3_Engine.pdf

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ENGINE 3-1
ENGINE
CONTENTS
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN
PLACE
3- 2
ENGINE REMOVAL AND INSTALLATION
3- 3
ENGINE REMOVAL
3- 3
ENGINE INSTALLATION
3-14
S
ENGINE DISASSEMBLY
3-23
ENGINE TOP SIDE
3-23
ENGINE BOTTOM SIDE
3-30
ENGINE COMPONENTS INSPECTION AND SERVICING
3-40
CYLINDER HEAD COVER
3-40
CAMSHAFT/CAMSHAFT JOURNAL
3-41
CYLINDER HEAD AND VALVE
3-44
CYLINDER
3-53
PISTON AND PISTON RING
3-54
CONROD AND CRANKSHAFT
3-56
CRANKCASE
3-60
CRANKSHAFT JOURNAL BEARING
3-64
CRANKCASE BEARING AND OIL SEAL
3-69
CLUTCH
3-72
PRIMARY DRIVEN GEAR ASSEMBLY
3-73
GEARSHIFT SHAFT/GEARSHIFT ARM
3-74
TRANSMISSION
3-75
STARTER CLUTCH
3-82
GENERATOR AND SIGNAL GENERATOR
3-83
OIL PUMP
3-84
CLUTCH RELEASE
3-84
ENGINE REASSEMBLY
3-85
ENGINE BOTTOM SIDE
3-85
ENGINE TOP SIDE
3-97
10725019.002.png
3-2 ENGINE
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE
Engine components which can be removed while the engine is installed on the chassis are listed below . For
the installing and removing procedures, refer to respective paragraphs describing each component .
ENGINE LEFT SIDE
'4
PARTS
REMOVAL
INSTALLATION
i
Engine sprocket
3-8
3-18
Generator
3-30,3-36
3-89,3-96
Gear position switch
3-37
3-88
Clutch release
3-7
3-19
Starter idle gear
3-30
3-96
ENGINE RIGHT SIDE
PARTS
REMOVAL
INSTALLATION
Clutch
3-31
3-93
Primary driven gear
3-33,3-73
3-73,3-93
Primary drive gear
3-35
3-90
Oil pump
3-33
3-92
Gearshift shaft
3-34
3-91
Water pump
6-14
6-17
ENGINE CENTER
PARTS
REMOVAL
INSTALLATION
Throttle body
5-17
5-29
Cylinder head covers
3-24
3-109
Camshafts
3-25,3-27
3-102, 3-105
Cylinder heads
3-26,3-29
3-100
Cylinders
3-27,3-29
3-99
Pistons
3-27,3-30
3-97
Cam chain tension adjusters
3-26,3-28
3-104, 3-107
Thermostat
6-12
6-13
Oil filter
2-15
2-15
Oil pressure switch
3-61
3-61
Starter motor
3-30
3-97
10725019.003.png
ENGINE 3-3
ENGINE REMOVAL AND INSTALLATION
r/
ENGINE REMOVAL
Before taking the engine out of the frame, wash the engine
using a steam cleaner . Engine removal is sequentially explained
in the following steps. Reinstall the engine by reversing the
removal procedure.
•
Remove the cowling . (SV650S) (=7-6)
•
Remove the front and rear seat . (r r'7-4)
•
Lift and support the fuel tank with the prop stay . (F-75-6)
•
Disconnect the battery O lead wire and OO
lead wire.
•
Drain engine oil. (=2-14)
i~. 4F
•
Drain engine coolant . (F-7-2-20)
44
10725019.004.png
3-4 ENGINE
•
Loosen the throttle body clamp screws 10 at the air cleaner
box side .
•
Disconnect the IAP sensor coupler CU and hose U.
•
Disconnect the IAT sensor coupler 4.
•
Disconnect the front side of crankcase breather hose O and
rear side of crankcase breather hose © .
0
•
Disconnect the PAIR hose 07 and coupler © .
10725019.005.png
ENGINE 3-5
• Disconnect the cooling fan thermo-switch lead wire coupler .
•
Disconnect the radiator outlet hose .
•
Disconnect the reserve tank hose .
•
Remove the radiator mounting bolts .
•
Disconnect the radiator inlet hose .
•
Disconnect the horn coupler O and cooling fan coupler C2 .
Remove the radiator (I.
CAUTION
Be careful not to bent the radiator fin .
•
Remove the throttle body . (f-r5-17)
•
10725019.001.png

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