Suzuki SV650 99 - Generator and Signal Generator

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Main Page

Group Index2
To Locate What You Are Looking for3
Component Parts and Work to be Done3
Symbol4
General Information5
Warning/Caution/Note6
General Precautions6
Right Side8
Left Side8
Serial Number Location8
Fuel9
Engine Oil9
Brake Fluid9
Front Fork Oil9
Engine Coolant10
Water for Mixing10
Anti-Freeze/Engine Coolant10
Liquid Amount of Water/Engine Coolant10
Information Labels11
Specifications12
Dimensions and Dry Mass12
Country and Area Codes14
Periodic Maintenance15
Periodic Maintenance Schedule16
Periodic Maintenance Chart16
Lubrication Points17
Maintenance and Tune-Up Procedures18
Air Cleaner18
Spark Plug19
Spark Plug Removal19
No.2 Spark Plug Removal20
Heat Range21
Carbon Deposits21
Spark Plug Gap21
Electrode's Condition21
Tappet Clearance22
Tappet Clearance Adjustment24
Intake Side25
Exhaust Side26
Engine Oil and Oil Filter27
Engine Oil Replacement27
Oil Drain Plug27
Oil Filter Replacement28
Oil Filter Wrench28
Necessary Amount of Engine Oil28
Fuel Hose29
Engine Idle Speed29
Carburetor Synchronization29
Pair System29
Throttle Cable Play30
Clutch Cable Play31
Cooling System32
Engine Coolant Level Check32
Engine Coolant Change32
Air Bleeding the Cooling Circuit33
Radiator Hoses33
Drive Chain34
Checking34
Cleaning and Lubricating35
Brake36
Brake Fluid Level Check36
Brake Pads37
Brake Pedal Height37
Brake Light Switch37
Air Bleeding the Brake Fluid Circuit38
Tires39
Tire Tread Condition39
Tire Pressure40
Tire Type40
Steering40
Cold Inflation40
Front Fork41
Rear Suspension41
Exhaust Pipe Bolt and Nut41
Chassis Bolt and Nut42
Compression Pressure Check44
Compression Pressure Specification44
Low Compressure Pressure44
Overhaul the Engine44
Oil Pressure Check45
Low Oil Pressure45
High Oil Pressure45
Oil Pressure Test Procedure45
Engine46
Engine Components Removable with Engine in Place47
Engine Left Side47
Engine Right Side47
Engine Center47
Engine Removal48
Engine Installation58
Engine Disassembly65
Cylinder Head Cover66
No.1 Camshafts66
No.2 Camshafts68
Front Cylinder Head70
Front Cylinder72
Piston73
Starter Motor73
Oil Filter73
Generator Cover74
Clutch Cover74
Clutch75
Oil Pump77
Gearshift System78
Oil Pipe79
Primary Drive Gear79
Rear Cam Chain80
Generator Rotor80
Front Cam Chain81
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 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
Conrod I.D.105
Crank Pin I.D105
Bearing Thickness105
Conrod and Bearing Reassembly105
Crankshaft Journal Bearing106
Selection107
Bearing Selection Table107
Crank Shaft Journal I.D.107
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 Shaft122
Gearshift Arm122
Countershaft Disassembly123
Driveshaft Disassembly124
Gearshift Fork to Groove Clearance128
Gearshift Fork Groove Width128
Gearshift Fork Thickness128
Starter Clutch129
Generator and Signal Generator130
Engine Reassembly132
Engine Serial Number135
Cam Chain Drive Sprocket137
Camchain Tension Adjuster160
Fuel and Lubrication System165
Fuel System166
Fuel Pump Operation167
Intake Process167
Discharge Process167
Control of Fuel Pressure167
Fuel Tank Lift-Up168
Fuel Tank Removal169
Vacuum Fuel Valve170
Fuel Level Indicator Light Switch172
Fuel Pump Removal173
Carburetor Construction175
Carburetor Specifications176
I.D. No. Location177
Diaphragm and Piston Operation178
Slow System179
Transient Enrichment System179
Main System180
Starter System181
Float System181
Carburetor Removal182
Carburetor Cleaning191
Carburetor Inspection191
Needle Valve Inspection191
Fuel Filter Inspeciton192
Float Height Adjustment192
Throttle Position Sensor Inspection192
Carburetor Heater Inspection193
Carburetor Thermo-Switch Inspection193
Carburetor Heater194
Coasting Valve195
Funnel195
Pilot Screw195
Carburetor Top Cap195
Throttle Position Sensor Positioning197
Carburetor Clamps198
Calibrating each Gauge199
Fuel Level Adjustment202
Fuel Level Gauge202
Fuel Level202
Lubrication System203
Oil Strainer203
Engine Lubrication System Chart204
Engine Lubrication System205
Rear Cylinder206
Cooling Circuit209
Cooling Circuit Inspection209
Radiator and Water Hoses210
Radiator Removal210
Radiator Cap Inspection211
Radiator Inspection and Cleaning211
Water Hose Inspection211
Radiator Remounting212
Cooling Fan Removal212
Cooling Fan Inspection212
Cooling Fan Installation212
Cooling Fan Thermo-Switch213
Engine Coolant Temperature Switch214
Thermostat215
Water Pump Removal and Disassembly218
Bearing Inspection221
Mechanical Seal221
Oil Seal222
Seal Washer222
Chassis227
Exterior Parts Construction228
Rear Seat229
Frame Side Cover229
Front Seat229
Front Fender229
Seat Tail Cover230
Front Wheel Construction231
Speed Sensor234
Wheel Bearings234
Front Wheel234
Front Axle234
Brake Disc235
Wheel Bearing235
Inner and Outer Tubes240
Fork Spring240
Steering Construction245
Handlebars246
Steering Removal249
Steering Inspection and Disassembly250
Steering Installation252
Steering Tension Adjustment254
Rear Wheel255
Wheel Damper258
Sprocket259
Rear Suspension Construction263
Rear Shock Absorber and Cushion Rod265
Spacer265
Bearing265
Rear Shock Absorber266
Swingarm267
Chain Buffer269
Bearing Installer269
Suspension Setting271
Spring Pre-Load Adjustment271
Front Brake Construction272
Brake Fluid Replacement273
Brake Pad Replacement274
Front Brake Caliper274
Brake Caliper Inspection275
Brake Caliper Piston Inspection275
Front Master Cylinder277
Rear Brake281
Tire and Wheel290
Tire Removal290
Wheel Inspection290
Tire Inspection290
Valve Inspection291
Valve Installation291
Tire Installation291
Cold Inflation Tire Pressure292
Electrical System293
Cautions in Servicing294
Connector294
Coupler294
Clamps294
Battery295
Connecting Battery295
Wiring Procedure295
Using Multi Circuit Tester295
Location of Electrical Components296
Charging System299
Function of Regulator299
Battery Runs down Quickly301
Battery Current Leak Inspection302
Charging Output Inspection302
Generator Coil Resistance Inspection303
Generator No-Load Performance Inspection303
Regulator/Rectifier Inspection303
Starter System Description304
Side-Stand/Ignition Interlock System Description304
Side-Stand305
Starter Motor will Not Run306
Starter Motor Removal and Disassembly307
Starter Motor Inspection307
Carbon Brushes307
Commutator308
Armature Coil Inspection308
Oil Seal Inspection308
Starter Motor Reassembly308
Starter Relay Inspection311
Side-Stand/Ignition Interlock System Part Ispection312
Neutral Switch312
Side-Stand Switch313
Turn Signal/Side-Stand Relay313
Side-Stand Relay Inspection313
Diode Inspection314
Ignition System315
No Spark or Poor Spark316
Ignition Coil Primary Peak Voltage317
Ignition Coil Resistance318
Signal Generator Peak Voltage319
Signal Generator320
Speedometer Removal321
Bulb Replacement322
Electrical System Construction323
Fuel Level Indicator Light Inspection325
Oil Pressure Indicator Light Inspection326
Water Temperature Indicator Light Inspection326
Speed Sensor Inspection327
Relays328
Starter Relay328
Turn Signal Side-Stand Relay328
Lamps329
Headlight329
Brake Light/Taillight331
Turn Signal Lights331
Switches332
Ignition Switch332
Lighting Switch332
Starter Button332
Ignition Switch Removal333
Battery Specifications334
Initial Charging334
Filling Electrolyte334
Recharging Operation336
Recharging Time336
Servicing Information337
Compression too Low338
Plugs Not Sparking338
No Fuel Reaching the Carburetors338
Excessive Valve Chatter338
Noise Seems to Come from Crankshaft339
Noise Seems to Come from Transmission339
Noise Seems to Come from Water Pump339
Radiator341
Wiring Diagram346
Wiring Harness Routing349
Wire Harness Routing350
Speed Sensor Lead Wire Routing351
Cable Routing352
Fuel System Hose Routing353
Cooling System Hose Routing355
Front Brake Hose Routing356
Rear Brake Hose Routing357
Pair System Hose Routing358
Fuel Tank Set-Up359
Special Tools360
Tightening Torque363
Tightening Torque Chart366
Service Data367
Valve + Guide367
Camshaft + Cylinder Head368
Conrod + Crankshaft369
Transmission + Drive Chain370
Themrostat + Radiator + Fan + Coolant370
Sv650Y376
Tightening Torque481

Suzuki SV650 99 - Generator and Signal Generator

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