12 SV650SK1 '01 Model.pdf

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SV650SK1 ('01-MODEL)
12-1
This manual describes service data, service specifications and servicing procedures which
differ from those of the SV650K1 ('01-MODEL) .
NOTE:
Any differences between the SV650K1 ('01-MODEL) and SV650SK1 ('01-MODEL) in
specifications and service data are clearly indicated with an asterisk mark (*).
Please refer to the SV650 Service Manual for details which are not given in this manual .
CONTENTS
INFORMATION LABELS
2
SPECIFICATIONS
3
PERIODIC MAINTENANCE
5
BRAKE
5
CHASSIS BOLT AND NUT
6
EXTERIOR PARTS
8
CONSTRUCTION
8
COWLING
9
FRONT FORK
11
REMOVAL
11
REMOUNTING
12
STEERING
13
CONSTRUCTION
13
HANDLEBARS
14
STEERING REMOVAL
17
STEERING INSTALLATION
18
FRONT BRAKE
19
CONSTRUCTION
19
BRAKE FLUID REPLACEMENT
20
FRONT MASTER CYLINDER
21
SPEEDOMETER
26
REMOVAL
26
CONSTRUCTION
27
INSPECTION
27
HEADLIGHT
30
BULB REPLACEMENT
30
WIRING DIAGRAM
31
WIRE HARNESS ROUTING
32
CABLE ROUTING
34
FRONT BRAKE HOSE ROUTING
35
COWLING AND SEAT TAIL COVER SET-UP
36
SERVICE DATA
37
PRIMARY DRIVEN GEAR CONSTRUCTION
47
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12-2
SV650SK1 ('01-MODEL)
INFORMATION LABELS
1
Noise label
6 Warning screen label
2
Information label
7
Warning steering label
3
Vacuum hose routing label (For E-33)
8
Tire pressure label
9 Warning safety label
4
Manual notice label
5
Frame caution plate
10
Safety plate
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0
SV650SK1 ('01-MODEL)
12-3
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length
* 2 045 mm (80 .5 in)
Overall width
* 740 mm (29 .1 in)
Overall height
* 1 130 mm (44 .5 in)
Wheelbase
* 1 420 mm (55 .9 in)
Ground clearnce
140 mm ( 5 .5 in)
Seat height
805 mm (31 .7 in)
Dry mass
* 169 kg (372 Ibs)
ENGINE
Type
Four-stroke, Liquid-cooled, DOHC, TSCC,
90-degree V-twin
2
Number of cylinders
Tappet clearance, IN
0.10 - 0.20 mm (0 .004 - 0.008 in)
EX
0.20 - 0 .30 mm (0 .008 - 0.012 in)
Bore
81 .0 mm (3.189 in)
Stroke
62 .6 mm (2.465 in)
Piston displacement
645 cm3 (39 .4 cu. in)
Compression ratio
11 .5 :1
Carburetor
Air cleaner
Starter system
Lubrication system
MIKUNI BDSR39 x 2
Non-woven fabric element
Electric starter
Wet sump
TRANSMISSION
Clutch
Wet multi-plate type
Transmission
6-speed constant, mesh
Gearshift pattern
1-down, 5-up
Primary reduction ratio
2 .088 (71/34)
Gear ratios, Low
2 .461 (32/13)
2nd
1 .777 (32/18)
3rd
1 .380 (29/21)
4th
1 .125 (27/24)
5th
0 .961 (25/26)
Top
0 .851 (23/27)
Final reduction ratio
* 2 .933 (44/15)
Drive chain
* D.I .D 525 V9, 108 links
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12-4
SV650SK1 ('01-MODEL)
CHASSIS
Front suspension
Telescopic, coil spring, oil damped
Rear suspension
Link type system, gas/oil damped, coil spring
Front fork stroke
130 mm (5.1 in)
Rear wheel travel
125 mm (4.9 in)
Steering angle
* 30° (right & left)
Caster
25°
Trail
100 mm (3.94 in)
Turning radius
* 3.1 m (10 .2 ft)
Front brake
Rear brake
Front tire size
Rear tire size . . . . . . . . . .. .. . . . . . . . . .... . . . . . . . . .. .. . . . . . . . . . ... . . . . . . . . . .... .. .
Disc brake, twin hydraulically operated
Disc brake, hydraulically operated
120/60 ZR17 (55 W), tubeless
160/60 ZR17 (69 W), tubeless
ELECTRICAL
Ignition type
Electronic ignition (Transistorized)
Ignition timing
5° B.T D.C. at 1 300 r/min
Spark plug
NGK CR8E, DENSO U24ESR-N
Battery
12V 36 .0 kC(10 Ah)/10HR
Generator
Three-phase A.C . Generator
Main fuse
30A
Fuse
15/15/15/10/10A
Headlight
* 12V 45/45W x 2
Turn signal light
12V 21W
Brake light/Taillight
12V 21/5W x 2
License plate light
12V 5W
Speedometer light
* 12V 0.84W x 3
Neutral indicator light
12V 1 .7W
High beam indicator light
12V 1 .7W
Turn signal indicator light
* 12V 3W
Oil pressure indicator light
. . . .. ... . . . . . . . ..... . . . . . . . .... . . . . . . . . . . . . .
12V 1 .7W
Fuel level indicator light
12V 1 .7W
Water temp. indicator light
LED
CAPACITIES
Fuel tank, including reserve
16.0 L (4.2/3 .5 US/Imp gal)
E-03
15.0 L (4.0/3 .3 US/Imp gal)
E-33
Engine oil, oil change
with filter change
overhaul
2 300 ml (2.4/2 .0 US/Imp qt)
2 400 ml (2.5/2 .1 US/Imp qt)
2 700 ml (2.9/2.4 US/Imp qt)
1 600 ml (1 .7/1 .4 US/Imp qt)
These specifications are subject to change without notice .
0
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SV650SK1 ('01-MODEL)
12-5
PERIODIC MAINTENANCE
BRAKE
(BRAKE)
Inspect initially at 1 000 km (600 miles, 1 month) and ev-
ery 6 000 km (4 000 miles, 6 months) thereafter.
(BRAKE HOSE AND BRAKE FLUID)
Inspect every 6 000 km (4 000 miles, 6 months). Replace
hoses every 4 years. Replace fluid every 2 years.
BRAKE FLUID LEVEL CHECK
Keep the motorcycle upright and place the handlebars straight .
Remove the rear seat. (CLF 6-3 of the SV650 Service Manual)
Check the brake fluid level by observing the lower limit lines on
the front and rear brake fluid reservoirs .
When the level is below the lower limit line, replenish with brake
fluid that meets the following specification .
BF
Specification and Classification : DOT 4
A WARNING
• The brake system of this motorcycle is filled with a
glycol-based brake fluid. Do not use or mix different
types of fluid such as silicone-based and petroleum-
based fluids. Do not use any brake fluid taken from
old, used or unsealed containers. Never re-use brake
fluid left over from the last servicing or stored for a
long period of time .
Brake fluid, if it leaks, will interfere with safe running
and immediately discolor painted surfaces. Check the
brake hoses and hose joints for cracks and oil leakage
before riding.
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