Suzuki 1999 SV650 - Piston Ring Free End Gap and Piston Ring End Gap; Oversize Piston Ring; Oversize Oil Ring

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Foreword2
Group Index2
How to Use this Manual3
To Locate What You Are Looking for3
Component Parts and Work to be Done3
Symbol4
General Information5
Contents5
Warning/Caution/Note6
General Precautions6
Suzuki SV650X ('99-Model) View8
Right Side8
Left Side8
Serial Number Location8
Fuel, Oil and Engine Coolant Recommendation9
Engine Oil9
Brake Fluid9
Front Fork Oil9
Anti-Freeze/Engine Coolant10
Liquid Amount of Water/Engine Coolant10
Break-In Procedures10
Cylinder Identification10
Information Labels11
Specifications12
Dimensions and Dry Mass12
Electrical13
Capacities13
Country and Area Codes14
Periodic Maintenance15
Periodic Maintenance Schedule16
Periodic Maintenance Chart16
Lubrication Points17
Maintenance and Tune-Up Procedures18
Air Cleaner18
Front Spark Plug Removal19
Rear Spark Plug Removal20
Heat Range21
Carbon Deposits21
Spark Plug Gap21
Spark Plug Installation21
Tappet Clearance22
Tappet Clearance Adjustment24
Intake Side25
Tappet Shim Selection Table (Intake)25
How to Use this Chart25
Exhaust Side26
Tappet Shim Selection Table (Exhaust)26
Engine Oil and Oil Filter27
Engine Oil Replacement27
Oil Filter Replacement28
Necessary Amount of Engine Oil28
Fuel Hose29
Engine Idle Speed29
Throttle Cable Play30
Clutch Cable Play31
Engine Coolant Level Check32
Engine Coolant Change32
Air Bleeding the Cooling Circuit33
Radiator Hoses33
Drive Chain34
Checking34
Adjusting35
Cleaning and Lubricating35
Brake Fluid Level Check36
Brake Pads37
Brake Pedal Height37
Brake Light Switch37
Air Bleeding from Brake Fluid Circuit38
Tire Tread Condition39
Tire Pressure40
Steering40
Front Fork41
Rear Suspension41
Exhaust Pipe Bolt and Nut41
Chassis Bolts and Nuts42
Compression Pressure Check44
Compression Pressure Specification44
Compression Test Procedure44
Oil Pressure Check45
Oil Pressure Specification45
Low Oil Pressure45
High Oil Pressure45
Engine46
Engine Components Removable with the Engine in Place47
Engine Left Side47
Engine Right Side47
Engine Center47
Engine Removal48
Engine Installation58
Exhaust Gas Sealer: Permatex 137263
Engine Disassembly65
Cylinder Head Cover66
Front Camshafts66
Rear Camshafts68
Front Cylinder Head70
Rear Cylinder Head71
Front Cylinder72
Rear Cylinder72
Piston73
Starter Motor73
Oil Filter73
Generator Cover74
Clutch Cover74
Clutch75
Gearshift System76
Oil Pipe77
Primary Drive Gear77
Rear Cam Chain78
Generator Rotor78
Front Cam Chain79
Oil Pump81
Neutral Indicator Light Switch82
Crankcase82
Crankshaft83
Transmission83
Engine Components Inspection and Service85
Camshaft Identification85
Cam Wear85
Camshaft Journal Wear86
Camshaft Runout87
Cam Chain Tension Adjuster87
Cam Chain Tensioner87
Cam Chain Guide87
Cylinder Head and Valve88
Valve and Valve Spring Disassembly88
Cylinder Head Distortion89
Valve Stem Runout89
Valve Head Radial Runout89
Valve Face Wear89
Valve Stem Deflection90
Valve Stem Wear90
Valve Guide Servicing90
Valve Seat Width Inspection91
Valve Seat Servicing92
Initial Seat Cut92
Top Narrowing Cut93
Bottom Narrowing Cut93
Final Seat Cut93
Valve Stem End Condition95
Valve Spring95
Valve and Valve Spring Reassembly96
Intake Pipe97
Exhaust Pipe98
Water Union98
Cylinder Distortion98
Cylinder Bore98
Piston and Piston Ring99
Piston Diameter99
Piston-To-Cylinder Clearance99
Piston Ring-To-Groove Clearance99
Piston Ring Free End Gap and Piston Ring End Gap100
Oversize Piston Ring100
Oversize Oil Ring100
Piston Ring Reassembly101
Piston Pins and Pin Bore102
Conrod and Crankshaft102
Conrod Small End I.D.102
Conrod Big End Side Clearance103
Conrod Removal and Bearing Inspection103
Conrod-Crank Pin Bearing Selection104
Bearing Selection Table104
Conrod I.D.105
Crank Pin O.D.105
Bearing Thickness105
Conrod and Bearing Reassembly105
Crankshaft Journal Bearing106
Inspection106
Selection107
Crank Shaft Journal I.D.107
Replacement108
Removal108
Installation109
Crankshaft Thrust Bearing112
Bearing and Oil Seal113
Bearing Remover Attachment114
Bearing Installer Attachment114
Oil Pressure Switch115
Oil Pressure Regulator116
Oil Strainer Cleaning116
Oil Plate117
Oil Jet118
Gearshift Arm Stopper119
Clutch Drive Plates120
Clutch Driven Plates120
Clutch Spring120
Clutch Bearing Inspection121
Primary Driven Gear Assembly121
Gearshift Shaft/Gearshift Arm122
Countershaft Disassembly123
Driveshaft Disassembly124
Gearshift Fork to Groove Clearance128
Gearshift Fork Groove Width128
Gearshift Fork Thickness128
Starter Clutch129
Generator and Signal Generator130
Oil Pump Inspection131
Engine Reassembly132
Gearshift132
Engine Sprocket Spacer135
Cam Chain Drive Sprocket137
Cylinder151
Cam Timing156
Front Camshaft156
Rear Camshaft160
Camchain Tension Adjuster162
Fuel and Lubrication System167
Fuel System168
Fuel Pump Operation169
Intake Process169
Discharge Process169
Control of Fuel Pressure169
Fuel Tank Lift-Up170
Fuel Tank171
Remounting172
Vacuum Fuel Valve172
Inspection and Cleaning173
Fuel Level Indicator Light Switch174
Fuel Pump175
Carburetor Construction177
I.D. No. Location179
Diaphragm and Pistor Operation180
Slow System181
Transient Enrichment System181
Main System182
Starter (Enricher) System183
Float System183
Carburetor184
Disassembly186
Carburetor Cleaning193
Carburetor Inspection193
Needle Valve Inspection193
Fuel Filter Inspection194
Float Height Adjustment194
Throttle Position Sensor Inspection194
Carburetor Heater Inspection (Only for E-02 Model)195
Carburetor Heater-Switch Inspection (Only for E-02 Model)195
Reassembly and Remounting196
(Only for E-02 Model)196
Carburetor Heater (Only for E-02 Model)196
Coasting Valve197
Funnel197
Pilot Screw197
Carburetor Top Cap197
Throttle Position Sensor Positioning199
Carburetor Clamps200
Carburetor Synchronization201
Calibrating each Gauge201
Fuel Level Adjustment204
Oil Strainer205
Engine Lubrication System Chart206
Engine Lubrication System207
Front Cylinder View207
Rear Cylinder View208
Cooling System209
Engine Coolant210
Cooling Circuit Inspection211
Radiator and Water Hoses212
Radiator Removal212
Radiator Cap Inspection213
Radiator Inspection and Cleaning213
Water Hose Inspection213
Radiator Remounting214
Cooling Fan214
Cooling Fan Thermo-Switch215
Engine Coolant Temperature Switch216
Thermostat217
Water Pump220
Bearing223
Mechanical Seal223
Oil Seal224
Seal Washer224
Reassembly and Installation224
Chassis229
Exterior Parts Construction230
Rear Seat231
Frame Side Cover231
Front Seat231
Front Fender231
Seat Tail Cover232
Front Wheel Construction233
Speed Sensor236
Wheel Bearing236
Front Wheel236
Front Axle236
Brake Disc237
Front Fork Construction239
Inner and Outer Tubes242
Fork Spring242
Steering Construction247
Handlebars248
Steering Removal251
Steering Inspection and Disassembly252
Steering Installation254
Steering Tension Adjustment256
Rear Wheel Construction257
Wheel Damper260
Rear Wheel260
Rear Axle260
Sprocket261
Rear Suspension Construction265
Rear Shock Absorber and Cushion Rod267
Spacer267
Rear Shock Absorber268
Swingarm269
Chain Buffer271
Swingarm Pivot Shaft271
Suspension Setting273
Spring Pre-Load Adjustment273
Front Brake Construction274
Brake Fluid Replacement275
Brake Pad Replacement276
Front Brake Caliper276
Brake Caliper Inspection277
Brake Caliper Piston Inspection277
Front Master Cylinder279
Rear Brake Construction283
Rear Brake Caliper285
Rear Master Cylinder289
Tire and Wheel292
Tire Removal292
Wheel Inspection292
Tire Inspection292
Valve Inspection293
Valve Installation293
Tire Installation293
Cold Inflation Tire Pressure294
Electrical System295
Cautions in Servicing296
Connector296
Coupler & Clamp296
Semi-Conductor Equipped Part296
Connecting Battery297
Wiring Procedure297
Using Multi Circuit Tester297
Location of Electrical Components298
Charging System301
Description301
Function of Regulator301
Battery Current Leak Inspection304
Charging Output Inspection304
Generator Coil Resistance Inspection305
Generator No-Load Performance Inspection305
Regulator/Rectifier Inspection305
Starter System and Side-Stand Ignition Interlock System Description306
Starter Motor Removal and Disassembly309
Starter Motor Inspection309
Carbon Brushes309
Commutator310
Armature Coil Inspection310
Oil Seal Inspection310
Starter Motor Reassembly310
Starter Relay Inspection313
Side Stand/Ignition Interlock System Parts Inspection314
Neutral Switch314
Side-Stand Switch315
Turn Signal/Side-Stand Relay315
Side-Stand Relay Inspection315
Diode Inspection316
Ignition System (Digital Ignitor)317
Ignition Coil Primary Peak Voltage319
Ignition Coil Resistance320
Signal Generator Peak Voltage321
Signal Generator322
Speedometer323
Bulb Replacement324
Construction325
Fuel Level Indicator Light Inspection327
Oil Pressure Indicator Light Inspection328
Water Temperature Indicator Light Inspection328
Speed Sensor Inspection329
Relays330
Turn Signal Side-Stand Relay330
Brake Light/Taillight333
Turn Signal Lights333
Switches334
Ignition Switch Removal335
Battery Specifications336
Initial Charging336
Filling Electrolyte336
Servicing337
Recharging Operation338
Servicing Information339
Troubleshooting340
Wiring Diagram (for U.S.A. and Canada Models)348
Wiring Diagram (for E-24 Model)349
Wiring Diagram (for E-02, 04, 17, 18, 22, 25 and 34 Models)350
Wiring Harness, Cable and Hose Routing351
Speed Sensor Lead Wire Routing353
Cable Routing354
Fuel System Hose Routing355
Cooling System Hose Routing357
Front Brake Hose Routing358
Rear Brake Hose Routing359
Pair (Air Supply) System Hose Routing360
Fuel Tank Set-Up361
Special Tools362
Tightening Torque365
Tightening Torque Chart368
Service Data369
Valve + Guide369
Camshaft + Cylinder Head370
Conrod + Crankshaft371
Transmission + Drive Chain372
Thermostat + Radiator + Fan + Coolant372
Wattage374
Brake + Wheel375
Tire376
Suspension376
Fuel + Oil377
Emission Control Information378
Emission Control Carburetor Components379
Evaporative Emission Control System (California Model Only)380
Canister Hose Routing (California Model Only)381
Hoses382
Canister382
Tank Pressure Control Valve382
Pair (Air Supply) System Diagram383
Hoses and Pipes385
Reed Valve of Pair Control Valve385
Pair Control Valve385
SV650Y ('00-Model)386
Cylinder + Piston + Piston Ring389

Suzuki 1999 SV650 - Piston Ring Free End Gap and Piston Ring End Gap; Oversize Piston Ring; Oversize Oil Ring

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