Suzuki SV650 2003 Service Manual

Suzuki SV650 2003Suzuki SV650 2003




Service Manual for Suzuki SV650 2003 motorcycles. Service Manual Suzuki, a great reference for the repair and maintenance.

Service Manual, fix motorcycle yourself with a repair manual.

Content Suzuki SV650 2003 Service Manual

General information
Warning/caution/note
General precautions
Serial number location
Fuel, oil and engine coolant recommendation
Fuel
Engine oil
Brake fluid
Front fork oil
Engine coolant
Water for mixing
Anti-freeze/engine coolant
Liquid amount of water/engine coolant
Break-in procedures cylinder identification
Information labels specifications
Country and area codes

Periodic maintenance
Periodic maintenance schedule
Periodic maintenance chart
Lubrication points
Maintenance and tune-up procedures
Air cleaner
Spark plug
Tappet clearance
Engine oil and oil filter
Fuel hose
Engine idle speed
Carburetor synchronization
Throttle cable play
Clutch
Cooling system
Drive chain
Brake
Tire
Steering
Front fork
Rear suspension
Exhaust pipe bolt and nut
Chassis bolt and nut
Compression pressure check
Oil pressure check

Engine
Engine components removable with the engine in place
Engine removal and installation
Engine removal
Engine installation
Engine disassembly
Engine components inspection and service
Camshaft
Cam chain tension adjuster
Cam chain tensioner
Cam chain guide
Cylinder head and valve
Cylinder
Piston and piston ring
Conrod and crankshaft
Crankshaft journal bearing
Crankshaft thrust bearing
Crankcase
Clutch
Primary driven gear
Gearshift shaft/gearshift arm
Transmission
Starter clutch
Generator and signal
Generator oil pump
Engine reassembly

FI system diagnosis
Precautions in servicing
Electrical parts
Fuse
ECM/Various sensors
Electrical circuit inspection procedure
Using testers
FI system technical features
Injection time (injection volume)
Compensation of injection time (volume)
Injection stop control
FI system parts location
FI system wiring diagram
Self-diagnosis function
User mode
Dealer mode
TPS adjustment
Fail-safe function
FI system troubleshooting
Customer complaint analysis
Self-diagnostic procedures
Self-diagnosis reset procedure
Malfunction code and defective condition
“C12” ckp sensor circuit malfunction
“C13” lap sensor circuit malfunction
“C14” tp sensor circuit malfunction
“C15” ect sensor circuit malfunction
“C21” iat sensor circuit malfunction
“C23” to sensor circuit malfunction
“C24” or “C25” ignition system malfunction
“C28” stv actuator circuit malfunction
“C29” stp sensor circuit malfunction
“C31” gear position (GP) switch circuit malfunction
“C32” or “C33” fuel injector circuit malfunction
“C41″fp relay circuit malfunction
“C42” ig switch circuit malfunction
“C49” pair control solenoid valve circuit
Malfunction
Sensors
CKP sensor inspection
CKP sensor removal and installation
IAP sensor inspection
IAP sensor removal and installation
TP sensor inspection
ECT sensor inspection
ECT sensor removal and installation
IAT sensor inspection
IAT sensor removal and installation
TO sensor inspection
TO sensor removal and installation
STP sensor inspection
STP sensor removal and installation
STP sensor adjustment

Fuel system and throttle body
Fuel System
Fuel delivery system
Fuel pump
Fuel pressure regulator
Fuel injector
Fuel pump control system
Fuel tank lift-up
Fuel tank removal
Fuel tank installation
Fuel pressure inspection
Fuel pump inspection
Fuel pump relay inspection
Fuel pump and fuel filter removal
Fuel mesh filter inspection and cleaning
Fuel pump case bushing inspection
Fuel level switch
Fuel pump and fuel mesh filter installation
Throttle body and stv actuator
Construction
Air cleaner and throttle body removal
Throttle body disassembly
Throttle body cleaning
Throttle body inspection
Throttle body reassembly
STV synchronization
Throttle body installation
STP sensor adjustment
Air cleaner box installation
Tp sensor adjustment
Fast idle inspection
Fast idle adjustment
Throttle valve synchronization

Cooling and lubrication system
Engine coolant
Cooling circuit
Cooling circuit inspection
Radiator and water hoses
Radiator removal
Radiator cap inspection

Radiator inspection and cleaning
Water hose inspection
Radiator remounting
Cooling fan
Removal
Inspection
Cooling fan thermo-switch
Removal
Inspection
Installation
Engine coolant temperature switch
Removal
Inspection
Installation
Thermostat
Removal
Inspection
Installation
Water pump
Removal and disassembly
Inspection
Reassembly and installation
Lubrication system
Oil pressure
Oil filter
Oil pressure regulator
Oil strainer
Oil jet
Oil pump
Oil pressure switch
Oil cooler
Removal
Inspection and cleaning
Installation
Engine lubrication flow chart
Engine lubrication circuit

Chassis
exterior parts
Construction
Rear seat
Frame side cover
Front seat
Front fender
Seat tail cover
Front wheel
Construction
Removal
Disassembly
Inspection
Reassembly and remounting
Front fork
Construction
Removal and disassembly
Inspection
Reassembly and remounting
Steering
Construction
Handlebars
Steering removal
Steering inspection and disassembly
Steering installation
Steering tension adjustment
Rear wheel
Construction
Removal
Disassembly
Inspection
Reassembly and remounting
Rear suspension
Construction
Rear shock absorber and cushion rod
Swingarm
Suspension setting
Front brake
Construction
Brake fluid replacement
Brake pad replacement
Front brake caliper
Front master cylinder
Rear brake
Construction
Brake fluid replacement
Brake pad replacement
Rear brake caliper
Rear master cylinder
Tire and wheel
Tire removal
Inspection
Tire installation

Electrical system
Cautions in servicing
Location of electrical components
Charging system
Description
Troubleshooting
Inspection
Starter system and side-stand/ignition
Interlock system
Starter system description
Side-stand/ignition interlock system
Description
Troubleshooting
Starter motor removal and disassembly
Starter motor inspection
Starter motor reassembly and installation
Starter relay inspection
Side-stand/ignition interlock system part inspection
Ignition system (digital ignitor)
Description
Troubleshooting
Inspection
Speedometer
Removal
Construction
Inspection
Relays
Starter relay
Turn signal/side-stand relay
Lamps
Headlight
Brake light/taillight
Turn signal lights
Switches
Ignition switch removal
Battery
Specifications
Initial charging
Servicing
Recharging operation

Servicing information
Troubleshooting
Engine
Radiator
Carburetor
Chassis
Brakes
Electrical
Battery
Wiring diagram
Wire harness, ca le and hose routing
Wire harness routing
Wiring harness routing
Speed sensor lead wire routing
Cable routing
Fuel system hose routing
Cooling system hose routing
Front rake hose routing
Rear rake hose routing
Pair (air supply) system hose routing
Fuel tank set-up
Special tools
Tightening torque
Engine
Chassis
Tightening torque chart
Service data

Emission control information
Emission control carburetor components
Evaporative emission control system
Canister hose routing
Evaporative emission control system inspection
Pair (air supply) system diagram
Pair (air supply) system hose routing
Ipair (air supply) system inspection