synchronization
22
Fuel Line
23
Clutch
23
Engine Oil and Oil Filter
24
Necessary Amount of Engine Oil
24
Drive Chain
25
Brakes
27
Brake Fluid Level/Pads/Pedal Height
27
Air Bleeding the Brake Fluid Circuit
28
Tires
29
Steering
29
Front Forks
30
Rear Suspension
30
Exhaust Pipe and Muffler Bolts
30
Chassis Bolts and Nuts
31
Maintenance Illustrations
32
Compression Pressure Check
33
Compression Test Procedure
33
Oil Pressure Check/Test Procedure
34
Engine
35
Engine Components Removable with the Engine in Place
36
Engine Removal
37
Engine Reinstallation
41
Engine Disassembly
44
Engine Reassembly
52
Oil Seals
52
Balancer Shaft
53
Gearshift Mechanism
53
Crankcase
54
Cam Driven Gear
54
Gearshift Shaft
55
Neutral Position Indicator Switch
55
Oil Pump
56
Cam Chain and Primary Drive Gear/Generator and Starter Motor
56
Clutch Installation
58
Piston and Cylinder
60
Cylinder Head
61
Camshaft
62
Cylinder Head Cover
63
Cylinder Head Cover/Rocker Arm
65
Cylinder Head Cover Removal
66
Rocker Arm Removal
67
Inspection and Service
68
Cylinder Head Cover Distortion
68
Rocker Arm Shaft O.D./Rocker Arm I.D.
68
Rocker Arm Installation
68
Cylinder Head Cover Installation
69
Camshaft/Cylinder Head/Valves
71
Camshaft/Cylinder Head Removal
72
Valve Removal
73
Inspection and Service - Camshaft/Automatic De-Comp. Assembly
73
Camshaft Check
74
Camshaft Cam Wear/Journal Wear
74
Camshaft Runout
75
Cylinder Head Distortion
75
Valve Face Wear/Stem Runout
75
Valve Head Radial Runout
76
Valve Stem Deflection/Wear
76
Valve Guide Servicing
77
Valve Seat Width
77
Valve Seat Servicing
78
Valve Stem End Condition
80
Valve Spring
80
Valve Installation
81
Cylinder Head/Camshaft Installation
82
Cylinder/Piston
83
Cylinder/Piston Removal
84
Cylinder Distortion/Bore
84
Piston Diameter
84
Piston-Cylinder Clearance
84
Piston Ring-Groove Clearance
85
Piston Ring Free and Gap and Piston Ring End Gap
85
Piston/Cylinder Installation
86
Oil Ring
86
Top Ring and 3Nd Ring
86
Piston Pin and Pin Bore
86
Starter Motor/Generator Rotor/Gearshift
87
Starter Motor Removal
88
Generator Rotor Removal
88
Gearshift Shaft Removal
89
Starter Clutch Inspection
89
Starter Torque Limiter
89
Generator Rotor Installation
90
Gearshift Shaft Installation
90
Starter Motor Installation
90
Clutch Operations
91
Clutch Removal
92
Clutch Inspection and Service
93
Clutch Drive Plate
93
Clutch Driven Plate
93
Clutch Spring Free Length
93
Clutch Release Bearing
94
Clutch Release Pinion and Rack/Clutch Installation
94
Gearshift Cam/Transmission
95
Gearshift Cam/Transmission Removal
96
3Nd Drive Gear Disassemlby
96
Gearshift Cam/Transmission Inspection and Service
96
Gearshift Fork Groove Clearance
96
Transmission/Gearshift Cam Installation
97
3Rd Deiven Gear Bushing
97
Transmission Diagram
98
Balancer Shaft/Crankshaft/Crankcase
99
Balancer Shaft/Crankshaft/Crankcase Removal
100
Balancer Shaft Disassembly
100
Crankshaft Disassembly
100
Balancer Shaft/Crankshaft/Crankcase Inspection and Service
100
Conrod Deflection and Conrod Big End Side Clearance
101
Crankshaft Runout/Balancer Shaft
101
Crankshaft Assembly
102
Balancer Shaft Assembly
102
Crankcase Bearings
102
Crankcase/Crankshaft/Balancer Shaft Installation
103
Engine Lubrication System
104
Oil Filter
105
Oil Pump Removal and Disassembly
105
Oil Pump Inspection
106
Oil Nozzle and Oil Jet Removal
107
Oil Nozzle and Oil Jet Inspection/Reassembly
108
Oil Sump Filter Removal/Inspection
108
Fuel and Lubrication System
109
Fuel System
110
Fuel Valve Mechanism
111
Fuel Valve/Fuel Filter Removal
111
Fuel Valve/Fuel Filter Inspection and Cleaning
112
Fuel Tank Removal
112
Carburetor Construction/Diagram
114
Carburetor Specificatons
115
Slow System
116
Main System
117
Diaphragm and Piston Operation
118
Upper/Lower Position of Piston Valve
118
Piston Valve Lift Control System
119
Starter System
120
Float System
120
Removal
121
Disassembly
122
Pilot Screw Removal (for E-18 Model)
125
Carburetor Cleaning
126
Carburetor Inspection
127
Needle Valve Inspection
127
Float Height/Solenoid Valve Inspection
127
V.T.V. Inspection
128
Throttle Position Sensor Inspection
128
Carburetor Reassembly and Remounting
128
Throttle Position Sensor Positioning
129
Piston Valve Lift Control System/Carburetor Clamps
130
Carburetor Synchronization/Calibrating each Gauge
131
Lubrication System and Cooling System
133
Oil Pressure/Filter/Sump Filter
133
Engine Lubrication/Cylinder Head Cooling System Chart
134
Fuel and Lubrication System Diagram
135
Oil Cooler Diagram
136
Oil Cooler Removal
137
Chassis
138
Chassis Exterior Parts, Construction
139
Chassis Removal - Fairing
140
Frame Cover
142
Frame Covers and Fairing Remounting
142
Front Wheel Diagram
143
Front Wheel Removal
145
Front Wheel Inspection and Disassembly
145
Wheel Bearing
145
Front Axle
146
Wheel Rim
146
Spoke Nipple
146
Front Wheel Reassembly and Remounting
147
Brake Disc
147
Front Fork Diagram/Removal and Disassembly
149
Front Fork Inspection
152
Fork Spring
152
Inner Tube and Outer Tube
152
Front Fork Reassembly and Remounting
153
Damper Rod Ring
153
Outer Tube Metal, Oil Seal and Dust Seal
154
Damper Rod Bolt
154
Front Oil/Spring
155
Front Fork Remounting
155
Steering Diagram/Removal and Disassembly
156
Steering Inspection
160
Steering Reassembly and Remounting
161
Bearing Races
161
Stem Unit
161
Handlebars
162
Rear Wheel Diagram
163
Rear Wheel Removal
164
Wheel Bearing and Sprocket Drum Bearing
166
Rear Wheel Reassembly and Remounting
167
Rear Axle/Sprocket/Rear Sprocket Damper
167
Brake Disc/Rear Axle Nut
168
Rear Swingarm and Suspension
169
Rear Swingarm and Suspension Reassembling Information
170
Rear Swingarm and Suspension Removal
171
Rear Swingarm and Suspension Inspection and Disassemlby
173
Swingarm
173
Cushion Lever
173
Rear Swingarm and Suspension Reassembly and Remounting
174
Swingarm Bearing
174
Cushion Lever Bearing
174
Shock Absorber
174
Rear Swingarm and Suspension Final Inspection and Adjustment
175
Shock Absorber Spring Pre-Load Adjustment
175
Shock Absorber Damping Force Adjustment
175
Front Brake
176
Brake Pad Replacement
177
Brake Fluid Replacement
177
Caliper Removal and Disassembly
178
Caliper Inspection
179
Caliper Reassembly and Remounting
179
Brake Disc Inspection
180
Master Cylinder Removal and Disassembly
180
Master Cylinder Inspection
182
Master Cylinder Reassembly and Remounting
182
Rear Brake Exploded Diagram
183
Rear Brake Pad Replacement
184
Rear Brake Fluid Replacement
184
Rear Brake Caliper Removal and Disassembly
185
Rear Brake Caliper and Disc Inspection
186
Rear Brake Caliper Reassembly and Remounting
186
Rear Brake Master Cylinder Removal and Disassembly
187
Rear Brake Master Cylinder Inspection
188
Rear Brake Master Reassembly and Remounting
188
Lowering the Seat Height
189
Front Fork Exploded Diagram
190
Front Fork Removal and Disassembly
191
To Reassemble and Remount the Front Fork and Fron Wheel
193
Rear Shock Absorber
197
Rear Shock Absorber Removal and Disassembly
198
Side-Stand Exploded Diagram
199
Spring Setting Table
199
Side-Standing Removal and Installation
200
Warning Label
200
Electrical System
201
Cautions in Servicing the Electrical System
202
Connector, Coupler, Clamp, Fuse, Semi-Conductor Equipped Part
202
Battery/Connecting Battery
203
Wiring Procedure
203
Using Multi Circuit Tester
203
Location of Electrical Components
204
Charging System Description and Schematic Diagram
206
Troubleshooting: Battery Runs down Quickly
207
Battery Leak Current Inspection
208
Charging Output Inspection
208
Generator Coil Continuity Inspection
209
Generator No-Load Performance Inspection
209
Regulator/Rectifier Inspection
210
Starter System Description and Schematic Disgram
211
Side-Stand/Ignition Interlock System Description and Schematic Disgram
211
Troubleshooting: Starter Motor will Not Run
213
Starter Motor Removal and Disassembly
214
Starter Motor Inspection
214
Carbon Brush Inspection
214
Commutator/Armature Coil/Oil Seal Inspection
215
Starter Motor Reassembly
215
Starter Relay Inspection
216
Starter Relay Circuit Diagram
217
Side-Stand/Ignition Interlock System Inspection
217
Diode
217
Neutral Switch
218
Side-Stand Switch
218
Side-Stand/Ignition Interlock Relay
219
Clutch Lever Position Switch
219
Ignition System Description and Circuit Diagram
220
Troubleshooting: no Spark or Poor Spark
221
Ignition Coil Primary Peak Voltage Inspection
222
Ignition Coil - Checking with Electro Tester
223
Ignition Coil Resistance
223
Power Source Coil and Pick-Up Coil
224
Spark Plug Inspection
225
Carbon Deposit, Spark Plug Gap Check
225
Combinator Meter Removal/Disassembly
226
Combinator Meter Inspection
227
Speedometer/Speed Sensor Inspection
228
Fuel Meter Inspection
229
Fuel Level Gauge Removal/Installation
229
Fuel Level Gauge Inspection
230
Lamps
230
Headlight and Position Light Diagram
230
Headlight/Position Light Replacement
231
Tail/Brake Light, Turn Signal Light and License Plate Light Exploded Diagram
232
Tail/Brake Light Replacement
232
Turn Signal Relay
233
Turn Signal Light Replacement
233
Switches Inspection
234
Battery Specifications
235
Battery Initial Charging
235
Battery Servicing
236
Battery Recharging Operation
237
Servicing Information
238
Troubleshooting - Engine
239
Troubleshooting - Carburetor
242
Troubleshooting - Chassis
242
Troubeshooting - Brakes
243
Troubleshooting - Electrical
244
Troubleshooting - Battery
245
Wiring Diagram for Australia
246
Wiring Diagram for the Other Market
247
Wire Routing Diagrams
248
Cable Routing Diagrams
252
Carburetor and Air Cleaner Hose Routing Diagrams
254
Pair (Air Supply) System Hose Routing Diagram (for Austria and Switzerland)
255
Front Brake Hose Routing Diagrams
256
Rear Brake Hose Routing Diagram
257
Fuel Tank Water Drain Hose Routing Diagram
258
Oil Hose Routing Diagram
259
Fairing Set-Up Diagram
260
Fuel Tank Cover Set-Up Diagram
260
Protector and Heat Shield Adhering
261
Side Stand Spring Set-Up
262
Special Tools Illustrations
263
Tighterning Torque - Engine
266
Tighterning Torque - Chassis
267
Tighterning Torque for Other Bolts and Nuts Chart
268
Service Data - Valve+Guide
269
Service Data - Camshsft + Cylinder Head
270
Service Data - Cylinder + Piston + Piston Ring
270
Service Data - Conrod + Crankshaft/Oil Pump
271
Service Data - Clutch/Transmission + Drive Chain
272
Service Data - Carburetor
273
Service Data - Electrical/Wattage
274
Service Data - Brake + Wheel
275
Service Data - Suspension/Tire Pressure/Fuel + Oil
276
XF650W/UW/X/UX ('98, '99-Models)
277
XF650W/UW/X/UX ('98, '99-Models) - Specifications
278
XF650W/UW/X/UX ('98, '99-Models) Service Data - Valve+Guide
279
XF650W/UW/X/UX ('98, '99-Models) Service Data - Camshaft + Cylinder Head
280
XF650W/UW/X/UX ('98, '99-Models) Service Data - Cylinder + Piston + Piston Ring
280
XF650W/UW/X/UX ('98, '99-Models) Service Data - Conrod + Crankshaft/Oil Pump
281
XF650W/UW/X/UX ('98, '99-Models) Service Data - Clutch/Transmission + Drive Chain
282
XF650W/UW/X/UX ('98, '99-Models) Service Data - Carburetor
283
XF650W/UW/X/UX ('98, '99-Models) Service Data - Electrical/Wattage
284
XF650W/UW/X/UX ('98, '99-Models) Service Data - Brake + Wheel
285
XF650W/UW/X/UX ('98, '99-Models) Service Data - Suspension/Tire Pressure/Fuel + Oil
286
XF650W/UW/X/UX ('98, '99-Models): Carburetor and Air Cleaner Hose Routing
287
XF650W/UW/X/UX ('98, '99-Models): Oil Pump (from X-Model)
288
XF650Y (2000-Model)
289
XF650Y (2000-Model) Specifications - Dimensions and Dry Mass
291
XF650Y (2000-Model) Specifications - Engine/Transmission
291
XF650Y (2000-Model) Specifications - Chassis/Electrical/Capacities
292
XF650Y (2000-Model) Engine
293
XF650Y (2000-Model) Engine Reassembly - Clutch
294
XF650Y (2000-Model) Inspection and Service - Clutch Drive Plates/Driven Plates
298
XF650Y (2000-Model) Chassis
299
XF650Y (2000-Model) Exterior Parts Construction
300
XF650Y (2000-Model) Fairing Removal
301
XF650Y (2000-Model) Frame Cover Removal/Remounting
303
XF650Y (2000-Model) Electrical System
304
XF650Y (2000-Model) Lamps/Headlight and Position Light/Bulb Replacement
305
XF650Y (2000-Model) Position Light Removal
306
XF650Y (2000-Model) Servicing Information
307
XF650Y (2000-Model) Wiring Diagram
308
XF650Y (2000-Model) Wire Routing
309
XF650Y (2000-Model) Front Brake Hose Routing
310
XF650Y (2000-Model) Fairing Set-Up
311
XF650Y (2000-Model) Service Data - Valve + Guide
312
XF650Y (2000-Model) Service Data - Camshaft + Cylinder Head/Cylinder + Piston + Piston Ring
313
XF650Y (2000-Model) Service Data - Conrod + Crankshaft/Oil Pump
314
XF650Y (2000-Model) Service Data - Clutch/Transmission + Drive Chain
315
XF650Y (2000-Model) Service Data - Carburetor
316
XF650Y (2000-Model) Service Data - Electrical/Wattage
317
XF650Y (2000-Model) Service Data - Brake + Wheel
318
XF650Y (2000-Model) Service Data - Suspension/Tire Pressure/Fuel + Oil
319
XF650K1 ('01-Model)
320
XF650K1 ('01-Model) Specifications
321
XF650K1 ('01-Model) Service Data - Valve + Guide/Camshaft + Cylinder Head
322
XF650K1 ('01-Model) Service Data - Cylinder + Piston + Piston Ring/Conrod + Crankshaft/Oil Pump
323
XF650K1 ('01-Model) Service Data - Clutch/Transmission + Drive Chain/Carburetor
324
XF650K1 ('01-Model) Service Data - Electrical
325
XF650K1 ('01-Model) Service Data - Wattage/Brake + Wheel
326
XF650K1 ('01-Model) Service Data - Suspension/Tire Pressure/Fuel + Oil
327
WP Shock Absorber
331
WP Suspension Shock Absorber Set-Up and Adjustment
333
Spring Preload
333
Preload
334
Adjusting the Damping
334
The Ideal Setting
335
Adjustment Guidelines
335
WP Suspension Shock Absorber Maintenance
336
After each Race/Longer Period of Time
336
Workshop
336
Dismantling the Spring
337
Removing Nitrogen Pressure
338
Draining the Oil
338
Dismantling the Spindle
339
Fitting the Spindle
339
Refilling the Oil/Fitting the Spindle
340
Dismantling the CC Mechanism
341
Bleeding
341
Fitting the CC Mechanism
342
Refilling the Nitrogen
342
Checking the Shock Absorber
342
WP Suspension Shock Absorber Troubleshooting
343
MXMA Front Fork Adjustments
344
MXMA Front Fork Spring and Spring Pre-Load
345
MXMA Front Fork - Changing the Oil
346
MXMA Front Fork - Regular Maintenance/Troubleshooting
347
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