Suzuki Sv650 1999 2002 Service Repair Manual Parts Improved Pdf

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HOWTO USETHIS MANUAL ТО LOCATE WHATYOU ARE LOOKING FOR: 1 .The text of this manual is divided into sections.

2.The section titles are listed in the GHOUP INUEX. 3. Holding the manual as shovvn at the right will allovv you to find the first page of the section easily.

4.The contents are listed on the first page of each section to help find the item and page you need.

COMPONENT PARTS AND WORKTO BE DONE Under the name of each system or unit, is its exploded view. Work instructions and other service information such as the tightening torque, lubricating points and locking agent points, are provided.

Example: hront vvheel

CD bpacer (2) Spacer © Brake disc (R) ® Bearing (5) Spacer (6) Front vvheel (7) Brake disc (L) ® Speed sensor ® Front axle ® Front axle pinch bolt (c) Brake disc bolt

H ITEM

N-m

kgf-m

Ib-ft

® ® ©

65 23

6.5 2.3

47.0 16.5

23

2.3

16.5

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SYMBOL Listed in the table belovv are the symbols indicating instructions and other information necessary for servio ing. The meaning of each symbol is also included in the table.

SYMBOL

H ИГ

и

DEFINITION

SYMBOL

Torque control required.

Data beside it indicates specified torque.

rflTSI

Apply oil. Use engine oil unless othervvise specified.

i^^n

Apply molybdenum oil solution.

(Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1)

/^Л

Apply SUZUKI SUPER GREASE "A".

99000-25030

Л$М\

Apply SUZUKI SILICONE. GREASE 99000-25100

у^§Ц

Apply SUZUKI MOLY PASTE. 99000-25140

<1207в]

Apply SUZUKI BOND "1207B".

99104-31140

•Jl^ā

ApplyTHREAD LOCK SUPER "1303".

99000-32030

t£3

Apply THREAD LOCK "1342".

99000-32050

TS

Apply THREAD LOCK SUPER "1360".

99000-32130

0 ©

DEFINITION Use engine coolant.

Use fork oil.

99000-99044-10G

Apply or use brake fluid.

Measure in voltage range.

Measure in current range.

< &

e w Йш DATA

Measure in diode test range.

Measure in continuity test range.

Use special tool.

Indication of service data.

- www.instant-manuals.com GENERALINFORMATION 1-1

CONTENTS WARNING/CAUTION/NOTE

1- 2

GENERAL PRECAUTIONS

/- 2

SUZUKI SV650X ('99-MODEL)

1- 4

SERIAL NUMBER LOCATION

1- 4

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION

1- 5

FUEL

1- 5

ENGINE OIL

1- 5

BRAKE FLUID

1- 5

FRONT FORK OIL

1- 5

ENGINE COOLANT

1- 6

WATER FOR MIXING

1- 6

ANTI-FREEZE/ENGINE

COOLANT

LIOUID AMOUNT OF WATER/ENGINE COOLANT

1- 6 1- 6

BREAK-IN PROCEDURES

1- 6

CYUNDER IDENTIFICATION

1- 6

INFORMATION LABELS

1- 7

SPECIFICATIONS

1- 8

COUNTRY AND AREA CODES

1-10

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GENERALINFORMATION

WARNING/CAUTION/NOTE Please read this manual and follovv its instructions carefully. То emphasize special information, the symbol and the vvords VVARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal vvords.

A VVARNING Indicates a potential hazard that could result in death or injury.

A CAUTION Indicates a potential hazard that could result in motorcycle damage.

NOTE: Indicates special information to make maintenance easier or instructions clearer.

Please note, hovvever, that the vvarnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the motorcycle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.

GENERAL PRECAUTIONS A VVARNING k

Proper service and repair procedures are important for the safety of the service mechanic and the aafety and reliability of the motorcycle. ' When 2 or more persons work together, pay attention to the safety of each other.

'When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors. ' When vvorking with toxic or flammable materials, make sure that the area you work in is wellventilated and that you follovv all of the material manufacturer's instructions.

1 Never use gasoline as a cleaning solvent. 'То avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system until they have cooled. ' After servicing the fuel, oil, engine coolant, exhaust or brake systems, check all lines and fittings related to the system for leaks.

- www.instant-manuals.com GENERALINFORMATION

1-3

A CAUTION

* If parts replacement is necessary, replace the parts vuith Suzuki Genuine Parts or their equivaienl.

* When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinsīalled in the proper order. * Be sure to use special tools when instructed. * Маке sure that all parts used in reassembly are clean. Lubricate them when specified. * Use the specified lubricant, bond, or seaiant. * When removing the battery, disconnect the negative cable first and then the positive cable. * When reconnecilng the Ьапегу, connect the positive cable first and then the negative cable, and cover the positive terminal vvith the terminal cover. * When performing service to electrical parts, disconnect the battery negaiive cable unless the seruice procedure requires the battery power. * When tightening cylinder head and crankcase bolts and nuts, tighten the larger sizes first.

Always tighten the bolts and nuts diagonally from the inside working out and to the specified tightening torque. * VVhenever you remove oil seais, gaskets, packing, O-rings, locking washers, seif-iocking nuts, cotter pins, circlips, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating curfaooc.

* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. * Use a torque uvrench to tighten fasteners to the specified torque. Wipe off grease and oil if а thread is smeared with them. * After reassembling, check parts for tightness and proper operation.

* То protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other fluids - hatteries, and tires.

* То protect the earth's natural resources, properly dispose of used motorcycles and parts.

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GENERALINF0HMA710N

SUZUKI SV650X (99-MODEL)

HIGHT SIDE

LEFT SIOE

' Dtfferenge between photograpti andacttjafmotorevdettepefids от ine marhiels,

SERIAL NUMBER LOCATION Ths frame serial number or V.I.N. (Vehicle Ideritification Number) <§> is stamped on the rigtit side of the steering head pīpe. The engine sertal nuinber ® is located on the lefi side of the cnankcase. These numbers

- www.instant-manuals.com GENERALINFORMATION 1-5

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION FUEL (For U.S.A. model) 1. Use only unleaded gasoline of at least 87 pump octane ( R t M ) method or 91 octane or higher rated by the research method.

2.Suzuki recommends that customers use alcohol free, unleaded gasoline vvhenever possible.

3.Use of blended gasoline containing MTBE (Methyl Tertiary Butyl Ether) is permitted.

4.Use of blended gasoline/alcohol fuel is permitted, provided that the fuel contains not more than 10% ethanol. Gasoline/alcohol fuel may contain up to 5% methanol if appropriate cosolvents and corrosion inhibitors are present in it.

5.lf the performance of the vehicle is unsatisfactory vvhile using blended gasoline/alcohol fuel, you should svvitch to alcohol-free unleaded gasoline.

6.Failure to follovv these guideline could possibly void applicable warranty coverage. Check with your fuel supplier to make sure that the fuel you intend to use meets the requirements listed above.

ENGINE OIL SUZUKI recommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil vvhich is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 10W/40. If an SAE 10VV/40 oil is not available, select and alternative according to the right chart.

MULTIGRADE

TEMP.*;

- 3 0 - 2 0 - 1 0 0 10 20 30 40 -f 22 -4 14 32 60 68 86 104

BRAKE FLUID Use DOT4 brake fluid.

A VVARNING Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, othervvise serious damage will result.

Do not use any brake fluid taken from old or used or unsealed containers.

Never re-use brake fluid left over from a previous servicing, vvhich has been stored for a long period.

FRONT FORK OIL Use SUZUKI FORK OIL G10 or an eguivalent fork oil.

- www.instant-manuals.com 1-6

GENERALINFORMATION

ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled vvater only.

WATER FOR MIXING Use distilled vvater only. Water other than distilled vvater can corrode and clog the aluminum radiator.

ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust inhabit as well as anti-freeze. Therefore, the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point.

LIQUID AMOUNT OF VVATER/ENGINE COOLANT Solution capacity (total): 1 600 ml (1.7/1.4 US/lmp qt) For engine coolant mixture information, refer to cooling system section. ķzr 5-2) A CAUTION « Mixing of anti-freeze/engine coolant should be limited to 60%. Mixing beyond it vvould reduce its efficiency. If the anti-freeze/engine coolant mixing ratio is belovv 50%, rust inhabiting performance is greatly reduced. Be sure to mix it above 50% even though the atmospheric temperature doee not go down to the freezing point.

BREAK-IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allovv the moving parts to "BREAK-IN" before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follovvs.

• Keep to these Initial 800 Up to 1 600 Overto 1 600

break-in procedures: km ( 500 miles): Belovv 5 000 r/min km (1 000 miles): Belovv 8 000 r/min km (1 000 miles): Belovv 10 500r/min

• Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throttle operation. Hovvever, do not exceed 11 000 r/min at any time.

FRONT

CYLINDER IDENTIFICATION The two cylinders of this engine are identified as No.1 and No.2 cylinder, as vievved from front to rear (as vievved by the rider on the seat).

NO.1

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)

® Noise label (For E-03, 24, 33, 34) ® Information label (For E-03, 28, 33) ® Vacuum hose routing label (For E-33) ® Fuel caution label (For E-02, 24) © Manual notice label (For E-03, 33) © Frame caution label (For E-03, 28, 33) ® Frame caution label (Except for E-03,28,33) ®Tire pressure label © VVarning safety label ® ICES Canada label (For E-28) @ ID plate (Except for E-03,28,33) ©IDplate(ForE-18) ® Safety plate (For E-03,28,33)

<D

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GENERALINFORMATION

SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length Overall vvidth Overall height VVheelbase Ground cleamce Seat height Dry mass

ENGINE Туре

2 070 mm 750 mm 1 060 mm 1 430 mm 140 mm 805 mm 165 kg

(81.5 in) (29.5 in) (41.7 in) (56.3 in) ( 5.5 in) (31.7 in) (363 Ibs)

Number of cylinders Tappet clearance, IN EX Bore Stroke Piston displacement Compression ratio Carburetor Air cleaner Starter system Lubrication system

Four-stroke, Liquid-cooled, DOHC, TSCC, 90-degree V-twin 2 0.10 - 0.20 mm (0.004 - 0.008 in) 0.20 - 0.30 mm (0.008 - 0.012 in) 81.0 mm (3.189 in) 62.6 mm (2.465 in) 645 cm3 (39.4 cu. in) 11.5 : 1 MIKUNI BDSR39 x 2 Non-woven fabric element Electric starter Wet sump

TRANSMISSION Clutch Transmission Gearshift pattern Primary reduction ratio Gear ratios, Low 2nd 3rd 4th 5th Тор Final reduction ratio Drive chain

Wet multi-plate type 6-speed constant, mesh 1-down, 5-up 2.088 (71/34) 2.461 (32/13) 1.777(32/18) 1.380 (29/21) 1.125(27/24) 0.961 (25/26) 0.851 (23/27) 3.000 (45/15) D.I.D 525 V8,110 links

- www.instant-manuals.com GENERALINFORMATION 1-9 CHASSIS

Front suspension Rear suspension Front fork stroke Rear wheel travel Steering angle Caster Trail Turning radius Front brake Rear brake Front tire size Reartiresize

Telescopic, coil spring, oil damped Link type system, gas/oil damped, coil spring 130 mm (5.1 in) 125 mm (4.9 in) 33° (right & left) 25° 100 mm (3.94 in) 2.9 m (9.5 ft) Disc brake, twin hydraulically operated Disc brake, hydraulically operated 120/60 ZR17 (55 W), tubeless 160/60 ZR17 (69 W), tubeless

ELECTRICAL Ignition type Ignition timing Spark plug вапегу Generator Main fuse Fuse Headlight Turn signal light Brake light/Taillight License plate light Speedometer light Neutral indicator light High beam indicator light Turn signal indicator light Oil pressure indicator light

Electronic ignition (Transistorized) 5° B.T.D.C. at 1 300 r/min NGK CR8E, DENSO U24ESR-N 12V зб.о кС(ю A M ) / I O H R Three-phase A.C. Generator 30A 15/15/15/10/10A 12V 60/55VV 12V 21W 12V 21/5VV x 2 12V 5W 12V 1.7W x 2 12V 1.7W 12V 1.7W 12V 1.7W 12V 1.7W

CAPACITIES Fuel tank, including reserve Engine oil, oil change with filter change overhaul

Coolant

16.0 L (4.2/3.5 US/lmp gal) 15.0 L (4.0/3.3 US/lmp gal) 2 300 ml (2.4/2.0 US/lmp qt) 2 400 ml (2.5/2.1 US/lmp qt) 2 700 ml (2.9/2.4 US/lmp qt)

1 600 ml (1.7/1.4 US/lmp qt)

These specifications are subject to change vvithout notice.

Only for E-33

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GENERALINFORMATION

COUNTRY AND AREA CODES Th© follovving codes stand for the applicable country(-ies) and area(-s).

CODE

COUNTRY or AREA

E-02

U.K.

E-03

USA (Except for california)

E-04

France

E-17

Svveden, Finland (E-15), Norway (E-16)

E-18

Svvitzerland, Austria (E-39)

E-22

Germany

E-24

Australia

E-25

Netherlands

E-28

Canada

E-33

Califomia (USA)

E-34

ltaly, Belgium (E-21), Spain (E-53)

- www.instant-manuals.com PERIODIC MAINTENANCE 2-1

CONTENTS PERIODIC MAINTENANCE SCHEDULE

2- 2

PERIODIC MAINTENANCE CHART

2- 2

LUBRICATION POINTS

2- 3

MAINTENANCE AND TUNE-UP PROCEDURES

2- 4

AIR CLEANER

2- 4

SPARK PLUG

2- 5

TAPPET CLEARANCE

2- 8

ENGINE OIL AND OIL FILTER

2-13

FUELHOSE

2-15

ENGINEIDLE SPEED

2-15

CARBURETOR SYNCHRONIZATION THROTTLE CABLE PLAY

2-15 2-16

CLUTCH COOLING SYSTEM

2-17 2-18

DRIVECHAIN

2-20

BRAKE

2-22

TIRE

2-25

STEERING

2-26

FRONTFORK

2-27

REAR SUSPENSION

2-27

EXHAUST PIPE BOLT AND NUT

2-27

CHASSIS BOLT AND NUT

2-28

COMPRESSION PRESSURE CHECK

2-30

OIL PRESSURE CHECK

2-31

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PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE IMPOTANT: The periodic maintenance intervals and service requirements have been established in accordance with EPA regulations. Follovving these instructions will ensure that the motorcycle will not exceed emission standards and it will also ensure the reliability and performance of the motorcycle.

The chart belovv lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and есопоту. Maintenance intervals are expressed in terms of kilometer, miles and months, and are dependant on vvhichever comes first.

NOTES: More frequent servicing may be performed on motorcycles that are used under severe conditions.

PERIODIC MAINTENANCE CHART ^~~~~^-^^^ Item Air cleaner Spark plugs Tappet clearance Engine oil Engine oil filter Fuel hose

Interval

km miles ~~~~--^_ months

Engine idle speed Carburetor synchronization Evaporative amission control system (E-33 only) PAIR (air supply) system (E-33 only) Throttle cable play Clutch cable play Radiator hoses Engine coolant Drive chain Brakes Brake hoses Brake fluid Tire Steering Front forks Rear suspension Exhaust pipe bolt and nut Chassis bolt and nuts

1 000 600 1 R R I I (E-33 only) -

18 000 12 000 6 000 7 500 11 000 4 000 12 18 6 R I I I R I R R R R I I I Replace every 4 \^ears.

I I I -

I

24 000 15 000 24 R R

-

I Replace vapor hose every 4 years.

I I I I I I I I Replace every 2 years I I I Clean and lubricate every 1 000 km (600 miles).

I I I I I Replace every 4 ^/ears.

I I Replace every 2 \^ears.

I I I I I I T T T T T T T T

/ = Inspect and adjust, clean, lubricate or replace as necessary.

R = Replace T = Tighten

- www.instant-manuals.com PERIODIC MAINTENANCE 2-3

LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each vvorking part of the motorcycle.

Major lubrication points are indicated belovv.

""loļl Brake lever holder and t l throttle cables

у^нВгаке pedal pivot and footrest pivot

ļotl Clutch lever holder and clutch cable

,Sģ*Side-stand pivot and spring hook

, \

__ ļPļ1 Drive chain

^fgnFootrest pivot

NOTE: * Befoie lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime. * Lubricate exposed parts which are subject to rust, with a rust preventative spray, especially vvhenever the motorcycle has been operated under wet or rainy conditions.

- www.instant-manuals.com 2-4

PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart.

AIR CLEANER Inspect every 6 000 km (4 000 miles, 6 months) and replace every 18 000 km (11 000 miles, 18 months).

• Remove the front and rear seats. (CF 3 6-3) • Lift and support the fuel tank. (C~T 4-4)

• Remove the air cleaner element ф by removing the screvvs.

Carefully use air hose to blow the dust from the cleaner element.

A CAUTION Always use air pressure on the outside of the air cleaner element. If air pressure is used on the inside, dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element.

Reinstall th© cleaned or new air cleaner element in the reverse order of removal.

- www.instant-manuals.com PERIODIC MAINTENANCE 2-5 A CAUTION If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine vvithout the element or to use a torn element. Маке sure that the air cleaner is in good condition at all times. The life of the engine depends largely on this component!

Remove the drain plugs (© and (D) from the air cleaner drain hose and air cleaner box to allovv any vvater to drain out.

SPARK PLUG Inspect every 6 000 km (4 000 miles, 6 months) and replace every 12 000 km (7 500 miles, 12 months).

N0.1 (FRONT) SPARK PLUG REMOVAL • Disconnect the horn lead vvires.

• Remove the horn with its bracket.

- www.instant-manuals.com 2-6

PERIODIC MAINTENANCE

Remove the radiator mounting bolt.

Disconnect the cooling fan thermo-svvitch lead wire.

* Move the radiator lovver side to forvvard.

NOTE: * Do not extract the radiator hoses. * Place a wooden block ® between the radiator and the front cylinder to facilitate spark plug removal.

• Remove the spark plug cap.

• Remove the spark plug with a spark plug vvrench.

NOTE: Be careful not to damage the radiator fins.

A VVARNING тпе not radiator and the hot engine can burn you. wait until the radiator and the engine are cool enough to touch.

N0.2 (REAR) SPARK PLUG REMOVAL • Remove the front and rear seats. (C7" 6-3) • Lift and support the fuel tank. (C7* 4-4)

• Remove the spark plug cap.

• Remove the spark plug with a spark plug vvrench.

- www.instant-manuals.com PERIODIC MAINTENANCE 2-7 HEAT RANGE • Check to see the heat range of the plug.

—

■

_

_

_

_

_

Standard Colder type

NGK CR8E CR9E CR10E

DENSO U24ESR-N U27ESR-N U31ESR-N

NOTE: "R" type spark plug has a resistor located at the center electrode to prevent to prevent radio noise.

CARBON DEPOSITS • Check to see if there are carbon deposits on the spark plug.

• If carbon is deposited, remove it using a spark plug cleaner machine or carefully use a tool with a pointed end.

SPARK PLUG GAP • Measure the spark plug gap using a thickness gauge.

• If out of specification, regap the spark plug.

Spark plug gap Standard: 0.7 - 0.8 mm (0.028 - 0.031 in) 109900-20803: Thickness gauge ELECTRODE'S CONDITION • Check the condition of the electrode.

• If it is extremely worn or burnt, replace the spark plug. Replace the spark plug if it has a broken insulator, damaged thread, etc.

A CAUTION Check the thread size and reach when replacing the spark plug. If the reach is too short, carbon will be deposited on the screvv portion of the spark plug hole and engine damage may result.

SPARK PLUG INSTALLATION A CAUTION То avoid damaging the cylinder head threads, first finger tighten the spark plug and then tighten it to the proper torque using the spark plug vvrench.

• First, finger tighten the spark plugs, and then tighten them to the specified torque. Ш Spark plug: 11 N-m (1.1 kgfm, 8.0 Ib-ft)

ļ Gap: 0.7 - 0.8 mm

(0.028 - 0.031 in)

- www.instant-manuals.com 2-8

PERIODIC MAINTENANCE

NOTE: When fitting the sparkplug caps, front and rear, face the triangle marks on the water-proof covers @ to each cylinder exhaust side.

TAPPET CLEARANCE Inspect every 24 000 km (15 000 miles, 24 months).

Remove the front and rear seats. (С~Г 6-3) Lift and support the fuel tank. (Г~7° 4-4)

Remove the radiator. (СУ 5-4) Remove the spark plugs, front and rear. (E~T 2-5) Remove the cylinder head covers, front and rear.

The tappet clearance specification is different for intake and exhaust valves.

Tappet clearance must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshafts are disturbed by removing them for servicing.

1ДДИ Tappet clearance (vvhen cold): IN. : 0.10 - 0.20 mm (0.004 - 0.008 in) EX.: 0.20 - 0.30 mm (0.008 - 0.012 in) NOTE: * The tappet clearance should be taken when each cylinder is at Тор Dead Center (TDC) of compression stroke. * The cams (IN & EX) on the front cylinder at position ® show Ihe front uylinder at TDC of compression stroke. * The cams (IN & EX) on the rear cylinder at position ® show the rear cylinder at TDC of compression stroke. * The dearance specification is for COLD state. * То turn the crankshaft for clearance checking, be sure to use а wrench, and rotate in the normal running direction. АН spark plugs should be removed.

- www.instant-manuals.com PERIODIC MAINTENANCE 2-9

Remove the generator cover plug © and the timing inspection plug ®-

• Turn the crankshaft to set the No.1 (Front) cylinder at TDC of compression stroke. (Align the" | F" line on the generator rotor to the index mark of valve timing inspection hole and also bring the camshafts to the position as shovvn in page 2-8.)

То inspect the No.1 (Front) cylinder tappet clearance, use а thickness gauge betvveen the tappet and the cam. If the clearance is out of specification, adjust it into the specified range.

09900-20803: Thickness gauge

• Turn the crankshaft 270 degrees (3/4 turns) to set the No.2 (Rear) cylinder at TDC of compression stroke. (Align the " | R" line on the generator rotor to the index mark of valve timing inspection hole and also bring the camshafts to the position as shovvn in page 2-8.)

• Inspect the No.2 (Rear) cylinder tappet clearance as the same manner of No.1 (Front) cylinder and adjust the clearance if necessary.

109900-20803: Thickness gauge

- www.instant-manuals.com 2-10 PERIODIC MAINTENANCE TAPPET CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim.

• Remove the intake or exhaust camshafts. (C7* 3-21, 3-23) • Remove the tappet and shim by fingers or magnetic hand.

• Check the figures printed on the shim. These figures indicate the thickness of the shim, as illustrated.

• Select a replacement shim that will provide a clearance vvithin the specified range. For the purpose of this adjustment, a total of 21 sizes of tappet shim are available ranging from 1.20 to 2.20 mm in steps of 0.05 mm. Fit the selected shim to the valve stem end, with numbers tovvard tappet. Be sure to check shim size with micrometer to ensure its size. Refer to the tappet shim selection table (C~T 2-11, 2-12) for details.

NOTE: * Be sure to apply englne oll to tappet shim хор and bottom faces. * When seating the tappet shim, be sure to face figure printed surface to the tappet.

A CAUTION Reinstall the camshafts as the specified manner.

(C7* 3-109,3-113)

After replacing the tappet shim and camshafts, rotate the engine so that the tappet is depressed fully. This will squeeze out oil trapped betvveen the shim and the tappet that could cause an incorrect measurement, then check the clearance again to confirm that it is vvithin the specified range.

After finishing the tappet clearance adjustment, reinstall the follovving items.

Page Cylinder head cover 3-118 Spark plug and plug cap 2-7 and -8 Valve timing inspection plug 3-119 Generator cover plug 3-119

(V)c=>

1.70 mm

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TAPPET SHIM SELECTION TABLE [INTAKE] TAPPET SHIM N0. (12892-05С00-ХХХ) TAPPET SHIM SET (12800-05820)

N^ \

SUFFIX N0.

ТАРРЕГ

120

125

130

135

140

145

150

155

160

165

170

175

180

185

190

195

200

205

210

215

220

4 S H I M SIZE N . ( m m ) 1.20

1.25

1.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

PRESENT

X

CLEAFANCE (mm)

0.00-0.04 0.05-0.09

1.20

1.25

1.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

1.20

1.25

1.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

0.10-0.2Э

SPECIFIED CLEARANCE/NO ADJUSTMENT REQUIRED

0.21.0.25

1.30

1.36

1.40

1.45

1.50

1.55-

1.60

1.65

1.70

1.76

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15 J 2.20 2.20

0.26-0.30

1.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1 85 1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.31-0.35

1.40

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2,15

2.20

2.20

0.36-0.4Э

1.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

0.41-0.45

1.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.46-0.50

1.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.51-0.55

1.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.56-0.60

1.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.61-0.65

1.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.66-0.70

1.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.71-0.75

1.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.76-0.80

1.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.81-0.85

1.90

1.95

2.00

2.05

2.10

2.15

2.20

0.86-0.90

1.95

2.00

2.05

2.10

2.15

2.20

0.91-0.95

2.00

2.05

2.10

2.15

2.20

0.96-1.00

2.05

2.10

2.15

2.20

1.01-1.05

2.10

2.15

2.20

1.06-1.10

2.15

2.20

1.11-1.15

2.20

|

HOVVTO USE THIS CHART: I. Measure tappet clearance. "ENGINE IS COLD" II. Measure present shim size.

III. Match clearance in vertical column with present shim size ir EXAMPLE Tappet clearance is Present shim size Shim size to be used

0.23 mm 1.70 mm 1.80 mm

m </> о m

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