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Suzuki freewind User Manual

Suzuki freewind
349 pages
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Service Manual
XF650 Freewind
(CCM 644 Engine)

Table of Contents

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Suzuki freewind Specifications

General IconGeneral
Front SuspensionTelescopic, coil spring, oil damped
Rear SuspensionLink-type, coil spring, oil damped
Front BrakesSingle disc
Rear BrakesSingle disc
Front Tire100/90-19
Rear Tire130/80-17
IgnitionElectronic ignition
Fuel Capacity18.0 L
Cooling SystemAir/Oil cooled
Transmission5-speed

Summary

GENERAL INFORMATION

Safety Information

Covers essential safety warnings, cautions, notes, and general precautions for motorcycle maintenance.

Model Specifics and Identification

Details specific information for model variants and shows the location of serial numbers.

Fluid Recommendations and Break-in Procedures

Details recommended fluids, their types, and procedures for breaking in the motorcycle.

Technical Specifications

Lists detailed technical specifications of the motorcycle, including dimensions and engine details.

Country and Area Codes

Provides a list of country or area codes corresponding to specific symbols used in the manual.

PERIODIC MAINTENANCE

Maintenance Schedule and Chart

Provides the recommended schedule and chart for routine maintenance tasks.

Lubrication Points

Illustrates key lubrication points on the motorcycle with diagrams.

Engine and Fuel System Maintenance

Covers maintenance for valve clearance, spark plugs, air cleaner, idle speed, throttle, fuel line, clutch, engine oil/filter, and drive chain.

Chassis and Suspension Maintenance

Covers maintenance for brakes, tires, steering, front forks, rear suspension, exhaust/muffler bolts, and chassis bolts.

Engine Performance Checks

Covers procedures for checking engine compression and oil pressure.

ENGINE

Engine Components Overview

Lists engine components that can be removed with the engine still in place.

Engine Removal and Reinstallation

Provides detailed steps for removing and reinstalling the engine.

Engine Disassembly and Reassembly

Covers the procedures for disassembling and reassembling the engine.

CAMSHAFT/CYLINDER HEAD/VALVES

Cylinder Head Cover and Rocker Arm Service

Details procedures for removing, inspecting, and installing the cylinder head cover and rocker arm.

Camshaft and Valve Procedures

Covers removal, inspection, service, and installation of camshaft and valve components.

Cylinder and Piston Procedures

Details procedures for cylinder and piston removal, inspection, and installation.

STARTER MOTOR/GENERATOR ROTOR/GEARSHIFT

Starter Motor and Generator Rotor Service

Covers removal, installation, and inspection of the starter motor and generator rotor.

Gearshift Shaft Service

Details the removal, installation, and inspection of the gearshift shaft.

Starter Clutch Service

Covers inspection and service procedures for the starter clutch.

CLUTCH

Clutch Removal

Provides steps for removing the clutch assembly.

Clutch Inspection and Service

Details inspection and service procedures for clutch components.

Clutch Installation

Provides steps for installing the clutch assembly.

GEARSHIFT CAM/TRANSMISSION

Gearshift Cam/Transmission Removal

Covers procedures for removing the gearshift cam and transmission components.

Gearshift Fork and Groove Inspection

Details inspection of gearshift fork groove clearance and width.

Transmission/Gearshift Cam Installation

Covers steps for installing the transmission and gearshift cam.

BALANCER SHAFT/CRANKSHAFT/CRANKCASE

Removal Procedures

Details steps for removing the balancer shaft, crankshaft, and crankcase.

Disassembly and Inspection

Covers disassembly of balancer shaft, crankshaft, and inspection of conrod components.

Assembly and Installation

Covers procedures for assembling and installing the crankshaft, balancer shaft, and crankcase.

ENGINE LUBRICATION SYSTEM

Oil Filter Service

Provides procedures for oil filter removal and installation.

Oil Pump Procedures

Covers oil pump removal, disassembly, inspection, assembly, and installation.

Oil Nozzle and Sump Filter Service

Provides procedures for servicing oil nozzles, jets, and the oil sump filter.

FUEL AND LUBRICATION SYSTEM

Fuel System Overview

Introduces the fuel system components and their functions.

Carburetor Operation and Service

Covers carburetor construction, specifications, operation, removal, disassembly, cleaning, and synchronization.

Lubrication and Cooling Systems

Details the engine lubrication system, cooling system, and oil cooler components.

CHASSIS

Exterior Parts Construction

Provides an exploded view of the motorcycle's exterior parts construction.

Fairing and Frame Cover Procedures

Details procedures for removing and remounting fairing and frame covers.

Front Wheel and Fork Procedures

Covers removal, disassembly, inspection, and reassembly of the front wheel and fork.

Steering Procedures

Details procedures for removing, inspecting, and reassembling steering components.

Rear Wheel and Swingarm Procedures

Covers removal, inspection, and reassembly of the rear wheel, bearings, and swingarm.

Front Brake Procedures

Details procedures for front brake pad and fluid replacement, caliper service, and master cylinder service.

Rear Brake Procedures

Details procedures for rear brake pad and fluid replacement, caliper service, and master cylinder service.

Rear Shock Absorber Service

Covers removal, disassembly, inspection, and reassembly of the rear shock absorber.

ELECTRICAL SYSTEM

Servicing Cautions and Component Location

General cautions for electrical system servicing and location of components like battery, fuses, and starter.

Charging System

Details the charging system, its description, troubleshooting, and inspection.

Starter, Side-Stand, and Ignition Systems

Covers starter, side-stand, and ignition systems including their descriptions, troubleshooting, and inspections.

Meters and Lamps

Covers combination meter, speedometer, fuel meter, and lamp bulb replacement procedures.

Switches and Battery

Provides information on switches, turn signal relay, and battery specifications and servicing.

SERVICING INFORMATION

Troubleshooting

A guide to diagnosing and resolving common motorcycle issues across engine, chassis, and electrical systems.

Wiring and Component Routing

Diagrams and instructions for routing electrical wires, cables, and hoses.

Assembly and Setup Information

Procedures for setting up fairings, covers, protectors, and side stand springs.

Tools, Torque, and Service Data

Information on special tools, tightening torques, and general service data.

XF650W/UW/X/UX ('98, '99-MODELS)

Specifications

Detailed technical specifications for the specified XF650W/UW/X/UX models.

Service Data

Provides service data for various components specific to these models.

Carburetor and Hose Routing

Information on carburetor and air cleaner hose routing for these models.

Oil Pump

Details regarding the oil pump for the XF650W/UW/X/UX models.

XF650Y (2000-MODEL)

Specifications

Detailed technical specifications for the 2000-model XF650Y.

Service Data

Provides service data for various components of the 2000-model.

Chassis Information

Details related to the chassis of the 2000-model XF650Y.

Electrical System

Information on the electrical system of the 2000-model XF650Y.

Servicing Information

General servicing information for the 2000-model XF650Y.

ENGINE

Engine Reassembly

Provides steps for reassembling the engine for the 2000-model.

Clutch Inspection and Service

Details procedures for inspecting and servicing the clutch for the 2000-model.

CHASSIS

Exterior Parts Construction

Exploded view of exterior parts construction for the 2000-model.

Removal and Remounting Procedures

Covers removal and remounting procedures for chassis components of the 2000-model.

ELECTRICAL SYSTEM

Lamps

Information regarding motorcycle lamps for the 2000-model.

Headlight and Position Light

Procedures for headlight and position light bulb replacement for the 2000-model.

SERVICING INFORMATION

Wiring Diagram

Wiring diagram for the 2000-model motorcycle.

Wire, Cable, and Hose Routing

Information on routing wires, cables, and hoses for the 2000-model.

Fairing Set-up

Procedures for setting up the fairing components for the 2000-model.

Service Data

General service data for the 2000-model.

XF650K1 ('01-MODEL)

Specifications

Detailed technical specifications for the 2001-model XF650K1.

Service Data

Provides service data for various components of the 2001-model.

SERVICE DATA

Valve and Guide Specifications

Service data for valve and guide measurements for the 2001-model.

Camshaft and Cylinder Head Data

Service data for camshaft and cylinder head measurements for the 2001-model.

Cylinder, Piston, and Piston Ring Data

Service data for cylinder, piston, and piston ring specifications for the 2001-model.

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