9 9 5 0 1 - 3 9 5 4 0 - 0 1 E
SV1000
USE THIS MANUAL WITH:SV1000S SERVICE MANUAL (99500-39250-01E)
Page 1: ...9 9 5 0 1 3 9 5 4 0 0 1 E SV1000 USE THIS MANUAL WITH SV1000S SERVICE MANUAL 99500 39250 01E...
Page 2: ...fer to the SV1000S Service Manual for details which are not given in this man ual SPECIFICATIONS 2 PERIODIC MAINTENANCE 4 CHASSIS BOLT AND NUT 4 CHASSIS 4 FRONT FORK 4 SUSPENSION SETTING 5 HANDLEBARS...
Page 3: ...rs 2 Bore 98 0 mm 3 858 in Stroke 66 0 mm 2 598 in Displacement 996 cm 60 8 cu in Compression ratio 11 3 1 Fuel system Fuel injection Air cleaner Non woven fabric element Starter system Electric Lubri...
Page 4: ...Three phase A C Generator Main fuse 30 A Fuse 10 10 10 15 10 15 A Headlight 12 V 60 55 W Position light 12 V 5 W For E 02 19 License plate light 12 V 5 W Turn signal light 12 V 21 W 4 Brake light Tai...
Page 5: ...he locations of the following nuts and bolts on the motorcycle CHASSIS FRONT FORK REMOUNTING Align the upper surface A of the inner tube with the upper surface B of the steering stem upper bracket Tig...
Page 6: ...t stiffest position and turn it out to standard setting position STD position 1 and 1 4 turns out from stiffest position Compression damping force Fully turn the damping force adjuster 2 clockwise It...
Page 7: ...rew and then pull the balancer assembly out of handlebars Remove the rear view mirror 2 Disconnect the front brake light switch coupler 3 Remove the front brake master cylinder Remove the right handle...
Page 8: ...ebar clamp bolt 23 N m 2 3 kgf m 16 5 lb ft NOTE When tightening the handlebar clamp bolts first tighten the bolt 1 and then tighten the bolt 2 Install the throttle grip and cables Throttle cable rout...
Page 9: ...master cylinder holder s mating surface A with punch mark B on the handlebars and tighten the upper clamp bolt first as shown Front brake master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 lb ft CLUT...
Page 10: ...able guide Throttle cables Harness Handle switch L Clamp Starter motor Battery Clamp the lead wire under the frame Clamp HO2 sensor For E 02 19 Ignition coil Clamp Handle switch R Ignition switch Clam...
Page 11: ...t the high tension cord rear side as much as possible without contact with the fuel tank Taping clamp Speedometer wire Turn signal RH LH Inside of the head light Wiring harness Set the coupler inside...
Page 12: ...o 2 0 mm 0 mm Throttle cable No 1 Throttle cable No 2 Guide Harness Handle switch LH Clutch hose Guide Pass the throttle cables in front of the brake hose Guide Throttle cable No 1 Throttle cable No 2...
Page 13: ...1 14 B B C C After the clutch hose union touching to the stopper tighten the union bolt B Frame bridge After positioning the clutch hose with the frame bridge tighten the clamp bolt Pass through the c...
Page 14: ...fully Clamp VIEW D E E After positioning the clamp with the stopper tighten the clamp bolt D 42 Clamp the brake hose firmly Clamp the brake hose firmly 14 42 C Green paint mark is on upside After the...
Page 15: ...B D C Face the clamp ends backward Brake hose 35 Be careful not to contact the seat rail and reservoir tank when installing The white paint faces outside Insert the hose until dead end 35 After the b...
Page 16: ...ing Spacer Spring Footrest bracket Brake return spring Brake light switch spring A A Brake pedal Rear brake master cylinder Cotter pin SECT A E ring Footrest Footrest holder Brake pedal Footrest brack...
Page 17: ...orward Fuel tank prop stay Rear fender No 1 Rear fender No 2 Lift and support the fuel tank with its prop stay UP LH clearance Ais 0 mm RH clearance Ais 0 5 1 5 mm NOTE After installing the RH balance...
Page 18: ...23 2 3 16 5 Air bleeder valve Clutch 5 4 0 54 4 0 Air bleeder valve Front 7 5 0 75 5 5 Air bleeder valve Rear 6 0 6 4 4 Front brake disc bolt 23 2 3 16 5 Rear brake caliper mounting bolt 23 2 3 16 5 R...
Page 19: ...18 SV1000K3 ITEM N m kgf m lb ft Steering damper bolt 23 2 3 16 5 Steering damper nut 23 2 3 16 5 Steering stem nut 45 4 5 32 5...
Page 20: ...tion IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve seat width IN EX 0 9 1 1 0 035 0 043 Valve head radial runout IN EX 0 03 0 001 Valve spring free leng...
Page 21: ...iam 97 980 97 995 3 8575 3 8581 Measure at 10 mm 0 4 in from the skirt end 97 880 3 8535 Cylinder distortion 0 05 0 002 Piston ring free end gap 1st Approx 8 8 0 35 7 0 0 28 2nd Approx 10 1 0 40 8 1 0...
Page 22: ...ankshaft runout 0 05 0 002 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 350 kPa 3 5 kgf cm2 50 psi Below 650 kPa 6 5 kgf cm2 92 psi at 3 000 r min ITEM STANDARD LIMIT Drive plate thickness No...
Page 23: ...coolant type Use an anti freeze coolant compatible with aluminum radiator mixed with distilled water only at the ratio of 50 50 Engine coolant Reservoir tank side Approx 250 ml 0 3 0 2 US lmp qt Engi...
Page 24: ...put voltage 4 5 5 5 V ECT sensor resistance Approx 2 45 k at 20 C 68 F IAT sensor input voltage 4 5 5 5 V IAT sensor resistance Approx 2 45 k at 20 C 68 F AP sensor input voltage 4 5 5 5 V AP sensor o...
Page 25: ...0 Bl G Ignition coil resistance Primary 2 8 4 2 tap tap Secondary 24 36 k tap Plug cap Crankshaft position sensor peak voltage 5 0 V and more When cranking Ignition coil primary peak volt age 200 V an...
Page 26: ...55 65 2 17 2 56 Brake disc thickness Front 5 0 0 2 0 197 0 008 4 5 0 18 Rear 5 0 0 2 0 197 0 008 4 5 0 18 Brake disc runout Front Rear 0 30 0 012 Master cylinder bore Front 15 870 15 913 0 6248 0 626...
Page 27: ...free length 305 12 0 298 9 11 8 Front fork oil level without spring inner tube fully compressed 147 5 8 Front fork spring adjuster 7th groove from top Front fork damping force adjuster Rebound 1 and...
Page 28: ...n inhibitor is permissible E 03 28 33 Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended The others Fuel tank 16 L 4 2 3 5 US lmp gal E 33 17 L 4 5 3 7 US lmp gal T...
Page 29: ...RN SIGNAL LIGHT L POSITION LIGHT REAR TURN SIGNAL LIGHT R BRAKE LIGHT TAILLIGHT LICENSE LIGHT REAR TURN SIGNAL LIGHT L ACTUATOR MOTOR BATTERY 1 MAIN 30 A STARTER MOTOR STARTER RELAY FUSE BOX REGULATOR...
Page 30: ...SOR FUEL PUMP RELAY REAR TURN SIGNAL LIGHT R BRAKE LIGHT TAILLIGHT LICENSE LIGHT REAR TURN SIGNAL LIGHT L BATTERY 1 MAIN 30 A STARTER MOTOR STARTER RELAY REGULATOR RECTIFIER GENERATOR SIDE STAND SWITC...
Page 31: ...Prepared by May 2003 Part No 99501 39540 01E Printed in Japan 28...
Page 32: ...Printed in Japan K3...
