Suzuki freewind - Inspection and Service; Cylinder Head Cover Distortion; Rocker Arm Shaft O.D.;Rocker Arm I.D.; Rocker Arm Installation

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Index2
Symbols4
General Information5
Precautions6
Vehicle View8
Serial Number Location8
Fuel and Oil Recommendation8
Brake Fluid9
Front Fork Oil9
Break-In Procedures9
Information Labels10
Specifications12
Dimensions and Dry Mass12
Engine Specifications12
Transmission Specifications12
Chassis Specifications13
Electrical Specifications13
Capacities13
Country or Area - Series of Symbols14
Periodic Maintenance15
Periodic Maintenance Chart16
Lubrication Points17
Maintenance and Tune-Up Procedures18
Valve Clearance18
Spark Plugs19
Carbon Deposit Check19
Spark Plug Gap19
Electrode's Condition19
Air Cleaner Element20
Idle Speed21
Throttle Cable Play22
Carburetor Synchronization22
Fuel Line23
Clutch23
Engine Oil and Oil Filter24
Necessary Amount of Engine Oil24
Drive Chain25
Brakes27
Brake Fluid Level/Pads/Pedal Height27
Air Bleeding the Brake Fluid Circuit28
Tires29
Steering29
Front Forks30
Rear Suspension30
Exhaust Pipe and Muffler Bolts30
Chassis Bolts and Nuts31
Maintenance Illustrations32
Compression Pressure Check33
Compression Test Procedure33
Oil Pressure Check/Test Procedure34
Engine35
Engine Components Removable with the Engine in Place36
Engine Removal37
Engine Reinstallation41
Engine Disassembly44
Engine Reassembly52
Oil Seals52
Balancer Shaft53
Gearshift Mechanism53
Crankcase54
Cam Driven Gear54
Gearshift Shaft55
Neutral Position Indicator Switch55
Oil Pump56
Cam Chain and Primary Drive Gear/Generator and Starter Motor56
Clutch Installation58
Piston and Cylinder60
Cylinder Head61
Camshaft62
Cylinder Head Cover63
Cylinder Head Cover/Rocker Arm65
Cylinder Head Cover Removal66
Rocker Arm Removal67
Inspection and Service68
Cylinder Head Cover Distortion68
Rocker Arm Shaft O.D./Rocker Arm I.D.68
Rocker Arm Installation68
Cylinder Head Cover Installation69
Camshaft/Cylinder Head/Valves71
Camshaft/Cylinder Head Removal72
Valve Removal73
Inspection and Service - Camshaft/Automatic De-Comp. Assembly73
Camshaft Check74
Camshaft Cam Wear/Journal Wear74
Camshaft Runout75
Cylinder Head Distortion75
Valve Face Wear/Stem Runout75
Valve Head Radial Runout76
Valve Stem Deflection/Wear76
Valve Guide Servicing77
Valve Seat Width77
Valve Seat Servicing78
Valve Stem End Condition80
Valve Spring80
Valve Installation81
Cylinder Head/Camshaft Installation82
Cylinder/Piston83
Cylinder/Piston Removal84
Cylinder Distortion/Bore84
Piston Diameter84
Piston-Cylinder Clearance84
Piston Ring-Groove Clearance85
Piston Ring Free and Gap and Piston Ring End Gap85
Piston/Cylinder Installation86
Oil Ring86
Top Ring and 3Nd Ring86
Piston Pin and Pin Bore86
Starter Motor/Generator Rotor/Gearshift87
Starter Motor Removal88
Generator Rotor Removal88
Gearshift Shaft Removal89
Starter Clutch Inspection89
Starter Torque Limiter89
Generator Rotor Installation90
Gearshift Shaft Installation90
Starter Motor Installation90
Clutch Operations91
Clutch Removal92
Clutch Inspection and Service93
Clutch Drive Plate93
Clutch Driven Plate93
Clutch Spring Free Length93
Clutch Release Bearing94
Clutch Release Pinion and Rack/Clutch Installation94
Gearshift Cam/Transmission95
Gearshift Cam/Transmission Removal96
3Nd Drive Gear Disassemlby96
Gearshift Cam/Transmission Inspection and Service96
Gearshift Fork Groove Clearance96
Transmission/Gearshift Cam Installation97
3Rd Deiven Gear Bushing97
Transmission Diagram98
Balancer Shaft/Crankshaft/Crankcase99
Balancer Shaft/Crankshaft/Crankcase Removal100
Balancer Shaft Disassembly100
Crankshaft Disassembly100
Balancer Shaft/Crankshaft/Crankcase Inspection and Service100
Conrod Deflection and Conrod Big End Side Clearance101
Crankshaft Runout/Balancer Shaft101
Crankshaft Assembly102
Balancer Shaft Assembly102
Crankcase Bearings102
Crankcase/Crankshaft/Balancer Shaft Installation103
Engine Lubrication System104
Oil Filter105
Oil Pump Removal and Disassembly105
Oil Pump Inspection106
Oil Nozzle and Oil Jet Removal107
Oil Nozzle and Oil Jet Inspection/Reassembly108
Oil Sump Filter Removal/Inspection108
Fuel and Lubrication System109
Fuel System110
Fuel Valve Mechanism111
Fuel Valve/Fuel Filter Removal111
Fuel Valve/Fuel Filter Inspection and Cleaning112
Fuel Tank Removal112
Carburetor Construction/Diagram114
Carburetor Specificatons115
Slow System116
Main System117
Diaphragm and Piston Operation118
Upper/Lower Position of Piston Valve118
Piston Valve Lift Control System119
Starter System120
Float System120
Removal121
Disassembly122
Pilot Screw Removal (for E-18 Model)125
Carburetor Cleaning126
Carburetor Inspection127
Needle Valve Inspection127
Float Height/Solenoid Valve Inspection127
V.T.V. Inspection128
Throttle Position Sensor Inspection128
Carburetor Reassembly and Remounting128
Throttle Position Sensor Positioning129
Piston Valve Lift Control System/Carburetor Clamps130
Carburetor Synchronization/Calibrating each Gauge131
Lubrication System and Cooling System133
Oil Pressure/Filter/Sump Filter133
Engine Lubrication/Cylinder Head Cooling System Chart134
Fuel and Lubrication System Diagram135
Oil Cooler Diagram136
Oil Cooler Removal137
Chassis138
Chassis Exterior Parts, Construction139
Chassis Removal - Fairing140
Frame Cover142
Frame Covers and Fairing Remounting142
Front Wheel Diagram143
Front Wheel Removal145
Front Wheel Inspection and Disassembly145
Wheel Bearing145
Front Axle146
Wheel Rim146
Spoke Nipple146
Front Wheel Reassembly and Remounting147
Brake Disc147
Front Fork Diagram/Removal and Disassembly149
Front Fork Inspection152
Fork Spring152
Inner Tube and Outer Tube152
Front Fork Reassembly and Remounting153
Damper Rod Ring153
Outer Tube Metal, Oil Seal and Dust Seal154
Damper Rod Bolt154
Front Oil/Spring155
Front Fork Remounting155
Steering Diagram/Removal and Disassembly156
Steering Inspection160
Steering Reassembly and Remounting161
Bearing Races161
Stem Unit161
Handlebars162
Rear Wheel Diagram163
Rear Wheel Removal164
Wheel Bearing and Sprocket Drum Bearing166
Rear Wheel Reassembly and Remounting167
Rear Axle/Sprocket/Rear Sprocket Damper167
Brake Disc/Rear Axle Nut168
Rear Swingarm and Suspension169
Rear Swingarm and Suspension Reassembling Information170
Rear Swingarm and Suspension Removal171
Rear Swingarm and Suspension Inspection and Disassemlby173
Swingarm173
Cushion Lever173
Rear Swingarm and Suspension Reassembly and Remounting174
Swingarm Bearing174
Cushion Lever Bearing174
Shock Absorber174
Rear Swingarm and Suspension Final Inspection and Adjustment175
Shock Absorber Spring Pre-Load Adjustment175
Shock Absorber Damping Force Adjustment175
Front Brake176
Brake Pad Replacement177
Brake Fluid Replacement177
Caliper Removal and Disassembly178
Caliper Inspection179
Caliper Reassembly and Remounting179
Brake Disc Inspection180
Master Cylinder Removal and Disassembly180
Master Cylinder Inspection182
Master Cylinder Reassembly and Remounting182
Rear Brake Exploded Diagram183
Rear Brake Pad Replacement184
Rear Brake Fluid Replacement184
Rear Brake Caliper Removal and Disassembly185
Rear Brake Caliper and Disc Inspection186
Rear Brake Caliper Reassembly and Remounting186
Rear Brake Master Cylinder Removal and Disassembly187
Rear Brake Master Cylinder Inspection188
Rear Brake Master Reassembly and Remounting188
Lowering the Seat Height189
Front Fork Exploded Diagram190
Front Fork Removal and Disassembly191
To Reassemble and Remount the Front Fork and Fron Wheel193
Rear Shock Absorber197
Rear Shock Absorber Removal and Disassembly198
Side-Stand Exploded Diagram199
Spring Setting Table199
Side-Standing Removal and Installation200
Warning Label200
Electrical System201
Cautions in Servicing the Electrical System202
Connector, Coupler, Clamp, Fuse, Semi-Conductor Equipped Part202
Battery/Connecting Battery203
Wiring Procedure203
Using Multi Circuit Tester203
Location of Electrical Components204
Charging System Description and Schematic Diagram206
Troubleshooting: Battery Runs down Quickly207
Battery Leak Current Inspection208
Charging Output Inspection208
Generator Coil Continuity Inspection209
Generator No-Load Performance Inspection209
Regulator/Rectifier Inspection210
Starter System Description and Schematic Disgram211
Side-Stand/Ignition Interlock System Description and Schematic Disgram211
Troubleshooting: Starter Motor will Not Run213
Starter Motor Removal and Disassembly214
Starter Motor Inspection214
Carbon Brush Inspection214
Commutator/Armature Coil/Oil Seal Inspection215
Starter Motor Reassembly215
Starter Relay Inspection216
Starter Relay Circuit Diagram217
Side-Stand/Ignition Interlock System Inspection217
Diode217
Neutral Switch218
Side-Stand Switch218
Side-Stand/Ignition Interlock Relay219
Clutch Lever Position Switch219
Ignition System Description and Circuit Diagram220
Troubleshooting: no Spark or Poor Spark221
Ignition Coil Primary Peak Voltage Inspection222
Ignition Coil - Checking with Electro Tester223
Ignition Coil Resistance223
Power Source Coil and Pick-Up Coil224
Spark Plug Inspection225
Carbon Deposit, Spark Plug Gap Check225
Combinator Meter Removal/Disassembly226
Combinator Meter Inspection227
Speedometer/Speed Sensor Inspection228
Fuel Meter Inspection229
Fuel Level Gauge Removal/Installation229
Fuel Level Gauge Inspection230
Lamps230
Headlight and Position Light Diagram230
Headlight/Position Light Replacement231
Tail/Brake Light, Turn Signal Light and License Plate Light Exploded Diagram232
Tail/Brake Light Replacement232
Turn Signal Relay233
Turn Signal Light Replacement233
Switches Inspection234
Battery Specifications235
Battery Initial Charging235
Battery Servicing236
Battery Recharging Operation237
Servicing Information238
Troubleshooting - Engine239
Troubleshooting - Carburetor242
Troubleshooting - Chassis242
Troubeshooting - Brakes243
Troubleshooting - Electrical244
Troubleshooting - Battery245
Wiring Diagram for Australia246
Wiring Diagram for the Other Market247
Wire Routing Diagrams248
Cable Routing Diagrams252
Carburetor and Air Cleaner Hose Routing Diagrams254
Pair (Air Supply) System Hose Routing Diagram (for Austria and Switzerland)255
Front Brake Hose Routing Diagrams256
Rear Brake Hose Routing Diagram257
Fuel Tank Water Drain Hose Routing Diagram258
Oil Hose Routing Diagram259
Fairing Set-Up Diagram260
Fuel Tank Cover Set-Up Diagram260
Protector and Heat Shield Adhering261
Side Stand Spring Set-Up262
Special Tools Illustrations263
Tighterning Torque - Engine266
Tighterning Torque - Chassis267
Tighterning Torque for Other Bolts and Nuts Chart268
Service Data - Valve+Guide269
Service Data - Camshsft + Cylinder Head270
Service Data - Cylinder + Piston + Piston Ring270
Service Data - Conrod + Crankshaft/Oil Pump271
Service Data - Clutch/Transmission + Drive Chain272
Service Data - Carburetor273
Service Data - Electrical/Wattage274
Service Data - Brake + Wheel275
Service Data - Suspension/Tire Pressure/Fuel + Oil276
XF650W/UW/X/UX ('98, '99-Models)277
XF650W/UW/X/UX ('98, '99-Models) - Specifications278
XF650W/UW/X/UX ('98, '99-Models) Service Data - Valve+Guide279
XF650W/UW/X/UX ('98, '99-Models) Service Data - Camshaft + Cylinder Head280
XF650W/UW/X/UX ('98, '99-Models) Service Data - Cylinder + Piston + Piston Ring280
XF650W/UW/X/UX ('98, '99-Models) Service Data - Conrod + Crankshaft/Oil Pump281
XF650W/UW/X/UX ('98, '99-Models) Service Data - Clutch/Transmission + Drive Chain282
XF650W/UW/X/UX ('98, '99-Models) Service Data - Carburetor283
XF650W/UW/X/UX ('98, '99-Models) Service Data - Electrical/Wattage284
XF650W/UW/X/UX ('98, '99-Models) Service Data - Brake + Wheel285
XF650W/UW/X/UX ('98, '99-Models) Service Data - Suspension/Tire Pressure/Fuel + Oil286
XF650W/UW/X/UX ('98, '99-Models): Carburetor and Air Cleaner Hose Routing287
XF650W/UW/X/UX ('98, '99-Models): Oil Pump (from X-Model)288
XF650Y (2000-Model)289
XF650Y (2000-Model) Specifications - Dimensions and Dry Mass291
XF650Y (2000-Model) Specifications - Engine/Transmission291
XF650Y (2000-Model) Specifications - Chassis/Electrical/Capacities292
XF650Y (2000-Model) Engine293
XF650Y (2000-Model) Engine Reassembly - Clutch294
XF650Y (2000-Model) Inspection and Service - Clutch Drive Plates/Driven Plates298
XF650Y (2000-Model) Chassis299
XF650Y (2000-Model) Exterior Parts Construction300
XF650Y (2000-Model) Fairing Removal301
XF650Y (2000-Model) Frame Cover Removal/Remounting303
XF650Y (2000-Model) Electrical System304
XF650Y (2000-Model) Lamps/Headlight and Position Light/Bulb Replacement305
XF650Y (2000-Model) Position Light Removal306
XF650Y (2000-Model) Servicing Information307
XF650Y (2000-Model) Wiring Diagram308
XF650Y (2000-Model) Wire Routing309
XF650Y (2000-Model) Front Brake Hose Routing310
XF650Y (2000-Model) Fairing Set-Up311
XF650Y (2000-Model) Service Data - Valve + Guide312
XF650Y (2000-Model) Service Data - Camshaft + Cylinder Head/Cylinder + Piston + Piston Ring313
XF650Y (2000-Model) Service Data - Conrod + Crankshaft/Oil Pump314
XF650Y (2000-Model) Service Data - Clutch/Transmission + Drive Chain315
XF650Y (2000-Model) Service Data - Carburetor316
XF650Y (2000-Model) Service Data - Electrical/Wattage317
XF650Y (2000-Model) Service Data - Brake + Wheel318
XF650Y (2000-Model) Service Data - Suspension/Tire Pressure/Fuel + Oil319
XF650K1 ('01-Model)320
XF650K1 ('01-Model) Specifications321
XF650K1 ('01-Model) Service Data - Valve + Guide/Camshaft + Cylinder Head322
XF650K1 ('01-Model) Service Data - Cylinder + Piston + Piston Ring/Conrod + Crankshaft/Oil Pump323
XF650K1 ('01-Model) Service Data - Clutch/Transmission + Drive Chain/Carburetor324
XF650K1 ('01-Model) Service Data - Electrical325
XF650K1 ('01-Model) Service Data - Wattage/Brake + Wheel326
XF650K1 ('01-Model) Service Data - Suspension/Tire Pressure/Fuel + Oil327
WP Shock Absorber331
WP Suspension Shock Absorber Set-Up and Adjustment333
Spring Preload333
Preload334
Adjusting the Damping334
The Ideal Setting335
Adjustment Guidelines335
WP Suspension Shock Absorber Maintenance336
After each Race/Longer Period of Time336
Workshop336
Dismantling the Spring337
Removing Nitrogen Pressure338
Draining the Oil338
Dismantling the Spindle339
Fitting the Spindle339
Refilling the Oil/Fitting the Spindle340
Dismantling the CC Mechanism341
Bleeding341
Fitting the CC Mechanism342
Refilling the Nitrogen342
Checking the Shock Absorber342
WP Suspension Shock Absorber Troubleshooting343
MXMA Front Fork Adjustments344
MXMA Front Fork Spring and Spring Pre-Load345
MXMA Front Fork - Changing the Oil346
MXMA Front Fork - Regular Maintenance/Troubleshooting347

Suzuki freewind - Inspection and Service; Cylinder Head Cover Distortion; Rocker Arm Shaft O.D.;Rocker Arm I.D.; Rocker Arm Installation

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