Suzuki SV1000 2003-2005 Service Manual 3 Engine

ENGINE

CONTENTS

ENGINE

3-1

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ENGINE REMOVAL AND INSTALLATION

ENGINE REMOVAL ENGINE INSTALLATION

ENGINE DISASSEMBLY

ENGINE TOP SIDE ENGINE BOTTOM SIDE

ENGINE COMPONENTS INSPECTION AND SERVICING

CYLINDER HEAD COVER CAMSHAFT/CYLINDER HEAD CYLINDER/PISTON INSPECTION CONRODICRANKSHAFT CLUTCH TRANSMISSION GEARSHIFT FORK PRIMARY DRIVE GEAR STARTER TORQUE LIMITER STARTER CLUTCH GEARSHIFT CRANKCASE CRANKCASE-CRANKSHAFT BEARING GENERATOR COVER CLUTCH COVER GEARSHIFT COVER

ENGINE REASSEMBLY

ENGINE BOTTOM SIDE ENGINE TOP SIDE

~

~ ~ ~

~

3- 2 3- 3 3- 3 3-10 3-17 3-17 3-24

3-34 3-34 3-35 3-48

3-50 3-54

3-56 3-62 3-63

3-64

3-65

3-66

3-73

3-77

3-78

3-93

40

3- 2

ENGINE

ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE

The parts listed below can be removed and reinstalled without removing the engine from the frame the page listed in this section for removal and reinstallation instructions

ENGINE LEFT SIDE

.

. Refer to

4

PARTS Generator rotor Gearshift

ENGINE RIGHT SIDE

PARTS Clutch cover

Clutch Oil pump driven gear

Primary drive gear Cam drive idle gear/sprocket Gear position switch Oil sump filter Oil pressure switch Oil jet

ENGINE CENTER

PARTS

Cylinder head cover

Camshaft Cylinder head (Front) Cylinder (Front) Piston (Front) Cam chain tension adjuster 3-18 and -22 Oil filter Starter motor

REMOVAL

3-30 3-31

REMOVAL

3-25 3-25 3-28 3-86

3-29 3-83 3-28

3-27

3-28 3-67 3-67

3-68

REMOVAL 3-17 and -20 3-18 and -21

3-19 3-96 3-20 3-95 3-20 3-93

3-24 3-19

INSTALLATION

3-82 3-80

INSTALLATION

3-91 3-86

3-84 3-85 3-85

3-68 and -95

INSTALLATION

3-112 3-106

3-102 and -105

3-93

3-113

4

It

~

ENGINE 3-3

ENGINE REMOVAL AND INSTALLATION

010

1

ENGINE REMOVAL

Before taking the engine out of the frame, wash the engine using a steam cleaner in the following steps removal procedure

•

Remove the under cowling.(C-,-6-5)

•

Drain engine oil

•

Drain engine coolant

•

Remove the seat

. Engine removal is sequentially explained

. Reinstall the engine by reversing the

.

. (=2-14)

. (172-17)

. (=6-7)

6-7)

r

•

Disconnect theObattery lead wire

•

Remove the radiator

•

Lift and support the fuel tank

•

Remove the air cleaner

. (C75-5)

.

(r-

. (174-75)

74-65)

.

r

40

•

Remove the throttle body

.(C-

74-76)

~

3-4 ENGINE

•

Disconnect the engine coolant temperature sensor lead wire coupler0

•

Disconnect the gear position switch 02 H02 sensor ® and camshaft position sensor lead wire couplers ($

•

Remove the rubber heat shield

.

,

side-stand switch

OO

,

1

.

OO

.

•

Remove the spark plug caps

•

Disconnect the generator lead wire coupler erator lead wire coupler 07 after removing the screws

•

Remove the gearshift lever

.

0

and signal gen-

.

OO

.

l

~

Bind the clutch lever with a rubber band to prevent the clutch

•

release cylinder piston from coming out

Remove the clutch release cylinder ®

•

.

ENGINE 3-

5

•

Remove the push rod 09

•

Remove the engine sprocket cover 10

•

Remove the speed sensor 11

Remove the engine sprocket nut while depressing the brake

•

pedal

.

40

~

3-6 ENGINE

•

Loosen the rear axle nut 1©

•

Loosen the chain adjusters 13 by loosening the lock nuts

.

(W

.

4

•

Remove the engine sprocket 15 and washer i

.

•

Disconnect the engine ground lead wire i

•

Remove the mufflers

•

Loosen the front exhaust pipe mounting bolts

. (L & R)

.

l

~

•

Remove the front exhaust pipe

ENGINE 3-7

.

J

•

Remove the rear exhaust pipe

•

Remove the oil cooler

•

Disconnect the starter motor lead wire 79 and oil pressure

switch lead wire 20

(I

.

(f"

.

r5-20)

~

3-8

ENGINE

•

After removing the pinch bolt (3, bolt

(2

.

Remove the engine mounting bolt 23

•

remove the engine mounting

, (3

.

•

Remove the engine mounting nut

(S,

26

.

I

11

~

ENGINE3-9

•

Loosen the engine mounting thrust adjuster lock nut

.

40

09940-14990

•

Loosen the engine mounting thrust adjuster v

: Engine mounting thrust adjuster socket

wrench

.

I'

•

Loosen the pinch bolt 28

•

Gradually lower the engine assembly by removing the bolts

(a

.

CAUTION

Be careful not to damage the frame and engine when removing the engine from the frame

.

~

3-10

ENGINE

ENGINE INSTALLATION

Remount the engine in the reverse order of engine removal Pay attention to the following points

NOTE

: * The engine mounting nuts are self-locking "

Once the nut has been removed, it is no longer of any use to the specified torque

.

:

.

. Be sure to use new nuts, and then tighten them

r

c

i

A=

' '

ITEM

~©© OE©

T WK

DJ ©

E

®

N

.m

kgf-m

55 5

®

93 9

12

45

23

1 .2

4

2

.5

.3

.5

.3

lb-ft

40

.0

67

.5

8

.5

32

.5

16

.5

l

~

•

Before installing the engine assembly, install the spacer

collar © and engine thrust adjuster

©, O,

OO

.

OO

,

ENGINE 3-

1 1

to

•

Install the collar © onto the crankcase properly as shown

.

~

3

-12 ENGINE

•

Put the drive chain on the driveshaft

Gradually raise the engine assembly and align all the bolt

•

holes

.

Install the engine mounting bolts and tighten them tempo-

•

rarily

.

Tighten the engine mounting thrust adjuster lock nut to the

•

specified torque with the special tool

.

Engine mounting thrust adjuster

•

Engine mounting thrust adjuster lock nut

09940-14990

: Engine mounting thrust adjuster socket

wrench

: 12 N

.m (1

45 N

.m (4 .5 kgf-m, 32

.2 kgf-m, 8

:

.5 Ib-ft)

•

After tightening the engine mounting bolt

bolt ©

.

Engine mounting bolt

•

Engine mounting pinch bolt

OA

:

55 N

.m (5 .5 kgf-m, 40

©

:

23 N

.m (2

tighten the pinch

A),

.3 kgf-m, 6

.0 Ib-ft)

.5 Ib-ft)

~

ENGINE 3-13

•

Tighten the engine mounting bolt to the specified torque

.

Engine mounting bolt

•

Tighten the engine mounting nuts specified torque

Engine mounting nut(: 93 N-m (9

•

Engine mounting bolt Engine mounting nut

•

After tightening the bolts ©, tighten the pinch bolt specified torque

•

Engine mounting bolt Engine mounting pinch bolt (L

.

OO

(F

©

:

55 N

:

55 N

:

55 N

:

55 N

23 N

.m (5

.5 kgf-m, 40

OO ,

OO

.3 kgf-m, 67

.m (5

.5 kgf-m, 40

.m (5

.5 kgf-m, 40

.m (5

.5 kgf-m, 40

.m (2

.0 lb-ft)

and bolt (

.6 lb-ft)

.0 lb-ft)

.3 kgf-m, 16

.5 lb-ft)

to the

4

•

Install the new washers and tighten the union bolt to the specified torque

Oil cooler hose union bolt

•

Install the new gaskets

.

: 23 N

.m (2

.3 kgf-m, 16

. (Front & Rear)

.5 lb-ft)

~

3

-14 ENGINE

•

Install the exhaust pipes and mufflers

NOTE

:

Apply THREAD LOCK to the bolt

. (L & R)

.

99000-32050

: THREAD LOCK "1342"

I

ITEM

OO©©OO®

N

.m

kgf-m

23 25

lb-ft

2

.3

16

.5

2

.5

18

.0

~

ENGINE 3-15

•

40

Adjust the brake pedal height

•

Brake pedal height

Standard

•

Install the gearshift arm as shown

•

Gearshift arm angle

: 55 -

65 mm (2

OA

©

.

.17

Approx

:

- 2

.

.56 in)

. 17

.5°

•

Install the engine sprocket and washer

•

Apply THREAD LOCK SUPER to the engine sprocket nut and tighten it to the specified torque while depressing the brake

pedal

.

Engine sprocket nut

0

99000-32030

•

Tighten the speed sensor rotor bolt

: 115 N

: THREAD LOCK SUPPER "1303"

.m (11

.

.5 kgf-m, 83

.

.0 lb-ft)

40

~

3

-16 ENGINE

•

Apply SUZUKI SUPER install it

•

Install the clutch release cylinder

.

GREASE to the push rod 10 and

.

99000-25030 99000-25010

•

Adjust the gearshift lever as shown

•

Gearshift lever height

Standard

•

After installing the engine, route the wire harness, cables and

hoses properly

•

Adjust the following items

•

Engine oil =2-14

•

Engine coolant L7'2-19

•

Engine idle speed C12-16

•

Throttle cable play

•

Engine oil capacity

Oil change Oil and filter change

Engine overhaul

: SUZUKI SUPER GREASE "A" (USA) : SUZUKI SUPER GREASE "A" (Others)

.

: 60-70 mm (2.4-

. (Cr8-14)

:

r

-

72-16

: 2

.7 L (2

.9/2

.4 US/Imp qt)

: 2

.9 L (3

: 3

.3 L (3

.8 in)

2

.6 US/Imp qt)

.1/2

.5/2

.9 US/Imp qt)

~

ENGINE 3-17

ENGINE DISASSEMBLY

ENGINE TOP SIDE

•

Remove the spark plugs.(

r -

7-2-6)

40

•

Remove the thermostat

.

•

Remove the valve timing inspection plugOand generator

cover plug 02

FRONT CYLINDER HEAD COVER

•

Remove the front cylinder head cover J

.

~

3-18 ENGINE

•

Turn the crankshaft to bring the "F I T" line on generator rotor to the index mark of the valve inspection hole and also to

bring the cams to the position as shown

NOTE

:

At the above condition, the No

compression stroke and also the engraved lines shafts are parallel with the mating surface of the cylinder head

cover

.

. 1 (Front) cylinder is at TDC of

.

(

on the cam-

FRONT CYLINDER CAMSHAFT

•

Remove the camshaft journal holders

CAUTION

Be sure to loosen the camshaft journal holder bolts evenly by shifting the wrench diagonally

•

Remove the camshafts

NOTE

:

Do not drop the dowel pins into the crankcase

FRONT CAM CHAIN TENSION ADJUSTER

•

After loosing the spring holder bolt tension adjuster

.

remove the cam chain

O,

~

ENGINE 3-19

FRONT CYLINDER HEAD

•

Remove the cam drive idle gear/sprocket 90 by removing its

shaft, copper washer and thrust washer

NOTE

:

Do not the drop the thrust washer

OO

.

into the crankcase

.

400

•

Remove the cylinder head bolts and cam chain tensioner mounting bolt

•

Remove the cam chain tensioner

.

STARTER MOTOR

(Z

.

D

.

(T

•

Remove the starter motor

•

Remove the cylinder head nut

•

Loosen the cylinder nuts

•

Remove the oil cooler mounting bracket

.

~

3-20 ENGINE

•

Remove the cylinder head bolts

•

Remove the cylinder head

NOTE

:

.

* When loosening the cylinder head bolts, loosen each bolt little

by little diagonally

.

* To identify each cylinder head, mark the cylinder as the front

and

rear,

cylinder head uses the same part

.

FRONT CYLINDER

•

Remove the cylinder head gasketO,dowel pinsOOand cam

chain guide (3

•

Remove the cylinder

NOTE

:

Firmly grip

cylinder does not come off, lightly

.

the cylinder at both ends, and lift it

tap

on the finless portions of

straight up

.

If the

the cylinder with a plastic mallet to make the gasketed joint

loose

.

•

Remove the cylinder base gasket ® and dowel pins

.

FRONT PISTON

•

Place a clean rag over the cylinder base so as not to drop the

piston pin circlip into the crankcase

•

Remove the piston pin circlip

•

Remove the piston by driving out the piston pin

NOTE

:

Scribe the

cylinder number on the head of the piston

.

REAR CYLINDER HEAD COVER

•

Remove the rear cylinder head cover 90

.

~

•

Turn the crankshaft to bring the "F I T" line mark on generator

rotor to the index mark of the valve inspection hole and also to bring the cams to the position as shown

NOTE

: At the above condition, the rear cylinder is at ATDC 90° on expansion stroke and also the engraved lines shafts are parallel with the mating surface of the cylinder head cover

.

on the cam-

OA

ENGINE

3-21

CAUTION

Pull the front cam chain upward, or the chain will be caught between the crankcase and cam drive idle gear/sprocket when turning the crankshaft

REAR CYLINDER CAMSHAFT

•

Remove the camshaft journal holders

CAUTION

Be sure to loosen the camshaft journal holder bolts

evenly by shifting the wrench diagonally

•

Remove the camshafts

.

NOTE

:

Do not drop the dowel pins into the crankcase

.

~

3-22 ENGINE

REAR CAM CHAIN TENSION ADJUSTER

After loosing the spring holder bolt t, remove the cam chain

•

tension adjuster

REAR CYLINDER HEAD

•

Remove the cam drive idle gear/sprocket 1O by removing its

shaft, copper washer and thrust washer 02

NOTE

:

Do not drop the thrust washer

•

Remove the cylinder head bolts and cam chain tensioner mounting bolt

•

Remove the cam chain tensioner

.

2

into the crankcase

.

c

k-

I

•

Remove the cylinder head nuts (O

•

Remove the cylinder head nut ®

•

Loosen the cylinder nuts 05

)-

.

~L

4

~

•

Remove the cylinder head bolts

•

Remove the cylinder head

NOTE

:

* When loosening the cylinder head bolts, loosen each bolt little

by little diagonally

* To identify each cylinder head, mark the cylinder as the Front

and Rear

REAR CYLINDER

•

Remove the cylinder head gasket 90, dowel pins 02 and cam

chain guide

•

Remove the cylinder

NOTE

Firmly grip the cylinder at both ends, and lift it straight up cylinder does not come off, lightly tap on the finless portions of the cylinder with a plastic mallet to make the gasketed joint loose

.

:

.

(1

.

. If the

ENGINE

3-23

40

•

Remove the cylinder base gasket ® and dowel pins

REAR PISTON

•

Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase

•

Remove the piston pin circlip

•

Remove the piston by driving out the piston pin

NOTE

:

Scribe the cylinder number on the head of the piston

.

~

3-24 ENGINE

ENGINE BOTTOM SIDE

OIL FILTER

•

Remove the oil filter with the special tool

.

:

09915-40610

•

Remove the generator cover

: Oil filter wrench

.

•

Remove the gasket 90 and dowel pin

•

Remove the starter torque limiter

•

Remove the bushings ® from the crankcase and generator

cover

.

and starter idle gear 03

O

.

~

ENGINE 3-25

•

Remove the water pump case

.

40

WATER PUMP DISASSEMBLY

CLUTCH

•

Remove the clutch cover

•

Remove the gasketDand dowel pins

(r

r5-14)

.

S

490

40

•

Hold the generator rotor with the special tool

09930-44541

•

While holding the generator rotor, remove the clutch spring set bolts and springs diagonally

•

Remove the pressure plate 02

: Rotor holder

.

40

~

3

-26 ENGINE

•

piece ©

.

I

•

.

k-

•

Unlock the clutch sleeve hub nut

While holding the clutch sleeve hub with the special tool,

•

remove the clutch sleeve hub nut

:

.

09920-53740

: Clutch sleeve hub holder

.

~

ENGINE 3-27

•

40

•

Remove the clutch drive cam

clutch sleeve hub

NOTE

:

The clutch drive and driven cams should be replaced as a set

•

Remove the thrust washer

•

Remove the primary driven gear assembly 14

(2

.

(2,

clutch driven cam 11 and

.

(D

.

4-

•

Remove the needle roller bearing 15

washer 17

GEAR POSITION SWITCH

•

Remove the gear position switch

•

Remove the gear position switch contacts ® and springs

.

,

spacer(* and thrust

.

OO

.

~

3-

2 8

ENGINE

OIL SUMP FILTER

•

Remove the oil sump filter

OIL PUMP

•

Remove the oil pump driven gear 90 by removing the snap ring

.

. .

09900-06107

: Spring ring pliers

.

•

Remove the pinOOand washer 03

NOTE

:

Do not drop the snap ring, pin and washer into the crankcase

Hold the generator rotor with the special tool

•

09930-44541

CAM DRIVE IDLE GEAR/SPROCKET

•

While holding the generator rotor, remove the cam drive idle

gear/sprocket nut

: Rotor holder

.

~

ENGINE 3-29

•

Insert a suitable bar into the holes of primary drive gears to

410

align the teeth of scissors gears

•

Remove the cam drive idle gear/sprocket and cam chain

•

Remove the key

O

.

PRIMARY DRIVE GEAR

•

Hold the generator rotor with the special tool

09930-44541

•

While holding the generator rotor, remove the primary drive gear nut

CAUTION

This bolt has left-hand thread clockwise may cause damage

•

Remove the washer ®

•

Remove the primary drive gear assembly

.

: Rotor holder

. Turning it counter-

.

0

.

9

~

3-30

ENGINE

•

Remove the key ® and thrust washer ®

.

GENENRATOR ROTOR

While holding the generator rotor with the special tool, remove

•

its bolt

. .

•

.

09930-44541

Install the special tool to the boss Remove the generator rotor by turning the special tool while

holding the generator rotor with the special tool

09930-30450

: Rotor holder

.

: Generator rotor remover bolt

k.

I

Remove the key 1O and starter driven gear E

•

Remove the cam drive idle gear shaft ® and cam chain ®

•

.