Suzuki SV 1000S 2003 Service Manual Download Page 358

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SV1000K3 15

BRAKE PEDAL/FOOTREST SET-UP

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Summary of Contents for SV 1000S 2003

Page 1: ...SERVICE MANUAL I II II II II S V 10005 1 99500 39250 03E 0...

Page 2: ...nual includes specific information required to properly inspect and service SV1000S in accordance with all EPA regulations It is strongly recommended that the chapter on Emission Control Periodic Serv...

Page 3: ...motorcycle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual motorcycle exactly in detail This manual is written fo...

Page 4: ...the first page of each section to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instructions and other s...

Page 5: ...solution Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 1 BF Apply or use brake fluid Apply SUZUKI SUPER GREASE A 99000 25030 Lo a Measure in voltage range Apply SUZUKI MOLY PASTE 99000...

Page 6: ...ing Unit D DC Direct Current DMC Dealer Mode Coupler DOHC Double Over Head Camshaft DRL Daytime Running Light E ECM Engine Control Module Engine Control Unit ECU FI Control Unit ECT Sensor Engine Cool...

Page 7: ...dicator Lamp LED Minimum Nitrogen Oxides Over Head Camshaft Oil Pressure Switch Positive Crankcase Ventilation Crankcase Breather Right Hand Read Only Memory Society of Automotive Engineers Secondary...

Page 8: ...n Sensor CKPS D Data Link Connector DLC Crank Angle Dealer Mode Coupler Diagnostic Test Mode Diagnostic Trouble Code DTM DTC Diagnostic Code Malfunction Code E Electronic Ignition Engine Control Modul...

Page 9: ...MAF Air Flow 0 On Board Diagnostic OBD Self Diagnosis Function Open Loop P Programmable Read Only Memory Pulsed Secondary Air Injection OL PROM PAIR Diagnostic Pulse Air Control PAIR R Random Access...

Page 10: ...NDATION 1 4 FUEL FOR USA AND CANADA 1 4 FUEL FOR OTHER COUNTRIES 1 4 ENGINE OIL 1 5 BRAKE FLUID 1 5 FRONT FORK OIL 1 5 ENGINE COOLANT 1 5 WATER FOR MIXING 1 5 ANTI FREEZE ENGINE COOLANT 1 5 LIQUID AMO...

Page 11: ...must use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS A W...

Page 12: ...e bolts and nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci fied tightening torque Whenever you remove oil seals gasket...

Page 13: ...e num bers are required especially for registering the machine and ordering spare parts FUEL OIL AND ENGINE COOLANT RECOMMENDATION FUEL FOR USA AND CANADA Use only unleaded gasoline of at least 87 pum...

Page 14: ...distilled water only WATER FOR MIXING Use distilled water only Water other than distilled water can corrode and clog the aluminum radiator ANTI FREEZE ENGINE COOLANT The engine coolant perform as a co...

Page 15: ...during its early life The general rules are as follows Keep to these break in engine speed limits Initial 800 km 500 miles Below 6 000 r min Up to 1 600 km 1 000 miles Below 9 000 r min Over 1 600 km...

Page 16: ...routing label A For E 33 4 Fuel caution label A For E 02 24 Manual caution label A For E 03 33 Frame caution label A A A O7 Warning screen label A For E 28 LH RH Other RH A A Warning steering label A...

Page 17: ...8 0 mm 3 858 in Stroke 66 0 mm 2 598 in Displacement 996 cm3 60 8 cu in Compression ratio 11 3 1 Fuel system Fuel injection Air cleaner Non woven fabric element Starter system Electric Lubrication sys...

Page 18: ...A C Generator Main fuse 30 A Fuse 15 15 10 15 15 10 A Headlight 12 V 60 55 W x 2 Position light 12 V 5 W x 2 License plate light 12 V 5 W Turn signal light 12V21 W x 4 Brake light Taillight LED Speedo...

Page 19: ...MATION COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s CODE COUNTRY or AREA E 02 U K E 03 U S A Except for California E 19 EU E 24 Australia E 28 Canada E 33...

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Page 51: ...VER 3 40 CAMSHAFT CAMSHAFT JOURNAL 3 41 CYLINDER HEAD AND VALVE 3 44 CYLINDER 3 53 PISTON AND PISTON RING 3 54 CONROD AND CRANKSHAFT 3 56 CRANKCASE 3 60 CRANKSHAFT JOURNAL BEARING 3 64 CRANKCASE BEARI...

Page 52: ...Camshafts 3 25 3 27 3 102 3 105 Cylinder heads 3 26 3 29 3 100 Cylinders 3 27 3 29 3 99 Pistons 3 27 3 30 3 97 Cam chain tension adjusters 3 26 3 28 3 104 3 107 Thermostat 6 12 6 13 Oil filter 2 15 2...

Page 53: ...al is sequentially explained in the following steps Reinstall the engine by reversing the removal procedure Remove the cowling SV650S 7 6 Remove the front and rear seat r r 7 4 Lift and support the fu...

Page 54: ...at the air cleaner box side Disconnect the IAP sensor coupler CU and hose U Disconnect the IAT sensor coupler 4 Disconnect the front side of crankcase breather hose O and rear side of crankcase breat...

Page 55: ...utlet hose Disconnect the reserve tank hose Remove the radiator mounting bolts Disconnect the radiator inlet hose Disconnect the horn coupler O and cooling fan coupler C2 Remove the radiator I CAUTION...

Page 56: ...pipe connector bolt Remove the No 1 Front cylinder exhaust pipe bolts O Loosen the No 2 Rear cylinder exhaust pipe connector bolt Remove the muffler mounting bolt and nut Remove the exhaust pipe mount...

Page 57: ...ate and spring Remove the clutch push rod Remove the clutch cable from the generator cover NOTE If it is necessary to replace the clutch cable or clutch release lever pry up and bend down the stopper...

Page 58: ...wheel forward and make sure that the drive chain has enough slack Disengage the drive chain with the rear sprocket Remove the engine sprocket 30 Remove the oil cooler Disconnect the oil pressure swit...

Page 59: ...nect the generator lead wire coupler 1 Disconnect the CKP sensor lead wire coupler Disconnect the clamp Disconnect the GP sensor lead wire coupler 5 Remove the side stand switch lead wire coupler C Su...

Page 60: ...Remove the engine mounting nuts 10 and 20 Remove the engine mounting bolt 03 Remove the engine mounting thrust adjuster locknuts with the special tool 09940 14990 Engine mounting thrust adjuster socke...

Page 61: ...40 Loosen the engine mounting thrust adjusters fully NOTE Do not remove the engine mounting bolts at this stage Loosen the engine mounting clamp bolts 90 and OO ENGINE 3 11...

Page 62: ...GINE Remove the No 1 Front left engine mounting bolt and spacer 02 Remove the No 1 Front right engine mounting bolt and spacer Remove the No 2 Rear right engine mounting bolt Remove the engine mountin...

Page 63: ...ually lower the front side of the engine Then take the drive chain OO off the driveshaft Remove the engine mounting bolt O3 and lower the engine CAUTION Be careful not to contact the No 2 Rear exhaust...

Page 64: ...Pay attention to the following points NOTE The engine mounting nuts are self locking Once the nut has been removed it is no longer of any use Be sure to use new nuts and then tighten them to the speci...

Page 65: ...ally raise the rear side of the engine assembly and then put the drive chain 1 on the driveshaft Align the collar OO to the crankcase groove Install all engine mounting bolts and tighten them temporar...

Page 66: ...to the specified torque Engine mounting thrust adjuster 12 N m 1 2 kgf m 8 5 Ib ft Tighten the engine mounting thrust adjuster locknuts to the specified torque with the special tool Engine mounting t...

Page 67: ...lf locking Once the nuts have been removed they are no longer of any use Tighten all engine mounting clamp bolts to the specified torque 3 14 NOTE After tightening the engine mounting bolt or nut to t...

Page 68: ...e engine sprocket and the washer Apply a small quantity of THREAD LOCK to the drive shaft thread portion MR 99000 32050 THREAD LOCK 1342 Tighten the engine sprocket nut 02 to the specified torque Engi...

Page 69: ...mporarily Apply SUZUKI MOLY PASTE to the clutch release 99000 25140 SUZUKI MOLY PASTE Assemble the clutch release so that the lever arm AO will be angle of 80 degree with axle Adjust the clutch cable...

Page 70: ...23 N m 2 3 kgf m 16 5 lb ft Exhaust pipe mounting bolt 23 N m 2 3 kgf m 16 5 lb ft Muffler mounting nut 23 N m 2 3 kgf m 16 5 Ib ft CAUTION Replace the gaskets with new ones NOTE Apply gas sealer to...

Page 71: ...40 ENGINE 3 21...

Page 72: ...rshift lever height O Gearshift lever height 50 60 mm 1 97 2 36 in for SV650 60 70 mm 2 36 2 76 in for SV650S Adjust the following items Engine oil C r2 14 Engine coolant 2 20 Throttle cable play 2 17...

Page 73: ...e g intake exhaust so that they can be reinstalled in their origi nal positions Remove the spark plugs C72 6 Disconnect the crankcase breather hoses D Disconnect the PAIR hoses OO Remove the thermosta...

Page 74: ...cooler bracket 7 Remove the rear exhaust pipe and gasket Remove the valve timing inspection plug O and generator cover plug S CYLINDER HEAD COVER Remove the front cylinder head cover 1O Remove the dow...

Page 75: ...e OO on generator rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown in illustration NOTE At the above condition the front cylinder is at TDC of c...

Page 76: ...as F to the camshaft journal holders Remove the dowel pins Remove the intake camshaft 70 Remove the exhaust camshaft NOTE Do not drop the dowel pins into the crankcase FRONT CYLINDER HEAD Remove the...

Page 77: ...nkcase FRONT PISTON Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase Remove the piston pin circlip J Remove the piston Z by driving out the piston p...

Page 78: ...move the cam chain guide T Remove the spring holder bolt 02 spring and gasket Remove the cam chain tension adjuster OO Remove the intake camshaft journal holder Remove the exhaust camshaft journal hol...

Page 79: ...e cylinder head bolts loosen each bolt little by little diagonally Remove the cylinder head Remove the cylinder head gasket O dowel pins and cam chain guide 7O REAR CYLINDER Remove the cylinder nuts a...

Page 80: ...n pin NOTE Scribe the cylinder number on the head of the piston STARTER MOTOR Remove the starter motor mounting bolts and the clamp 11 Remove the starter motor 2 ENGINE BOTTOM SIDE OIL FILTER Remove t...

Page 81: ...et 03 CLUTCH Hold the generator rotor O with the special tool 09930 44530 Rotor holder Remove the clutch springs NOTE Loosen the clutch spring set bolts little by little and diagonally Remove the pres...

Page 82: ...netic hand or a wire Remove the clutch drive plates and driven plates Remove the spring washer Z and spring washer seat Flatten the clutch sleeve hub nut lock washer Hold the clutch sleeve hub with th...

Page 83: ...er 9 Remove the primary driven gear assembly 2 Remove the spacer a OIL PUMP Remove the snap ring T Remove the oil pump driven gear NOTE Do not drop the snap ring J into the crankcase Remove the pin O...

Page 84: ...he oil pump GEARSHIFT SYSTEM Remove the snap ring 1 and washer D2 Remove the gearshift shaft assembly O and washer Remove the gearshift cam plate bolt 50 Remove the gearshift cam plate Remove the gear...

Page 85: ...Washer OIL PIPE Remove the oil pipe stopper t0 Remove the oil pipe Z PRIMARY DRIVE GEAR Hold the generator rotor with the special tool 09930 44530 Rotor holder Remove the primary drive gear bolt CAUT...

Page 86: ...o not drop the washer 2O into the crankcase Remove the rear cam chain 3 and cam chain drive sprocket GENERATOR ROTOR Hold the generator rotor with the special tool 09930 44530 Rotor holder Remove the...

Page 87: ...T CAM CHAIN Remove the cam chain tensioner 90 NOTE Do not drop the washer O2 into the crankcase Remove the front cam chain 1 GEAR POSITION SWITCH Remove the driveshaft oil seal retainer 1O Remove the...

Page 88: ...he crankcase bolts diagonally and smaller sizes first Separate the crankcase into 2 parts right and left with the special tool 09920 13120 Crankcase separating tool NOTE Fit the crankcase separating t...

Page 89: ...Remove the crankshaft D TRANSMISSION Remove the gearshift fork shafts 90 Remove the gearshift cam 02 Remove the gear shift forks 1 Remove the driveshaft assembly and countershaft assem bly Remove the...

Page 90: ...out in groups designated as No 1 No 2 Exhaust Intake so that each will be restored to the original location during assembly Remove the PAIR reed valve cover 10 INSPECTION Inspect the PAIR reed valve f...

Page 91: ...ed to the original location during assembly CAMSHAFT All camshafts should be checked for runout and also for wear of cams and journals if the engine has been noted as giving abnormal noise vibration o...

Page 92: ...ring the oil clearance with the camshaft installed in place Use the plastigauge to read the clearance at the widest por tion which is specified as follows Camshaft journal oil clearance Service Limit...

Page 93: ...09900 20205 Micrometer 0 25 mm CAMSHAFT RUNOUT Measure the runout using the dial gauge Replace the camshaft if the runout exceeds the limit Camshaft runout Service Limit IN EX 0 1 mm 0 004 in 09900 2...

Page 94: ...and shims O2 by fingers or magnetic hand CAUTION Identify the position of each removed part Using special tools compress the valve springs and remove the two cotter halves 3 from valve stem 09916 145...

Page 95: ...head Cylinder head distortion Standard 0 05 mm 0 002 in 09900 20803 Thickness gauge VALVE STEM RUNOUT Support the valve using V blocks and check its runout using the dial gauge as shown If the runout...

Page 96: ...seat Measure the valve stem deflection in two directions X and Y perpendicular to each other by positioning the dial gauge as shown If the deflection measured exceeds the limit then determine whether...

Page 97: ...ys turn it clockwise Apply engine oil to the valve guide hole and valve guide Drive the valve guide into the hole with the special tools 09916 43210 Valve guide installer remover 09916 53330 Attachmen...

Page 98: ...h Standard 0 9 1 1 mm 0 035 0 043 in VALVE SEAT SERVICING The valve seats for both the intake and exhaust valves are machined to four different angles The seat contact surface is cut at 45 09916 21111...

Page 99: ...stem becoming too close to the camshaft If the valve seat is pitted or burned use the 45 cutter to con dition the seat some more TOP NARROWING CUT If the contact area is too high on the valve or if it...

Page 100: ...t is made The finished valve seat should have a velvety smooth finish but not a highly polished or shiny finish This will provide a soft surface for the final seating of the valve which will occur dur...

Page 101: ...ing their free length and also by the force required to compress them If the spring length is less than the service limit or if the force required to compress the spring does not fall within the range...

Page 102: ...a MOLYBDENUM OIL SOLUTION Install the valve springs with the small pitch portion OA facing cylinder head Large pitch portion Put on the valve spring retainer D and using the valve lifter press down th...

Page 103: ...f the cylinder for distortion with a straightedge and thickness gauge taking a clearance reading at several places as indicated If the largest reading at any position of the straightedge exceeds the l...

Page 104: ...ANCE As a result of the previous measurement if the piston to cylinder clearance exceeds the service limit rebore the cylinder and use an oversize piston or replace both the cylinder and piston Piston...

Page 105: ...piston ring end gap using the thickness gauge If any of the measurements exceed the service limit replace the piston ring with a new one Piston ring free end gap Service Limit 1st 7 6 mm 0 30 in 2nd 8...

Page 106: ...ll bore gauge 18 35 mm Measure the piston pin outside diameter at three positions using the micrometer If any of the measurements are out of specification replace the piston pin Piston pin O D Service...

Page 107: ...09900 20803 Thickness gauge CONROD BIG END WIDTH Check the conrod big end width Conrod big end width Standard 20 95 21 00 mm 0 825 0 827 in 09900 20205 Micrometer 0 25 mm CONROD REMOVAL AND BEARING IN...

Page 108: ...sure the width of the com pressed plastigauge using the envelope scale This measure ment should be taken at the widest part of the compressed plastigauge Conrod big end oil clearance Standard 0 032 0...

Page 109: ...OIL SOLUTION to the crank pin and bearing surface a MOLYBDENUM OIL SOLUTION Color Part No Thickness Green 1 480 1 484 mm 12164 46E01 OAO 0 0583 0 0584 in Black 1 484 1 488 mm 12164 46E01 0B0 0 0584 0...

Page 110: ...tightening the bolts to the above torque tighten them 1 4 of a turn 90 Apply engine oil to the conrod big end side surfaces Check the conrod movement for smooth turning CRANKCASE OIL PRESSURE REGULATO...

Page 111: ...and tighten it to the specified torque 1207B 99104 31140 SUZUKI BOND 1207B USA 99000 31140 SUZUKI BOND 1207B Others 0 Oil pressure switch 14 N m 1 4 kgf m 10 0 Ib ft NOTE Be careful not to apply SUZU...

Page 112: ...AD LOCK to the oil strainer plate screws and tighten them to the specified torque 99000 32050 THREAD LOCK 1342 Oil strainer plate screw 10 N m 1 0 kgf m 7 0 lb ft OIL JET Removal Remove the oil jets O...

Page 113: ...g oil jets to the left and right crank case halves Apply a small quantity of THREAD LOCK to the bolts and tighten them to the specified torque 99000 32050 THREAD LOCK 1342 Piston cooling oil jet bolt...

Page 114: ...ft journal O D Standard 41 985 42 000 mm 1 6529 1 6535 in 09900 20202 Micrometer 25 50 mm Select the specified bearings from the crankcase bore I D code The crankcase bore I D code O A B or C is stamp...

Page 115: ...the crankshaft journal bearings with the special tool 09913 60221 Journal bearing remover installer NOTE Remove the crankshaft journal bearings in only one direction from inside to outside of each cra...

Page 116: ...by using with the following special tools 09924 84510 Bearing installer set 09910 20116 Conrod holder 09913 60221 Journal bearing remover installer Set the specified crankshaft journal bearings to the...

Page 117: ...case chamfer by using an oilstone and wash the crankcase bore with enough engine oil Set the bearings installed in the special tool to the crankcase half as shown CAUTION Be sure the bearing protruded...

Page 118: ...al tool D contacts the special tool 2 NOTE Using the hand press is recommended to install the crankshaft journal bearings However the crankshaft journal bearings can be installed by using the followin...

Page 119: ...e and smooth rotation while the bearings are in the crankcase Replace the bearing with new ones if there is anything unusual Inspect the oil seals for any damage REMOVAL Remove the oil seals using the...

Page 120: ...3 70 ENGINE Remove the crankcase bearings by using the special tool 09921 20240 Bearing remover set NOTE Select the suitable size attachment as following illustration...

Page 121: ...uitable size attachment as following illustration Bearing installer attachment Bearing 040 mm Bearing c562 mm Oil seal 035 mm Oil seal 052 mm Right crankcase 040 mm 032 mm 047 mm Oil seal 022 mm Left...

Page 122: ...Drive plate claw width Service Limit 12 9 mm 0 507 in 09900 20102 Vernier calipers CLUTCH DRIVEN PLATES NOTE Wipe off engine oil from the clutch driven plates with a clean rag Measure each driven plat...

Page 123: ...e slot of the clutch sleeve hub and primary driven gear assembly for damage or wear caused by the clutch plates If necessary replace it with a new one PRIMARY DRIVEN GEAR ASSEMBLY DISASSEMBLY Remove t...

Page 124: ...rive plate Snap ring INSPECTION Check the gearshift shaft gearshift arm for wear or bend Check the return springs for damage or fatigue REASSEMBLY Install the following parts to the gearshift shaft ge...

Page 125: ...inal location during assembly Remove the 6th drive gear snap ring 90 from its groove and slide it towards the 3rd 4th drive gears O Slide the 6th and 2nd drive gears toward the 3rd 4th drive gears the...

Page 126: ...HAFT DISASSEMBLY Remove the washer 1O and 1st driven gear O2 Remove the 1st driven gear bushing washer and 5th driven gear 5 Remove the snap ring washer 07 and 4th driven gear Remove the 4th driven ge...

Page 127: ...ove the snap ring 14 and 6th driven gear 15 Remove the snap ring 16 and 2nd driven gear bushing T Remove the 2nd driven gear 18 INSPECTION Inspect the each gear and bushing for wear and damage If they...

Page 128: ...use a snap ring After a snap ring has been removed from a shaft it should be discarded and a new snap ring must be installed When installing a new snap ring do not expand the end gap larger than requi...

Page 129: ...ft oil hole with the bushing oil hole 90 6th drive gear bushing OO 3rd driven gear bushing 4th driven gear bushing After installing the 3rd driven gear onto the driveshaft install lock washer No 2 ont...

Page 130: ...m 105 Ib ft O 1st Low drive gear countershaft O 5th drive gear O 3rd 4th drive gear 6th Top drive gear E5 2nd drive gear C 1st Low driven gear O 5th driven gear C 4th driven gear 9 3rd driven gear j1...

Page 131: ...0803 Thickness gauge 09900 20102 Vernier calipers If the clearance checked is noted to exceed the limit specified replace the fork or its gear or both GEARSHIFT FORK GROOVE WIDTH Measure the gearshift...

Page 132: ...clutch or the starter clutch contacting surface on the starter driven gear for wear and damage If they are found to be damaged replace them with new ones Inspect the starter driven gear bearing for a...

Page 133: ...t 25 N m 2 5 kgf m 18 0 lb ft Apply engine oil to the one way clutch GENERATOR AND SIGNAL GENERATOR INSPECTION Refer to pages 8 10 27 for generator and CKP sensor inspec tion REASSEMBLY When installin...

Page 134: ...hat it moves smoothly If it does not move smoothly replace the oil pump assembly CAUTION Do not attempt to disassemble the oil pump assem bly The oil pump is available only as an assembly CLUTCH RELEA...

Page 135: ...t before reas sembling ENGINE BOTTOM SIDE TRANSMISSION Install the countershaft assembly D and the driveshaft assembly O2 to the left crankcase half Install the washer 03 onto the driveshaft assembly...

Page 136: ...dowel pins T Apply SUZUKI SUPER GREASE to the O rings O Z 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Apply SUZUKI BOND to the mating surface of the left crank case...

Page 137: ...shaft rotate crankshaft the driveshaft and the smoothly Fit the clamp to the bolt as shown OIL PLATE Install the oil plate i and the oil plate bolts tighten to the specified torque Oil plate bolt 10 N...

Page 138: ...ll the gear position switch OO as shown Install the drive shaft oil seal retainer NOTE Pass through the gear position switch lead wire under the drive shaft oil seal retainer FRONT CAM CHAIN Install t...

Page 139: ...the crankshaft completely Install the generator rotor assembly onto the crankshaft While holding the generator rotor with the special tool tighten its bolt to the specified torque 09930 44530 Rotor h...

Page 140: ...r bolt 10 N m 1 0 kgf m 7 0 Ib ft NOTE The front and rear cam chain tensioners are the same PRIMARY DRIVE GEAR Install the primary drive gear D and water pump drive gear OO Hold the generator rotor cr...

Page 141: ...O of its stopper GEARSHIFT SYSTEM Install the gearshift cam stopper 9 its bolt Z washer 30 and return spring Gearshift cam stopper bolt 10 N m 1 0 kgf m 7 0 Ib ft Confirm the gearshift cam stopper mo...

Page 142: ...ed torque 99000 32050 THREAD LOCK 1342 0 Gearshift cam stopper plate bolt 13 N m 1 3 kgf m 9 5 Ib ft Install the gearshift shaft gearshift arm 7 with the washer as shown Locate the gearshift arm stopp...

Page 143: ...driven gear assembly OO onto the counter shaft NOTE Be sure to engage the oil pump drive and driven gears primary drive and driven gears Install the thrust washer Install the clutch sleeve hub and loc...

Page 144: ...36 0 Ib ft Bend the lock washer to lock the nut securely Install the spring washer seat 7 and spring washer onto the clutch sleeve hub correctly Insert the clutch drive plates O 1o and driven plates...

Page 145: ...bearing 14 Hold the generator rotor crankshaft with the special tool 09930 44530 Rotor holder Install the clutch pressure plate Tighten the clutch spring set bolts to the specified torque 0Clutch spr...

Page 146: ...ll the dowel pins O and gasket CAUTION Use the new gasket to prevent oil leakage Install the generator cover 0Generator cover bolt 10 N m 1 0 kgf m 7 0 Ib ft NOTE Fit the gasket washer to the generato...

Page 147: ...en the starter motor mounting bolt AO ENGINE TOP SIDE PISTON Install the piston rings in the order of oil ring 2nd ring and 1st ring The first member to go into the oil ring groove is a spacer 1O Afte...

Page 148: ...pistons front and rear the indents OA on the piston heads must be located to each exhaust side Place a clean rag over the cylinder base so as not to drop the piston pin circlips into the crankcase In...

Page 149: ...as shown in the illustration CAUTION Use the new 0 rings to prevent oil leakage CYLINDER Coat SUZUKI BOND lightly to the mating surfaces at the part ing line between the right and left crankcases as...

Page 150: ...chain must not be caught between cam drive sprocket and crankcase when turning the crankshaft Tighten the cylinder nuts M6 temporarily CYLINDER HEAD The cylinder heads can be distinguished by the emb...

Page 151: ...lts Place the rear cylinder head on the cylinder NOTE When installing the cylinder head keep the cam chain taut Tighten the cylinder head bolts M10 to the specified two step torque with a torque wrenc...

Page 152: ...F line OO on the generator rotor with the index mark of the valve timing inspection hole while keeping the cam chains pulled upward CAUTION Pull the cam chains upward or the chain will be caught betw...

Page 153: ...the crankshaft until the camshaft journal holders and cam chain tension adjuster is secured Install the dowel pins Apply engine oil to the camshaft journal holders Install the camshaft journal holder...

Page 154: ...ed from the cam chain tension adjuster release locking of the ratchet mecha nism and push the push rod OO all the way in Install the gasket Install the cam chain tension adjuster 3 with UP mark faced...

Page 155: ...ill be caught between crankcase and cam drive sprocket CAUTION To adjust the camshaft timing correctly be sure to align I F line with the index mark and hold this position when installing the camshaft...

Page 156: ...haft side going towards the exhaust camshaft side Engage the 16th roller pin OD on the cam chain with the arrow mark 3 on the exhaust sprocket 3 106 NOTE The cam chain should now be on all three sproc...

Page 157: ...ter Tighten the camshaft journal holder bolts to the specified torque 0 Camshaft journal holder bolt 10 N m 1 0 kgf m 7 0 lb ft CAUTION The camshaft journal holder bolts are made of a spe cial materia...

Page 158: ...3 108 ENGINE...

Page 159: ...BOND 1215 Others CAUTION Use the new gaskets to prevent oil leakage The cylinder head covers can be distinguished by the embossedletters OA F Front cylinder head cover R Rear cylinder head cover Insta...

Page 160: ...ne When installing the water union apply engine coolant to the 0 ring ENGINE COOLANT INTAKE PIPE Apply SUZUKI SUPER GREASE to the 0 ring 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER...

Page 161: ...on plug 23 N m 2 3 kgf m 16 5 lb ft Generator cover plug 11 N m 1 1 kgf m 8 0 lb ft CAUTION Use the new O ring to prevent oil leakage THERMOSTAT CASE AND WATER HOSE Install the thermostat case 10 alon...

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Page 224: ...6 8 REMOVAL 6 8 INSTALLATION 6 8 COOLING FAN THERMO SWITCH 6 9 REMOVAL 6 9 INSPECTION 6 9 INSTALLATION 6 9 ENGINE COOLANT TEMPERATURE SENSOR 6 10 REMOVAL 6 10 INSPECTION 6 10 INSTALLATION 6 11 THERMO...

Page 225: ...AND LUBRICATION SYSTEM 6 1 OIL PUMP 6 20 OIL PRESSURE SWITCH 6 20 OIL COOLER 6 21 REMOVAL 6 21 INSPECTION AND CLEANING 6 21 INSTALLATION 6 22 ENGINE LUBRICATION FLOW CHART 6 23 ENGINE LUBRICATION CIR...

Page 226: ...f The engine must be cool before servicing the cooling system Coolant is harmful If it comes in contact with skin or eyes flush with water If swallowed accidentally induce vomiting and call physician...

Page 227: ...er A WARNING Do not remove the radiator cap when the engine is hot Give a pressure of about 120 kPa 1 2 kgf cm2 17 0 psi and see if the system holds this pressure for 10 seconds If the pressure should...

Page 228: ...SYSTEM RADIATOR REMOVAL Remove the cowling SV650S r 7 7 6 Drain engine coolant r 72 20 Disconnect the right and left radiator hoses from the radiator Disconnect the siphon hose from the radiator Disc...

Page 229: ...wire coupler 10 Remove the radiator by upper mounting bolt Remove the cooling fan Disconnect the cooling fan thermo switch Remove the cooling fan thermo switch Remove the horn CAUTION When removing t...

Page 230: ...screwdriver INSTALLATION Install the cooling fan and horn 0Cooling fan horn mounting bolt 8 N m 0 8 kgf m 6 0 Ib ft Install the cooling fan thermo switch l 76 9 Install the siphon hose to the radiator...

Page 231: ...the cap is capable of holding that pressure for at least 10 seconds Replace the cap if it is found not to satisfy above require ments Radiator cap valve opening pressure Standard 95 125 kPa 0 95 1 25...

Page 232: ...than 5 amperes If the fan motor does not turn replace the motor assembly with a new one NOTE When making above test it is not necessary to remove the cool ing fan INSTALLATION Install the cooling fan...

Page 233: ...the switch closes or opens 09900 25008 Multi circuit tester set Tester knob indication Continuity test l Cooling fan thermo switch operating temperature Standard OFF ON Approx 98 C 208 F ON OFF Approx...

Page 234: ...Heat the water to raise its temperature slowly and read the column thermometer O and the ohmmeter If the temperature sensor ohmic valve does not change in the proportion indicated replace it with a ne...

Page 235: ...fied torque 0 Engine coolant temperature sensor 18 N m 1 8 kgf m 13 0 lb ft CAUTION Take special care when handling the temperature sen sor It may cause damage if it gets a sharp impact Pour engine co...

Page 236: ...r Pass a string between flange as shown in the photograph Immerse the thermostat in the WATER contained in a beaker as shown in the illustration Note that the immersed thermo stat is in suspension Hea...

Page 237: ...tart to open temperature and valve lift must be replaced INSTALLATION Apply engine coolant to the rubber seal on the thermostat Install the thermostat NOTE The jiggle valve OA of the thermostat faces...

Page 238: ...utch cover f 7 3 31 NOTE Before draining engine oil and engine coolant inspect engine oil and coolant leakage between the water pump and clutch cover If engine oil is leaking visually inspect the oil...

Page 239: ...ve the screws and separate the water pump Remove the 0 rings OO Remove the E ring from the impeller shaft Remove the impeller from the other side Remove the mechanical seal ring and rubber seal from t...

Page 240: ...mechanical seal and the oil seal removal is not necessary CAUTION The removed mechanical seal and oil seal must be replaced with a new one INSPECTION BEARING Inspect the play of the bearing by hand w...

Page 241: ...damage Replace the water pump body if necessary REASSEMBLY AND INSTALLATION Install the oil seal using the special tool 09913 70210 Bearing installer set NOTE The stamped mark on the oil seal faces i...

Page 242: ...eal ring install it into the impeller NOTE The paint marked side OA of the mechanical seal ring faces to the impeller Apply SUZUKI SUPER GREASE to the impeller shaft 99000 25030 SUZUKI SUPER GREASE A...

Page 243: ...e coolant to the 0 ring Install a new 0 ring CAUTION Use a new 0 ring to prevent engine coolant leakage Connect the water hoses Pour engine coolant C12 20 Pour engine oil C 2 14 COOLING AND LUBRICATIO...

Page 244: ...D LUBRICATION SYSTEM LUBRICATION SYSTEM OIL PRESSURE C 2 35 OIL FILTER f72 15 OIL PRESSURE REGULATOR r 7 3 60 OIL STRAINER f T3 61 OIL JET r 7 3 62 63 and 99 OIL PUMP 3 84 and 92 OIL PRESSURE SWITCH 3...

Page 245: ...t 10 Remove the oil hoses I2 INSPECTION AND CLEANING Inspect the oil cooler and hose joints for oil leakage If any defect are found replace the oil cooler and oil hoses with the new ones Road dirt or...

Page 246: ...w gasket washers CAUTION Use the new gasket washers to prevent engine oil leakage Connect the oil hoses Install the oil cooler Oil cooler mounting bolt 10 N m 1 0 kgf m 7 0 Ib ft Tighten the oil coole...

Page 247: ...AL Ir p 11 I 0 STARTER DRIVEN GEAR BUSHING o f CAM FACES CAM FACES I EXHAUST CAMSHAFT CAM CHAIN CAM CHAIN LEFT SIDE CRANKSHAFT JOURNAL RIGHT CRANKSHAFT JOURNAL SIDE CAM FACES CAM FACES t INTAKE CAMSHA...

Page 248: ...6 24 COOLING AND LUBRICATION SYSTEM ENGINE LUBRICATION CIRCUIT FRONT CYLINDER I I 7 T r W _ I OW 411111 1 11i1i1iTiiill ihlihlil hr I 1J 1 I 0...

Page 249: ...lw i 40 60 w REAR CYLINDER COOLING AND LUBRICATION SYSTEM 6 25...

Page 250: ...7 24 STEERING AND HANDLEBAR 7 25 CONSTRUCTION 7 25 REMOVAL 7 26 INSPECTION AND DISASSEMBLY 7 32 REASSEMBL Y AND REMOUNTING 7 33 STEERING TENSION ADJUSTMENT 7 40 REAR WHEEL 7 41 CONSTRUCTION 7 41 REMOV...

Page 251: ...R CYLINDER INSPECTION 7 74 MASTER CYLINDER REASSEMBLY AND REMOUNTING SV650S 7 74 MASTER CYLINDER REMOVAL AND REMOUNTING SV650 7 76 REAR BRAKE 7 78 CONSTRUCTION 7 78 BRAKE PAD REPLACEMENT 7 79 BRAKE FL...

Page 252: ...7 2 CHASSIS EXTERIOR PARTS CONSTRUCTION J D Wind screen O2 Meter panel Cowling bracket RH Cowling bracket LH 5 Meter panel lid RH Meter panel lid LH 7 Body cowling Cowling brace O Cowling inner cover...

Page 253: ...G Seat rail 02 Rear fender No 1 O Rear fender No 2 Pillion rider handle 05 Taillight upper cover Taillight lower cover 0 07 Seat tail cover R Seat tail cover L ITEM N m kgf m Ib ft C Seat rail mountin...

Page 254: ...IDE COVER Remove the frame side cover NOTE indicates hook location FRONT SEAT Remove the frame side covers right and left C i Above Remove the front seat FRONT FENDER Remove the front fender PILLION R...

Page 255: ...4 Remove the front seat f 77 4 Remove the pillion rider handle 7 4 Remove the screws O and clips O Disconnect the brake light taillight lead wire coupler 3 Disconnect the seat lock cable Remove the s...

Page 256: ...ING AND COWLING BRACE SV650S Remove the rear view mirrors Remove the cowling inner cover by removing the screws 10 and clips OO Remove the wind screen by removing screws 30 Remove the meter panel lids...

Page 257: ...ght coupler NOTE V indicates hook location Remove the meter panel 07 Remove the cowling brace Disconnect the combination meter couplers Remove the combination meter 9 11 1 8 29 REASSEMBLY Reassemble t...

Page 258: ...7 8 CHASSIS FRONT WHEEL CONSTRUCTION 0 ITEM W N m 65 23 kgf m 6 5 2 3 l b ft 47 0 16 5 D Brake disc 20 Dust seal 03 Bearing Center spacer 05 Front wheel Tire valve OA Front axle Brake disc bolt lJ...

Page 259: ...y loosen the front axle by using the special tool EM 0990Q 18710 Hexagon bit 12mmnn Raise the front wheel off the ground and support the motorcy cle with a jack or a wooden block Remove the front axle...

Page 260: ...nd replace it if the runout exceeds the limit 09900 20607 Dial gauge 1 100 09900 20701 Magnetic stand 09900 21304 V block set 100 mm Axle shaft runout Service Limit 0 25 mm 0 010 in WHEEL Make sure th...

Page 261: ...eel bearings by finger while they are in the wheel Rotate the inner race by finger to inspect for abnor mal noise and smooth rotation Replace the bearing in the following procedure if there is any thi...

Page 262: ...ount the front wheel in the reverse order of removal and disassembly Pay attention to the following points 0 39 N m 3 9 kgf m 28 0 lb ft I A II Ii Left c Right 1 111 a n Wn L AEEM P W A I 0 39 N m 3 9...

Page 263: ...25010 SUZUKI SUPER GREASE A Others 61 I First install the left wheel bearing then install the right wheel bearing and spacer by using the special tools 09941 34513 Bearing Steering race installer set...

Page 264: ...CK SUPER 1360 WHEEL Install the front wheel with the front axle and tighten the front axle temporarily A WARNING The directional arrow on the wheel must point to the wheel rotation when remounting the...

Page 265: ...E Tighten the front axle to the specified torque with special tool 09900 18710 Hexagon bit 12 mm Front axle 65 N m 6 5 kgf m 47 0 lb ft NOTE Before tightening the two axle pinch bolts on the right fro...

Page 266: ...nner tube 7 Slide metal Gasket Dust seal 1o Oil seal stopper ring 11 Oil seal 10 Oil seal retainer 13 Guide metal 14 Oil lock piece Outer tube 16 Cylinder Washer Front fork cap bolt Front axle pinch b...

Page 267: ...front fork cap bolts before loosening the lower clamp bolts to facilitate later disassembly Loosen the front fork lower clamp bolts NOTE Hold the front fork by hand to prevent it from sliding out of t...

Page 268: ...NOTE If the damper rod turns together with the damper rod bolt tem porarily install the fork spring spacer washer and cap bolt to prevent the damper rod from turning Remove the cylinder 9 and rebound...

Page 269: ...lock piece INSPECTION INNER AND OUTER TUBES Inspect the inner tube outer surface and the outer tube inner sur face for scratches If any defects are found replace them with the new ones FORK SPRING Mea...

Page 270: ...rk oil to the Anti friction metals and lip of the oil seal Assemble the following parts as shown Oil seal Oil seal retainer Guide metal Slide metal NOTE Stamped mark on the oil seal must face upward I...

Page 271: ...LOCK to the cylinder bolt and tighten it to the specified torque 99000 32050 THREAD LOCK 1342 0 Cylinder bolt 20 N m 2 0 kgf m 14 5 lb ft CAUTION Use a new gasket to prevent oil leakage NOTE If the cy...

Page 272: ...be up and down several strokes until no more bubbles come out from the oil Keep the front fork vertically and leave it during 5 6 minutes NOTE Take extreme attention to pump out air completely Hold th...

Page 273: ...meter must face downward SV650 Apply fork oil lightly to the 0 ring CAUTION Use a new O ring to prevent oil leakage Tighten the front fork cap bolt temporarily Set the front fork to the front fork low...

Page 274: ...N m 2 3 kgf m 16 5 lb ft Install the front wheel J7 9 Install the front brake calipers Cr7 68 NOTE After install the brake calipers front brake should be efficient by pumping the front brake lever SUS...

Page 275: ...wer bracket 70 Steering stem nut Handlebar balancer O Expander 100 Spacer 11 Washer a Expander ra Handlebar clamp bolt Steering stem head nut Handlebar holder nut CD Front fork upper clamp bolt EO Ste...

Page 276: ...bar switch box Throttle case O7 Handlebar balancer Throttle grip O9 Front brake master cylinder Reservoir CAUTION Do not turn the front brake master cylinder upside down Disconnect the clutch switch l...

Page 277: ...ebar balancer Grip rubber 5O Clutch cable Clutch lever holder Rear view mirror Right handlebar switch box Throttle cables O9 Handlebar balancer 10 Throttle grip 11 Front brake master cylinder CAUTION...

Page 278: ...0 11920 Torx bit JT40H 09930 11940 Bit holder Remove the front brake assembly by removing the brake hose guide OO CAUTION Do not turn the front brake master cylinder upside down Remove the steering st...

Page 279: ...wer bearing 05 STEERING STEM SV650 Remove the following items Front wheel F r7 9 Handlebar 117 27 Front fork C 7 17 Remove the headlight and its housing Remove the front brake assembly by removing the...

Page 280: ...dometer connector 1 Remove the speedometer assembly and throttle cable guides Remove the ignition switch by using the special tools 09930 11920 Torx bit JT40H 09930 11940 Bit holder Remove the headlig...

Page 281: ...steering stem upper bracket by removing the steering stem head nut Remove the handle holder nuts and disassemble the han dle holder The removal procedure of steering stem is the same as SV650S C 7 28...

Page 282: ...tion of the steering stem If any abnormal points are found replace defective parts with the new ones Remove the steering stem lower bearing inner race using a chisel CAUTION The removed bearing inner...

Page 283: ...he special tool 09925 18011 Steering bearing installer Apply SUZUKI SUPER GREASE to the bearings and dust seal Install the lower bearing to the steering stem lower bracket Install the upper bearing be...

Page 284: ...tools 09940 14911 Steering stem nut wrench 09940 14960 Steering stem nut wrench socket 0 Steering stem lock nut 80 N m 8 0 kgf m 58 0 lb ft Install the handlebar holders and then tighten the handleba...

Page 285: ...items Front brake assembly Front wheel 01 7 12 Cowling SV650S f 7 7 HANDLEBARS SV650S Install the handlebars D to the front forks Tighten the steering stem head nut and front fork upper clamp bolts t...

Page 286: ...n the front brake master cylinder mounting bolts to the specified torque 0 Front brake master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 Ib ft Apply SUZUKI SUPER GREASE to the throttle cable and cabl...

Page 287: ...0 Install the handlebars with the punch mark WO aligned with the mating surface of the handlebar holder Set the punch mark on the handlebar clamp forward Tighten the handlebar clamp bolts to the speci...

Page 288: ...the front brake master cylinder mounting bolts to the specified torque Front brake master cylinder mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Install the following items to the left handlebar 90 Clutch...

Page 289: ...n 1O Throttle grip Handlebar 7 Washer Clearance OO 0 mm LH 0 5 1 5 mm RH 02 Handlebar balancer 05 Nut Expander OO Screw O Expander NOTE After installing the RH balancer make sure that throttle grip op...

Page 290: ...ale If the initial force read on the scale when the handlebar starts turning is either too heavy or too light adjust it till it satisfies the specification 1 First loosen the front fork upper clamp bo...

Page 291: ...disc Collar Bearing Rear wheel 7 Tire valve 08 Damper Spacer 1o Bearing 11 Retainer Sprocket mounting drum 13 Rear sprocket 19 14 Bearing Dust seal ITEM N m kgf m Ib ft 16 Spacer 23 2 3 16 5 AO Brake...

Page 292: ...and draw out the rear axle CAUTION Do not operate the brake pedal while removing the rear wheel Remove the collars C3 Remove the rear sprocket mounting drum assembly C from the wheel hub NOTE Before r...

Page 293: ...axle Axle shaft runout Service Limit 0 25 mm 0 010 in 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set 100 mm WHEEL DAMPER Inspect the dampers for wear and damage Rep...

Page 294: ...one Remove the dust seal with the special tool 09913 50121 Oil seal remover CAUTION Do not reuse the removed dust seal BEARING Inspect the play of the wheel and sprocket mounting drum bear ings by han...

Page 295: ...40 Remove the sprocket mounting drum bearing and wheel bear ings by using the special tool 09921 20240 Bearing remover set CAUTION The removed bearings must be replaced with the new ones CHASSIS 7 45...

Page 296: ...mble and remount the rear wheel in the reverse order of removal and disassembly Pay attention to the following points 0 60 N m 6 0 kgf m 43 5 lb ft 100 N m 10 kgf m 72 5 lb ft E03 28 33 Left Right I r...

Page 297: ...g installer set NOTE When installing the bearing non sealed side of bearing must face the special tool First install the right wheel bearing then install the left wheel bearing and spacer using the sp...

Page 298: ...er Apply THREAD LOCK SUPER to the disc bolts and tighten them to the specified torque 99000 32130 THREAD LOCK SUPER 1360 Brake disc bolt 23 N m 2 3 kgf m 16 5 Ib ft REAR SPROCKET Tighten the sprocket...

Page 299: ...rear wheel and rear axle install the washer and rear axle nut Tighten the rear axle nut O to the specified torque Adjust the chain slack after rear wheel installation f 2 22 0 Rear axle nut 100 N m 1...

Page 300: ...0 CHASSIS REAR SHOCK ABSORBER CONSTRUCTION f 0 1 Rear shock absorber ITEM N m kgf m Ib ft CA 50 5 0 36 0 CA Rear shock absorber upper mounting nut CBC Rear shock absorber lower mounting bolt 50 5 0 36...

Page 301: ...he ground and support the motorcy cle with a jack or wooden block Remove the cushion rod bolt nut Remove the rear shock absorber upper mounting bolt Remove the rear shock absorber lower mounting bolt...

Page 302: ...Mishandling can cause explosion Keep away from fire and heat High gas pressure caused by heat can cause an explosion Release gas pressure before disposing GAS PRESSURE RELEASE Mark the drill hole at...

Page 303: ...ting upper nut 50 N m 5 0 kgf m 36 0 lb ft Install the cushion rod bolt Nut Tighten the cushion rod nuts to the specified torque Cushion rod nut 78 N m 7 8 kgf m 56 5 lb ft SUSPENSION SETTING After in...

Page 304: ...buffer 10 Swingarm 11 Center spacer Rear shock absorber upper mounting nut U Cusion lever nut c Cusion rod nut Swingarm pivot shaft Swingarm pivot lock nut Swingarm pivot nut Rear shock absorber lower...

Page 305: ...equipped with the hose guide O Remove the side stand switch Z Remove the cushion rods Remove the shock absorber C 7 51 Remove the cushion lever 0 Remove the swingarm pivot shaft locknut by using the...

Page 306: ...spacers for any flaws or other damage If any defects are found replace the spacers with the new ones Swingarm pivot spacer Cushion lever rear spacer Cushion lever center spacer Cushion rod spacer Cus...

Page 307: ...a new one Remove the swingarm pivot bearing and spacer with the spe cial tools 09923 74511 Bearing remover 09930 30102 Sliding shaft CAUTION Do not reuse the removed bearings Remove the cushion rod b...

Page 308: ...ut Service limit 0 3 mm 0 01 in CUSHION LEVER BEARING Insert the spacer into bearing and check the play when moving the spacer up and down If excessive play is noted replace the bearing with a new one...

Page 309: ...rder of disassembly and removal Pay attention to the following points CHASSIS 7 59 OO 0 100 N m 10 0 kgf m 72 5 lb ft Left J E Right 1 L o I 15 N m 1 5 kgf m 11 0 lb ft 0 19 90 N m 9 0 kgf m 65 0 lb f...

Page 310: ...ecial tool 09941 34513 Steering race installer NOTE When installing the bearing the dust seal that is embedded in the bearing must face outside CUSHION LEVER BEARING Press the bearings into the cushio...

Page 311: ...09944 28320 Hexagon bit 19 mm Hold the swingarm pivot shaft 1O and tighten the swingarm pivot nut 02 to the specified torque Swingarm pivot nut 100 N m 10 0 kgf m 72 5 Ib ft Tighten the swingarm pivo...

Page 312: ...cushion rod nut and rear shock absorber nut to the specified torque 0Cushion lever mounting nut 78 N m 7 8 kgf m 56 5 Ib ft Cushion rod nut 78 N m 7 8 kgf m 56 5 Ib ft Rear shock absorber mounting nut...

Page 313: ...7 5 0 75 5 5 39 3 9 28 0 10 Diaphragm Brake pad OO Brake master cylinder 02 Dust boot Piston seal mounting bolt 3 Piston cup set 0 Dust seal Brake hose union bolt Brake hose 11 Piston Front caliper ai...

Page 314: ...c or brake pad reduces braking performance Discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent CAUTION Handle brake fluid with care the fluid reacts chemi...

Page 315: ...cycle on a level surface and keep the handle bars straight Remove the brake fluid reservoir cap and diaphragm Suck up the old brake fluid as much as possible Fill the reservoir with the new brake flui...

Page 316: ...tch any spilt brake fluid Remove the brake calipers by removing the caliper mounting bolts CAUTION Do not reuse the brake fluid left over from previous servicing and stored for long periods of time A...

Page 317: ...t the brake caliper cylinder wall for nicks scratches and other damage If any damage is found replace the caliper with a new one BRAKE CALIPER PISTON Inspect the brake caliper piston surface for any s...

Page 318: ...4 CAUTION Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Do not wipe the brake fluid off after washing the components with a r...

Page 319: ...ter setting the brake hose union to the stopper refer to page 9 33 9 34 tighten the union bolt to the specified torque Front brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft CAUTION The seal washers...

Page 320: ...ain the brake fluid 7 65 Disconnect the brake light switch coupler U Place a rag underneath the union bolt on the master cylinder to catch any spilt brake fluid Remove the brake hose union bolt and di...

Page 321: ...ake lever O and brake light switch OO Remove the dust cover and dust boot Remove the snap rings Remove the piston and return spring Piston Cup set 5 Primary cup Return spring 07 O ring Brake hose conn...

Page 322: ...aster cylinder to catch any spilt brake fluid Remove the brake hose union bolt and disconnect the brake hose CAUTION Immediately and completely wipe off any brake fluid contacting any part of the moto...

Page 323: ...we Remove the snap ring Remove the piston and return spring Piston Cup set Primary cup Return spring I CHASSIS 7 73...

Page 324: ...oints CAUTION Wash the master cylinder components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Do not wipe the components with a rag Apply brake fluid t...

Page 325: ...KI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Align the projection on the brake light switch with the hole on the master cylinder Install the reservoir to the master cylinder When rem...

Page 326: ...in the reverse order of removal and disassembly Pay attention to the following points CAUTION Wash the master cylinder components with fresh brake fluid before reassembly Never use cleaning solvent or...

Page 327: ...nting the brake master cylinder onto the handle bar align the master cylinder holder s mating surface OO with punched mark on the handlebar and tighten the upper clamp bolt first as shown Front brake...

Page 328: ...oleum based Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for long periods When storing the brake fluid seal...

Page 329: ...versely affected Remove the pad mounting pin and brake pads with the rear caliper pivoted up Clean up the caliper especially around the caliper pistons Inspect the pad mounting pin for wear or damage...

Page 330: ...ft Install the plug 9 to the specified torque Pad pin plug 2 5 N m 0 25 kgf m 1 8 lb ft NOTE After replacing the brake pads pump the brake pedal several times in order to operate the brake parts corre...

Page 331: ...CAUTION Do not reuse the brake fluid left over from previous servicing and stored for long periods A WARNING Brake fluid if it leaks will interfere with safe running and discolor painted surfaces Chec...

Page 332: ...and piston seal CAUTION Do not reuse the dust seal and piston seal to prevent fluid leakage CALIPER INSPECTION BRAKE CALIPER Inspect the brake caliper cylinder wall for nicks scratches and other dama...

Page 333: ...t the boot and spacer for damage and wear If any dam ages are found replace boot and spacer with new ones BRAKE DISC INSPECTION Inspect the rear brake disc in the same manner as that of the front one...

Page 334: ...reuse the dust seal and piston seal to prevent fluid leakage BF Specification and Classification DOT 4 PISTON SEAL Install the piston seals as shown in the right illustration Install the piston to the...

Page 335: ...ds Tighten the brake hose union bolt with the brake hose union pipe seated in the cutout on the caliper Rear brake hose routing 9 34 and 35 0 Brake hose union bolt 23 N m 2 3 kgf m 16 5 lb ft CAUTION...

Page 336: ...any parts of the motorcycle The fluid reacts chemically with paint plastic and rubber mate rials etc and will damage them severely Loosen the lock nut T Remove the master cylinder mounting bolts Remov...

Page 337: ...fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Do not wipe the components with a rag Apply brake fluid to the cylinder bore and all the component to be insert...

Page 338: ...N m 1 0 kgf m 7 0 lb ft Connect the brake hose to the master cylinder Rear brake hose routing 9 34 9 34 and 35 Tighten the brake hose union bolt to the specified torque Brake hose union bolt 23 N m 2...

Page 339: ...halk to indicate the tire position relative to the valve position Even though the tire is refitted to the original position after repairing puncture the tire may have to be balanced again since such a...

Page 340: ...seal 1O has abnormal deforma tion replace the valve with a new one VALVE INSTALLATION Any dust or rust around the valve hole must be cleaned off Then install the valve in the rim NOTE To properly ins...

Page 341: ...ime of removal with the valve position For installation procedure of tire onto the wheel follow the instructions given by the tire changer manufacturer Bounce the tire several times while rotating Thi...

Page 342: ...e case deflate the tire completely and unseat the bead for both sides Coat the bead with lubricant and fit the tire again When the bead has been fitted properly adjust the pressure to specification As...

Page 343: ...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 344: ...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 345: ...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 346: ...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 347: ...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 348: ...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 349: ...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 350: ...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 351: ...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 352: ...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 353: ...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 354: ...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 355: ...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 356: ...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 357: ...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 358: ...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 359: ...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 360: ...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 361: ...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 362: ...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 363: ...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 364: ...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 365: ...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 366: ...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 367: ...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 368: ...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 369: ...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 370: ...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 371: ...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 372: ...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 373: ...Prepared by May 2003 Part No 99501 39540 01E Printed in Japan 28...

Page 374: ...Printed in Japan K3...

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