Suzuki SV650/S - Front Brake Construction

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Main Page

Foreword3
Group Index3
How to Use this Manual4
To Locate What You Are Looking for4
Component Parts and Work to be Done4
Symbol5
Abbreviations Used in this Manual6
SAE-To-Former Suzuki Term8
Wire Color10
General Information11
Contents11
Warning/Caution/Note12
General Precautions12
Product View14
Suzuki SV650 ('03-Model) View14
Suzuki SV650S ('03-Model) View14
Serial Number Location15
Liquid Amount of Water/Engine Coolant16
Anti-Freeze/Engine Coolant16
Water for Mixing16
Brake Fluid16
Break-In Procedures17
Cylinder Identification17
Information Labels18
Specifications19
Dimensions and Dry Mass19
Drive Train19
Capacities20
Electrical20
Country and Area Codes21
Periodic Maintenance22
Periodic Maintenance Schedule23
Periodic Maintenance Chart23
Lubrication Points25
Maintenance and Tune-Up Procedures26
Air Cleaner26
Front Spark Plug Removal27
Heat Range28
Rear Spark Plug Removal28
Spark Plug Gap29
Electrode's Condition29
Spark Plug Installation29
Carbon Deposits29
Tappet Clearance30
Tappet Clearance Adjustment32
Intake Side33
Tappet Shim Selection Table (Intake)33
How to Use this Chart33
Exhaust Side34
Tappet Shim Selection Table (Exhaust)34
Engine Oil and Oil Filter35
Engine Oil Replacement35
Oil Filter Replacement36
Evaporative Emission Control System (E-33 Only)37
Pair (Air Supply) System37
Engine Idle Speed/Throttle Valve Synchronization37
Fuel Hose37
Throttle Cable Play38
Minor Adjustment38
Major Adjustment39
Clutch40
Engine Coolant Level Check41
Engine Coolant Change41
Air Bleeding the Cooling Circuit42
Drive Chain43
Radiator Hoses43
Checking44
Adjusting45
Cleaning and Lubricating46
Brake Fluid Level Check47
Brake Pads48
Brake Pedal Height48
Brake Light Switch48
Air Bleeding from Brake Fluid Circuit49
Tire Tread Condition50
Steering51
Tire Pressure51
Front Fork52
Rear Suspension52
Exhaust Pipe Bolt and Nut52
Chassis Bolts and Nuts53
Compression Pressure Check55
Compression Pressure Specification55
Compression Test Procedure55
Oil Pressure Test Procedure56
Oil Pressure Specification56
Oil Pressure Check56
Engine57
Engine Components Removable with the Engine in Place58
Engine Left/Right Side58
Engine Center58
Engine Removal59
Engine Installation70
Engine Disassembly79
Engine Top Side79
Cylinder Head Cover80
Front Camshafts81
Front Cylinder Head82
Front Cylinder/Piston83
Rear Camshafts83
Rear Cylinder Head85
Rear Piston86
Starter Motor86
Engine Botton Side86
Oil Filter/Generator Cover86
Clutch Cover87
Oil Pump89
Gearshift System90
Oil Pipe91
Primary Drive Gear91
Rear Cam Chain92
Generator Rotor92
Front Cam Chain93
Gear Position Switch93
Crankcase94
Crankshaft95
Transmission95
Engine Components Inspection and Service96
Cylinder Head Cover Disassembly/Inspection/Reassembly96
Camshaft/Camshaft Journal97
Cam Wear98
Camshaft Journal Wear98
Cam Chain Tensioner99
Cam Chain Tension Adjuster99
Camshaft Runout99
Cam Chain Guide100
Cylinder Head and Valve100
Valve and Valve Spring Disassembly100
Cylinder Head Distortion101
Valve Stem Runout101
Valve Head Radial Runout102
Valve Face Wear102
Valve Stem Deflection102
Valve Stem Wear102
Valve Guide Servicing103
Valve Seat Width Inspection104
Valve Seat Servicing104
Initial Seat Cut105
Top Narrowing Cut105
Bottom Narrowing Cut105
Final Seat Cut106
Valve Stem End Condition107
Valve Spring107
Valve and Valve Spring Installation108
Cylinder Distortion109
Cylinder Bore109
Piston and Piston Ring110
Piston Diameter110
Piston-To-Cylinder Clearance110
Piston Ring-To-Groove Clearance110
Piston Ring Free End Gap and Piston Ring End Gap111
Oversize Piston Ring111
Conrod Small End I.D.112
Oversize Oil Ring112
Conrod and Crankshaft112
Piston Pins and Pin Bore112
Conrod Big End Side Clearance113
Conrod Big End Width113
Crank Pin Width113
Conrod Removal and Bearing Inspection113
Conrod-Crank Pin Bearing Selection114
Bearing Selection Table114
Conrod and Bearing Reassembly115
Crank Pin O.D.115
Bearing Thickness115
Conrod I.D.115
Oil Pressure Regulator116
Oil Pressure Switch117
Oil Strainer117
Oil Jet Removal118
Inspection and Cleaning119
Gearshift Arm Stopper119
Crankshaft Journal Bearing Inspection/Selection120
Crank Shaft Journal I.D.120
Replacement121
Crankcase Bearing and Oil Seal Inspection/Removal125
Bearing Remover Attachment126
Crankcase Bearing and Oil Seal Installation127
Bearing Installer Attachment127
Clutch Drive Plates128
Clutch Driven Plates128
Clutch Spring128
Primary Driven Gear Assembly129
Clutch Bearing Inspection129
Clutch Sleeve Hub/Primary Driven Gear Assembly129
Gearshift Shaft/Gearshift Arm Reassembly130
Countershaft Disassembly131
Driveshaft Disassembly132
Gearshift Fork to Groove Clearance137
Gearshift Fork Groove Width137
Gearshift Fork Thickness137
Starter Clutch Inspection/Disassembly/Reassembly138
Generator and Signal Generator139
Oil Pump Inspection140
Clutch Release Inspection140
Engine Reassembly141
Engine Bottom Side141
Transmission141
Gearshift141
Oil Plate143
Engine Sprocket Spacer143
Cam Chain Drive Sprocket145
Generator Cover152
Oil Filter152
Piston153
Oil Jet155
Cylinder155
Cylinder Head156
Cam Shaft158
Camchain Tension Adjuster163
Front Cylinder TDC of Compression Stroke164
Exhaust Pipe166
Water Union166
Intake Pipe166
Generator Cover Plug167
Thermostat Case and Water Hose167
Spark Plug and Hose167
FI System Diagnosis168
Connector/Coupler170
Electrical Parts170
Precautions in Servicing170
Fuse171
Ecm/Various Sensors171
Electrical Circuit Inspection Procedure173
Open Circuit Check173
Continuity Check174
Voltage Check174
Short Circuit Check (Wire Harness to Ground)175
Using the Testers176
FI System Technical Features177
Injection Time (Injection Volume)177
Compensation of Injection Time (Volume)178
Injection Stop Control178
FI System Parts Location179
FI System Wiring Diagram181
Self-Diagnosis Function182
User Mode182
Dealer Mode183
TPS Adjustment184
Fail-Safe Function185
FI System Troubleshooting186
Self-Diagnostic Procedures188
Self-Diagnosis Reset Procedure188
Malfunction Code and Defective Condition189
"C12" CKP Sensor Circuit Malfunction191
"C13" IAP Sensor Circuit Malfunction193
Output Voltage195
"C14" TP Sensor Circuit Malfunction196
"C15" ECT Sensor Circuit Malfunction199
"C21" IAT Sensor Circuit Malfunction201
"C23" to Sensor Circuit Malfunction203
"C28" STV Actuator Circuit Malfunction205
"C29" STP Sensor Circuit Malfunction206
"C31" Gear Position (GP) Switch Circuit Malfunction209
"C32" or "C33" Fuel Injector Circuit Malfunction210
"C41" FP Relay Circuit Malfunction212
"C42" IG Switch Circuit Malfunction212
"C49" Pair Control Solenoid Valve Circuit Malfunction213
CKP Sensor Inspection/Removal/Installation215
IAP Sensor Inspection/Removal/Installation215
TP Sensor Inspection/Removal/Installation215
ECT Sensor Inspection/Removal/Installation215
IAT Sensor Inspection/Removal/Installation216
To Sensor Inspection/Removal/Installation216
STP Sensor Inspection/Removal/Installation216
Fuel System and Throttle Body217
Fuel Delivery System218
Fuel System218
Fuel Pump219
Fuel Pressure Regulator220
Fuel Injector220
Fuel Pump Control System221
Fuel Tank Lift-Up222
Fuel Tank Removal222
Fuel Pressure Inspection224
Fuel Discharge Amount Inspection225
Fuel Pump Inspection225
Fuel Pump Relay Inspection226
Fuel Pump and Fuel Filter Removal226
Fuel Mesh Filter Inspection and Cleaning228
Fuel Pump Case Bushing Inspection228
Fuel Pump and Fuel Mesh Filter Installation229
Throttle Body and STV Actuator Construction231
Air Cleaner and Throttle Body Removal232
Air Cleaner Box232
Throttle Body233
Throttle Body Disassembly235
Throttle Body Cleaning239
Throttle Body Inspection240
Throttle Body Reassembly240
STV Synchronization244
Throttle Body Installation245
STP Sensor Adjustment245
Air Cleaner Box Installation246
TP Sensor Adjustment246
Fast Idle Inspection247
Fast Idle Adjustment248
Throttle Valve Synchronization249
Calibrating each Gauge (for Vacuum Balancer Gauge)249
Cooling and Lubrication System252
Engine Coolant254
Cooling Circuit Inspection255
Radiator Removal256
Radiator Inspection/Cleaning/Installation258
Water Hose Inspection259
Radiator Cap Inspection259
Cooling Fan Inspection/Removal/Installation260
Cooling Fan Thermo-Switch261
Engine Coolant Temperature Sensor262
Temperature Sensor Specification262
Thermostat Removal/Inspection264
Thermostat Installation265
Water Pump Removal and Disassembly266
Mechanical Seal268
Water Pump Inspection268
Oil Seal269
Bearing Case269
Reassembly and Installation269
Oil Cooler Removal/Inspection and Cleaning273
Oil Cooler Installation274
Engine Lubrication Flow Chart275
Engine Lubrication Circuit276
Front Cylinder276
Rear Cylinder277
Chassis278
Exterior Parts280
Construction280
Rear/Front Seat282
Frame Side Cover282
Front Fender282
Pillon Rider Handle282
Seat Tail Cover283
Cowling and Cowling Brace (SV650S)284
Front Wheel Construction286
Front Wheel Removal287
Dust Seal288
Front Axle288
Wheel288
Speed Sensor289
Wheel Bearing289
Reassembly and Remounting290
Brake Disc292
Brake Caliper293
Front Fork Construction294
Front Fork Removal and Disassembly295
Front Fork Inspection297
Inner and Outer Tubes297
Fork Spring297
Metals and Seals298
Cylinder Bolt299
Fork Oil300
Suspension Setting302
Spring Pre-Load Adjustment302
Steering and Handlebar Construction303
Steering and Handlebar Removal304
Handlebars (SV650S)304
Handlebars (SV650)305
Steering Stem (SV650S)306
Steering Stem (SV650)307
Outer Races311
Steering Stem311
Handlebar Balancer Installation Information317
Steering Tension Adjustment318
Rear Wheel Construction319
Rear Wheel Removal320
Rear Wheel Inspection and Disassembly321
Wheel Damper321
Sprocket321
Bearing322
Rear Wheel Reassembly and Remounting324
Rear Sprocket326
Chain Cover327
Rear Axle327
Rear Shock Absorber Construction328
Rear Shock Absorber Removal329
Rear Shock Absorber Inspection330
Gas Pressure Release330
Rear Shock Absorber Remounting331
Rear Swingarm Construction332
Rear Swingarm Removal333
Chain Buffer334
Spacer334
Rear Swingarm Inspection and Disassembly334
Swingarm Bearing335
Swingarm Pivot Shaft336
Cushion Lever Bearing336
Cushion Rods336
Swingarm Reassembly337
Swingarm Remounting339
Cushion Lever and Cushion Rod340
Final Inspection and Adjustment340
Front Brake Construction341
Brake Pad Replacement342
Brake Fluid Replacement343
Caliper Removal and Disassembly344
Caliper Inspection345
Brake Caliper Piston345
Caliper Holder345
Piston Seal346
Caliper Reassembly and Remounting346
Rubber Parts346
Brake Disc Inspection347
Master Cylinder Removal and Disassembly (SV650S)348
Master Cylinder Removal and Disassembly (SV650)350
Master Cylinder Inspection352
Master Cylinder Reassembly and Remounting (SV650S)352
Master Cylinder Removal and Remounting (SV650)354
Rear Brake Construction356
Brake Caliper Sliding Pin361
Sliding Pin362
Cylinder, Piston and Cup Set365
Tire and Wheel367
Tire Removal367
Inspection Wheel/Tire367
Valve Inspection368
Valve Installation368
Tire Installation369
Electrical System371
Clamp373
Coupler373
Connector373
Cautions in Servicing373
Semi-Conductor Equipped Part374
Connecting the Battery374
Wiring Procedure374
Using the Multi Circuit Tester375
Location of Electrical Components376
Charging System378
Regulated Voltage380
Battery Current Leakage380
Generator Coil Resistance381
Generator No-Load Performance381
Regulator/Rectifier382
Starter System and Side-Stand/Ignition Interlock System383
Starter Motor Removal and Disassembly385
Starter Motor Inspection386
Carbon Bruch386
Commutator386
Armature Coil/Oil Seal Inspection386
Starter Motor Reassembly387
Starter Relay Inspection390
Side Stand/Ignition Interlock System Parts Inspection391
Side-Stand Switch391
Gear Position Switch Voltage392
Turn Signal/Side-Stand Relay392
Side-Stand Relay Inspection393
Diode Inspection393
Ignition System394
Ignition Coil Primary Peak Voltage396
Ignition Coil Resistance397
CKP Sensor Peak Voltage398
CKP Sensor Resistance399
Combination Meter Removal400
Led (Light Emitting Diode)403
Tachometer403
Engine Coolant Temperature Meter and Indicator405
Fuel Level Switch Inspection406
Fuel Level Indicator406
Oil Pressure Indicator407
Speed Sensor Removal/Installation408
Speed Sensor Inspection409
Lamps410
Headlight Beam Adjustment410
Bulb Replacement410
Brake Light/Taillight414
Turn Signal Light415
Relays416
Ignition Switch Removal/Installation417
Ignition Switch Inspection418
Battery Specification419
Initial Charging419
Filing Electrolyte419
Servicing421
Recharging Operation421
Servicing Information422
Troubleshooting423
Radiator (Cooling System)430
Brakes432
Battery434
Wire Harness, Cable and Hose Routing435
Cable Routing (SV650)435
Cable Routing (SV650S)436
Wire Harness Routing437
Wire Harness Routing (SV650S Only)438
Speed Sensor Lead Wire Routing439
Throttle Body Installation/Hose Routing440
Fuel System Hose Routing441
Battery Cushion Installation442
Cooling System Hose Routing443
Pair System Hose Routing445
Fuel Tank Installation446
Brake Pedal/Footrest Set-Up447
Side-Stand Set-Up449
Engine Electrical Parts Set-Up450
Seat Lock Cable Routing451
Head Shield Installation452
Front Brake Hose Routing for SV650453
Front Brake Hose Routing for SV650S454
Rear Brake Hose Routing for SV650455
Rear Brake Hose Routing for SV650S456
Special Tools457
Tightening Torque461
FI System Parts462
Tightening Torque Chart464
Service Data465
Valve + Guide465
Camshaft + Cylinder Head466
Cylinder + Piston + Piston Ring467
Conrod + Crankshaft468
Transmission + Drive Chain469
Thermostat + Radiator + Fan + Coolant470
Injector + Fuel Pump + Fuel Pressure Regulator470
FI Sensors + Secondary Throttle Valve Actuator471
Wattage473
Brake + Wheel474
Suspension475
Tire475
Fuel + Oil476
Emission Control Information477
Emission Control Systems478
Fuel Injection System478
Crankcase Emission Control System479
Exhaust Emission Control System (Pair System)480
Noise Emission Control System481
Evaporative Emission Control System (Only for E-33)481
Pair Reed Valve482
Pair (Air Supply) System Inspection482
Hoses482
Pair Control Solenoid Valve483
Evap Canister484
Tank Pressure Control Valve484
Evap Canister Hose Routing (Only for E-33)485
Wiring Diagram486
SV650 (for E-03, 24, 28, 33)486
SV650 (for E-02, 19)488
SV650S (for E-03, 24, 28, 33)490
SV650S (for E-02, 19)492
Instruction for Quoting the Catalogue496
Dimension496
Abbreviations496
Modification Notice/Serial Frame Number496
Millimeter-Inch Conversion Chart502
Color Code Chart504
Table of Contents571
Preface572
A Practical Understanding of Lead Acid Batteries572
Battery Basics and Safety573
About this Book573
About YUASA573
Standard Features574
The Lead Acid Battery574
- Points to Remember575
- Yuasa’s Conventional Battery576
The YUASA Battery Line576
Yumicron Battery576
Yumicron CX Battery577
Sealed VRLA Battery577
Battery Safety578
Selecting and Installing a New Battery579
Selecting the Proper Battery579
Cut-Away View of Sensor580
About Sensors580
Yumicron Battery Specifications581
Battery Activation for Conventional and Yumicron Types581
Activating Standard Batteries581
- Inspecting, Testing and Charging582
- The Discharge – Charge Cycle582
- Self-Discharge – Temperature Comparison583
- Checking Current Drain583
- Current Drain583
Reasons for Self-Discharge583
- Self-Discharge584
- Total Loss584
Ampere-Hour and Cold Cranking Amps585
Inspecting a Battery585
Battery Testing Devices586
Methods of Checking Battery Condition587
Battery Testing587
Specific Gravity Reading Using a Hydrometer588
Chargers and Charging588
Battery Voltage Reading Using a Voltmeter589
Charging a New Standard Battery589
Charging Times590
Quick Charges590
Maintenance and Storage591
Monthly Maintenance for Conventional and Yumicron Types591
Storage591
Sulfation and Freezing591
Electrolyte Freezing Points592
New Generation Battery Technology593
Sealed VRLA Battery Construction593
Features593
How a Sealed VRLA Battery Differs from Conventional Types594
Activation and Installation595
To Activate a Sealed VRLA Battery595
- Open Circuit Voltage Characteristics Immediately after Electrolyte Filling596
- Open Circuit Voltage Characteristics after End of Charge597
- Relation between State of Charge and Open Circuit Voltage597
Measuring Voltage597
- High Rate Discharge Characteristics of a Sealed VRLA 4 AH Battery598
- Discharge Characteristics of a Sealed VRLA Battery by Capacity598
Discharge Characteristics598
Self-Discharge599
Choosing a Charger599
Сharging Instructions for Newly Activated Sealed VRLA Batteries600
Charging a Newly Activated Sealed VRLA Battery600
Routine Charging601
How to Determine Battery Condition after Boost Charge602
Charging Instructions for Sealed VRLA Batteries with Voltage of 11.5 or Less602
Routine Maintenance for Sealed VRLA Batteries602
Glossary603

Suzuki SV650/S - Front Brake Construction

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