Ftear axle nut: 65 N m 6. If the drive chain tends to rust quickly, the intervals must be shortened. These fluids have too great a dissolving povver for this chain and they ean damage the O-rings. Use only kerosine to clean the drive chain. Such oil can damage the O-rings. Replace hoses every 4 years. Replace fluid every 2 years. Do not use or mix different types of fluid such as silicone-based and petroleumbased fluids. Do not use any brake fluid taken from old, used or unsealed containers.
Brake fluid, if it leaks, will intcrfcrc vvith safc running and immediately discolor painted surfaces. Check the brake hoses and hose joints for cracks and oil leakage before riding.
When the wear exceeds the grooved limit line, replace the pads with new ones. Replace the reservoir cap to prevent dirt from entering. Loosen the air bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle, this will remove the tension of the brake lever causing it to touch the handlebar grip.
Repeat this process until fluid flowing into the receptacle no longer contains air bubbles. NOTE: While bleeding the brake system, replenish the brake fluid in the reservoiras necessary. Fill the reservoir with brake fluid to the top of the inspection window. It is highly recommended to replace a tire when the remaining depth of tire tread reaches the follovving specification. Therefore, maintain the correct tire pressure for good roadability and a longer tire life.
Cold inflation tire pressure is as follovvs. The use of tires other than those specif ied may cause instability. It is highly recommended to use the specified tires. The steering should be adjusted properly for smooth turning of the handlebars and safe operation. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. Support the motorcycle so that the front vvheel is off the ground.
With the vvheel facing straight ahead, grasp the lovver fork tubes near the axle and pull forvvard. If play is found, readjust the steering. Inspect the front forks for oil leakage, scoring or scratches on the outer surface of the inner tubes. Replace any defective parts, if necessary. Inspect the rear shock absorbers for oil leakage and check that there is no play in the svvingarm.
Replace any defective parts if necessary. Check that all cnassis bolts and nuts are tightened to their specified torque. Refer to page for the locations of the follovving nuts and bolts on the motorcycle. Ib-ft Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.
Remove the related parts and test the compression pressure in the follovving manner. Record the maximum gauge reading as the cylinder compression. This will give a good indication of the condition of the moving parts.
If the light stays on, check the oil pressure indicator light circuit. If the circuit is OK, check the oil pressure in the follovving manner.
VVinter: 20 min. Refer to the page listed in this section for removal and reinstallation instructions. Engine removal is sequentially explained in the follovving steps. Reinstall the engine by reversing the removal procedure. Disconnect the cooling fan thermo-svvitch lead wire coupler. Disconnect the radiator outlet hose. Disconnect the reserve tank hose.
Loosen the No. Remove the No. Remove the muffler mounting bolt and nut. Remove the cotter pin. For E, 28, 33 Loosen the rear axle nut.
Loosen the left and right chain adjusters Q. Disconnect the No. Remove the engine mounting bolt 2 and gradually lovver the front side of the engine. Then take the drive chain 3 off the drive shaft. Pay attention to the follovving point. Route vviring harness, cabl9s and hosgs properly rafgrring to the sections for wire routing, cable routing and hose routing.
NOTE: Apply gas sealer to inside and outside of the exhaust pipe connector. Organize the parts in their respective groups e. Remove the spark plugs. NOTE: Refer to the section 5 for their servicing. CT NOTE: Loosen the cam chain tension adjuster bolt 2 to facilitate later reassemblv. NOTE: Looscn the cam chain tension adjuster bolt to facilitate later reassemblv. NOTE: Scribe the cylinder number on the head of the piston.
Turning it counterclockwise may cause damage. Remove the generator rotor 2 with the special tool. Hold the clutch sleeve hub with the special tool.
NOTE: Loosen the crankcase bolt diagonally and the smaller sizes first. Engine serial number:Until P Until P Separate the crankcase into 2 parts, right and left with the crankcase separating tool. Organize the parts in their respective groups i. NOTE: Do not rotate the camshaft with the plastigauge in place. Using special tools, compress the valve springs and remove the two cotter halves 3 from valve stem.
Replace any valve with an abnormally worn face. The thickness of the valve face decreases as the face vvears. If it is out of specification, replace the valve with a new one. Standard IN : 4. Part No. Insert the reamer from the combustion chamberand always turn the reamer handle clockvvise. Rotate the valve with light pressure. Seat the pilot snugly. Rotate the cutter one or two turns. NOTE: Cut only the minimum amount necessary from the seat to prevent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle.
If so, re-cut the valve seat to the correct vvidth. The finished valve seat should have a velvety smooth finish but not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve vvhich will occur during the first few seconds of engine operation. NOTE: After servicing the valve seats, be sure to check the tappet clearance after the cylinder head has been reinstalled. Clean and assemble the head and valve components.
Fill the intake and exhaust ports with gasollne to check for leaks. If any leaks occur, inspect the valve seat and face for burrs or other things that could prevent the valve from sealing. Weakened springs result in reduced engine povver output, and often account for the chattering noise coming from the valve mechanism. Check the valve springs for proper strength by measuring their free length and also by the force required to compress them.
If the spring length is less than the service limit, or if the force required to comprsss the spring does not fall vvithin the range specified, replace both the inner and outer springs as a set.
F: No. Piston ring thickness Standard 1st : 1. After placing the spacer, fit the two side rails. Be sure to bring the marked side to the top when fitting them to the piston. Before inserting each piston into the cylinder, check that the gaps are so located. Service Limit: Conrod big end side clearance Service Limit: 0. Remove the conrods, and mark them to identify the cylinder position. If any, replace them with a specified set of bearings. Never rotate the crankshaft or conrod when a piece of plastigauge is installed.
This measurement should be taken at the vvidest part of the compressed plastigauge. Bearing selection table Crank pin O.
Thickness 1. Standard: The crankcase bore I. Bearing selection table Crankcase I. The replacement procedure is as follovvs. NOTE: Remove the crankshaft journal bearings in only one direction, from inside to outside of each crankcase half. NOTE: Using the hand-press is recommended to remove the crankshaft journal bearings.
NOTE: The upper and lower bearings are same. A CAUTION Before installing the bearings, lightly shave off the sharp edge part of the crankcase chamfer by using an oilstone and vvash the crankcase bore with enough engine oil. Set the bearings installed in the special tool to the crankcase half as shovvn.
NOTE: Install the bearing from inside to outside of each crankcase halves. Apply enough engine oil to the special tool and the bearings and then set the special tool carefully. NOTE: Using the hand-press is recommended to install the crankshaft journal bearings. Remove the crankcase bearings using the special tool.
Engine serial number: From P : From P NOTE: If it is difficult to remove the oiljet, use a sting. Replace the bushings if there is anything unusual. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed.
When installing a new circlip, do not expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, mako sure that it is completely seated in its groove and securely fitted. The cross sectional view shows the correct poaition of the gears, bushings, washers and circlips. Fit it to the side vvhere the thrust is as shovvn in the illustration. The gear turns in one direction only.
Inspect the starter driven gear bearing for any damage. The oil pump is available only as an assembly. NOTE: Apply engine oil to each running and sliding part before reassembling. It will be easy to install the crankshaft to left crankcase.
Tighten all the securing bolts to the specified torque values. NOTE: Pass through the neutral indicator light lead wire under the driveshaft oil seal retainer. Use nonflammable cleaning solvent to wipe off oily or greasy matter and make these surfaces completely dry. Install tha genarator rotor assambly onto the crankshaft. Apply engine oil to the rotor bolt and install it with the vvasher.
While holding the generator rotor with spacial tool, tightan its bolt to tha spacified torque. Hold the generator rotor crankshaft with the special tool.
Okgfm, 7. NOTE: Locate the gearshift arm stopper 2 betvveen return spring ends. NOTE: Be sure to engage the oil pump drive and driven gears, primary drive and driven gears.
Hold the generator rotor crankshaft using the special tool. H Clutch spring set bolt: 5. W Generator cover bolt: 10 N-m 1. Apply engine oil to the sliding surface of the pistons. Apply engine oil to the sliding surface of the cylinders. NOTE: When installing the cylinders, keep the cam chains taut.
The cam chain must not be caught between cam drive sprocket and crankcase when turning the crankshaft. NOTE: The front and rear cam chain guides are the same. NOTE: When installing the cylinder head, keep the cam chain taut.
H Cylinder head bolt M6 : 10 N-m 1. INF No. Turn the exhaust camshaft so that the arrovv is aligned with the gasket surface of the cylinder head. NOTE: The cam chain should now be on all three sprockets. Be careful not to move the crankshaft until the camshaft journal holders and cam chain tension adjuster is secured.
H Camshaft journal holder bolt Nm 1. Take special care not to use other types of bolts instead of these special bolts. Recheck the No. Now the cam chain tension adjuster is ready to install. NOTE: Click sound is heard when the cam chain tension adjuster rod is released.
Turn the intake camshaft so that the arrovv is aligned with th9 gasket surface of the cylind9r head. W C a m chain tension adjuster mounting bolt: 10 Nm 1. NOTE: Be sure to check the tappet clearance. Valve timing inspection plug: 23 N-m 2. Connect the ground lead wire. Install the crankcase breather hose Install the spark plugs. The pump is necessary when the level in the fuel tank is lovver than th9 carburetor fuel bowl. The fuel sent undgr pressura by the fuel pump flovvs into the float chamber when the float of the carburetor has dropped and the needle valve is open.
When the needle valve closes, the pressure of the fuel in the hose connecting the carburetor and the fuel pump increases, and when the set pressure is reached, relief valve ball valve in the fuel pump is opened by the fuel pressure to prevent 9xcessive supply. Keep hcat, spark and flame away. Refer to page for the air breather hose routing. Extreme care must be taken. Apply negative pressure to the vacuum fuel valve and blow into the fuel outlet port.
If air does not flow out, replace the vacuum fuel valve with a new one. There usually remains a small amount of fuel in the vacuum fuel valve, so vvhen checking the valve make sure you do not swallow the fuel when blovving into the fuel outlet port. Do not appiy high negative pressure to more than If the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine povver may result.
Clean the fuel filter vvith compressed air. These system inspection are explained as follovvs. The test bulb should come on after several seconds if the svvitch is in good condition. When the svvitch is immersed and stirred in gasoline under the above condition, the bulb should go out.
If the bulb remains lit, replace the unit with a new one. Keep heat, spark and flames away from gasoline. If vacuum fuel valve is correct, replace the fuel pump with a new one. The piston valve moves according to the negative pressure present on the dovvnstream side of the venturi. This mixture, rich with fuel, then goes up through pilot pipe to pilot screw. But when the throttle valve is closed suddenly, a large negative pressure generated on cylinder side vvorks on to a diaphragm D. This causes the piston valve D moves upvvard.
The clearance through vvhich the emulsified fuel must flow ultimately depends on throttle position. NOTE: A starter enricher system is operated almost the same way as a choke. Remove the air cleaner with the oil catch tank and the drain hose. Study the service manual carburetor diagram and familiarize yourself with component locations and the different fuel circuits and their routing through the carburetor.
Avoid removing the throttle position sensor from the carburetor body unless you really need to do so. Set the drill-stop 6 mm from the end of the bit to prevent drilling into the pilot screvv. Carefully drill through the plug. Thread a self-tapping shefit metal screw into the plug.
Pull on the screvv head with pliers to remove the plug. Carefully clean any metal shavings from the area. Clean all jets with a spray-type carburetor cleaner and dry them using compressed air. Clean all circuits of the carburetor thoroughly - not just the perceived problem area.
Clean the circuits in the carburetor body with a spray-type cleaner and allovv each circuit to soak if necessary to loosen dirt and varnish. Blow the body dry using compressed air. If the components cannot be cleaned with a spray cleaner, it may be necessary to use a dip-type cleaning solution and allow them to soak. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Conversely, if the needle valve sticks, the gasoline will not flow into the float chamber.
Clean the float chamber and float parts with gasoline. If the needle valve is worn, as shown in the illustration, replace it along with a new valve seat. Clean the fuel passage of the mixing chamber using compressed air. Clean the fuel filter with compressed air. Check each heater coil for open and ohmic resistance with the multi circuit tester. The coil is in good condition if the resistance is as follovvs.
Connect 12V battery to the carburetor heater terminals and check the carburetor float chamber temperature with your hand vvhich is vvarmed up after 5 minutes. If the carburetor float chamber temperature heater with a new one.
If there is no continuity, replace the thermo-svvitch with a new one. Pay attention to the follovving points:. When installing the starter enricher plunger, replace the Oring with a new one and apply a small quantity of grease to it.
After all of the work has been completed, install the carburetor assembly onto the engine and perform the follovving adjustments. Engine idle speed NOTE: Keep the air cleaner box removing while performing this procedure. Apply negative pressure to the fuel valve. Dirt drawn into the carburetor will damage the internal engine parts.
Dirt dravvn into the carburetor will damage the internal engine parts. The engine will still be hot for sometime after stopping the engine. After completing the carburetor synchronization, remove the carburetor assembly. Retnove the balancer gauge hose from carburetor inlets and install vacuum hoses respectively.
Carburetor set position. See illustration belovv. This inspection must be performed in an area well ventilated, away from fire or sparks since gasoline, an explosive fluid, is used in this operation. NOTE: The apparent fuel level measured in the level gauge is higher than the actual level in the float chamber because of meniscus effect. Meniscus is approximately 1 mm. Do not mix an alcohol base anti-freeze and different brands of anti-freeze.
Refer to Right figure. Do not use a radiator anti-leak additive. After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a quarter turn to allovv pressure to escape and then turn the cap all the way off. The engine must be cool before servicing the cooling system. Give a pressure of about kPa 1. If the pressure should fa. CZ73 Remove the cooling fan lead wire coupler 2.
Refer to the follovving pages. Test the cooling fan motor for load current with an ammeter connected as shovvn in the illustration.
With the motor with electric motor fan running at full speed, the ammeter should be indicating not more than 5 amperes. NOTE: When making above test, it is not necessary to remove the cooling fan. Connect the thermo-svvitch to a circuit tester and place it in the oil contained in a pan, which is placed on a stove. It may cause damage if it gets a sharp impact. Disconnect the engine coolant temperature svvitch lead wire. Test the thermostat at the bench for control action, in the follovving manner.
Note that the immersed thermostat is in suspension. Heat the vvater by placing the beaker on a stove and observe the rising temperature on a thermometer. This reading, vvhich is the temperature level at vvhich the thermostat valve begins to open, should be vvithin the standard value. Install the air cleaner box. Install the fuel tank. Install th9 front and rear seat.
NOTE: Before draining engine oil and engine coolant, inspect engine oil and coolant leakage betvveen the vvater pump and clutch cover. If engine oil is leaking, visually inspect the oil seal and O-ring. If engine coolant is leaking, visually inspect the mechanical seal, seal vvasher and O-rings. Also replace the seal ring if necessary. Install the new mechanical seal using the special tool. Install the new bearing using the special tool. NOTE: When remounting the rear seat, make sure to lock its striker.
NOTE: When installing the frame side cover, first install the upper side to the front seat. NOTE: When remount the front seat, make sure the seat hook is in retainer. Face the triangle mark on the front fender plate to front side. Drive out both vvheel bearings by striking the wedge bar. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the follovving procedure if there is any thing unusual.
An excessive runout is usually due to worn or loosen vvheel bearings. If bearing replacement fails to reduce the runout, replace the wheel. Wheel rim runout Axial and Radial Service Limit: 2. If the runout exceeds the limit, replace the front axle. NOTE: The seal sides of the bearings should face outside.
NOTE: Be careful not to drop the front fork when loosening the bolts. Hold the front fork cap when removing it, or it will jump out of the front fork due to spring pressure. Turn the fork upside down and stroke it several times to let out fork oil. Hold the fork upside down for a few minutes to drain oil. NOTE: Be careful not to damage the inner tube. Remove the follovving parts. If it is shorter than the service limit, replace it with a new one.
Install the rebound spring and the damper rod to the inner tube. Apply fork oil to the oil seal lip. Install the oil seal stopper ring to the outer tube. Instali the O-ring to the front fork cap bolt. Apply fork oil lightly to the O-ring. Install the from fork cap bolt to the inner tube temporarily. Install the front fender. Remove the follovving items from the right handlebar. Remove the brake hose joint. Remove the front brake assembly. Loosen the handlebar holder nuts.
Remove the handlebars. CT Remove the lower side handlebar holders. ZMN» Remove the steering stem nut using the special tool. Drive out the steering stem upper and lovver bearing races with the special tool. Press in the lovver bearing inner race and dust seat with the special tool.
NOTE: This adjustment will vary from motorcycle to motorcycle. Do the same on the other grip end. NOTE: Hold the front fork legs, move them back and forth and make sure that the steering is not loose.
Replace the damper if there is anything unusual. If bearing replacement fails to reduce the runout, replace the vvheel. If the runout exceeds the limit, replace the rear axle.
Measure the thickness with a micrometer. Replace the disc if the thickness is less than the service limit or if damage is found. Replace the disc if the runout exceeds the service limit. If they are worn as shown, replace the two sprockets and drive chain as a set. NOTE: The seal sides of bearings should face out side. Install the bearing into the sprocket mounting drum using the special tool.
NOTE: Face the stamped mark on the sprocket to outside. Remove the cushion rod bolt sand nuts. Remove the rear shock absorber mounting bolt Lovver side. Remove the cushion lever.
Remove the rear shock absorb9r by removing its mounting bolt upper side. Inspect the spacers and vvashers for any flaws or other damage. We will be happy to assist you in a prompt manner. Thank you. Tags: repair manual service manual suzuki sv Download Now - Here. Become a Reseller Want to sell Cyclepedia Manuals? Join the Cyclepedia Reseller network by becoming an online affiliate. There's no inventory to take on, nothing to ship and no customer service to deal with.
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