Suzuki SV650 1998 1999 2000 2001 2002 Workshop Service Repair Manual

Name: Suzuki SV650 1998 1999 2000 2001 2002 Workshop Service Repair Manual
Brand: Suzuki
SKU: 148751
Price: 16.99 USD
Availability: InStock

Normaler Preis: $16.99
Verkaufspreis: $16.99
Normaler Preis
Grundpreis: pro

27 people are viewing this right now

Typ: Motorcycle

Anbieter:

Suzuki

Art.-Nr: 148751

Stichworte: 1998 1999 2000 2001 2002 Agriculture Commando Series Motorcycle Same Suzuki SV650 Tractors

Produktvarianten

Beschreibung

Welcome to the comprehensive workshop service repair manual for the Suzuki SV650, covering model years 1998 through 2002. The SV650 is a celebrated sportbike/naked bike, recognized for its distinctive 90-degree V-twin engine, agile handling, and balanced performance, making it a popular choice for enthusiasts seeking a capable and engaging riding experience. This motorcycle's design philosophy emphasizes a blend of performance and usability, offering a sporty yet accessible platform that has earned acclaim for its value and character. This manual provides an exhaustive guide for maintaining and repairing your Suzuki SV650. It details essential procedures including routine maintenance, engine and transmission overhauls, chassis and suspension servicing, brake system repairs, and electrical system diagnostics. With over 500 pages of detailed instructions, exploded diagrams, and technical specifications, this resource is designed to assist owners, mechanics, and technicians in ensuring the optimal performance and longevity of their vehicle. It covers every aspect from basic adjustments to complex component rebuilds, ensuring comprehensive support for all service needs.

🏷️ Basic Information

Identification

Make:

Suzuki

Model:

SV650

Model Code:

Note: Specific model codes for these years are not provided, but variations like S (faired) and N (naked) exist.

Generation

Generation:

First Generation (1999-2002 for the US market, though production began in 1998 globally)

Codes

Chassis Codes:

Generally designated as 'N' for naked and 'S' for faired models. Specific chassis codes (e.g., BC-VP51A in Japan) are not detailed in the provided product information.

👋 Introduction

Market Position

Segment:

Sportbike/Naked Bike.

Target Audience:

Enthusiasts seeking a sporty, reliable, and relatively affordable V-twin motorcycle, suitable for commuting, spirited riding, and light touring. Appeals to both DIY mechanics and professional technicians.

Competitive Analysis

Competitors:

Ducati Monster series, Kawasaki ER-5, Honda CB500/CB600 Hornet, Yamaha FZS600 Fazer (depending on regional availability and specific model comparisons).

Key Features

Engine Layout:

Unique 90-degree V-twin architecture offering a distinctive character and sound.

Design Philosophy:

Emphasis on a balance of performance, usability, and value. The SV650 became renowned for its friendly power delivery and agile handling.

📋 Manual Details

Coverage Areas

Years Covered:

1998, 1999, 2000, 2001, 2002

Page Count

Total Pages:

503

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF

📖 Manual Coverage

Systems Covered

Engine:

V-twin, 90-degree, liquid-cooled, DOHC, 4-valve per cylinder. Includes disassembly, assembly, inspection, and repair of engine internals (pistons, rings, cylinders, crankshaft, connecting rods, camshafts, valves), lubrication system, cooling system, and fuel system (carburetors).

Transmission:

6-speed constant mesh. Covers clutch operation, transmission disassembly and assembly, gear shifting mechanisms, and related lubrication.

Chassis And Suspension:

Front telescopic fork (conventional or inverted depending on model variant), rear monoshock swingarm. Includes fork oil changes, seal replacement, shock absorber inspection and replacement, swingarm maintenance, and bearing checks.

Brakes:

Front dual discs with opposed piston calipers, rear single disc. Covers brake fluid replacement, caliper overhaul, master cylinder inspection, pad replacement, and bleeding procedures.

Electrical System:

Ignition system (CDI), charging system (alternator, regulator/rectifier), starter system, lighting, instrumentation, and wiring diagrams. Includes troubleshooting for electrical faults, component testing, and replacement.

Fuel System:

For these years, the SV650 utilized carburetors (typically Mikuni CV). The manual covers carburetor cleaning, adjustment, synchronization, jetting considerations, and fuel tank/petcock maintenance.

Exhaust System:

Covers inspection, removal, and installation of the exhaust system components, including mufflers and headers.

Cooling System:

Liquid cooling with radiator, fan, and coolant reservoir. Details coolant type, capacity, bleeding procedures, and component inspection.

Bodywork And Trim:

Includes procedures for removing and installing body panels, fairings (for 'S' models), seats, and fuel tank. Also covers minor bodywork repairs.

Procedures Included

Maintenance:

Routine maintenance tasks such as oil and filter changes, chain adjustment and lubrication, air filter replacement, spark plug replacement, brake fluid flush, coolant flush, and general inspection. Includes periodic maintenance schedules.

Troubleshooting:

Systematic diagnostic procedures for common problems, including hard starting, poor performance, electrical issues, braking problems, and suspension anomalies. Provides symptom-based troubleshooting charts.

Repair And Rebuild:

Detailed step-by-step instructions for engine disassembly, component inspection and measurement, reassembly, transmission overhaul, carburetor rebuilding, suspension fork servicing, and brake system repair.

Installation And Removal:

Comprehensive guidance on removing and installing virtually all components and systems of the motorcycle, from minor parts to major assemblies.

Adjustments:

Instructions for clutch cable adjustment, throttle cable adjustment, idle speed adjustment, carburetor synchronization, chain slack adjustment, and suspension pre-load adjustments.

Technical Depth

Depth:

Highly comprehensive, covering everything from basic owner maintenance to full engine rebuilds and advanced diagnostics. Includes factory specifications, tolerances, and wear limits.

Diagrams And Illustrations:

Abundant step-by-step procedures, exploded diagrams, detailed drawings, and photographs illustrating each service and repair operation, including the usage of special service tools.

Special Tools:

References specific Suzuki special service tools (SSTs) required for certain operations, often with illustrations showing their application.

📊 Manual Specifications

File Format

Format:

PDF

Print Quality

Printability:

Yes, all pages are printable.

Clarity:

High-resolution PDF ensures clear text and legible diagrams.

Binding Type

Binding:

Digital (PDF format - no physical binding)

Paper Type

Paper Type:

N/A (Digital document)

Compatibility

Operating Systems:

Windows, Mac, Linux OS.

Requirements

Software Requirement:

Adobe Reader or compatible PDF viewer.

⚙️ Engine Specifications

Primary Engine

Type:

90-degree V-twin, 4-stroke, DOHC, 4 valves per cylinder, liquid-cooled.

Displacement:

645cc (exact bore and stroke would be detailed in the manual).

Bore X Stroke:

Detailed in manual, but typically around 81 mm x 62.6 mm.

Compression Ratio:

Typically around 11.5:1. Specific values in manual.

Performance

Horsepower:

Approximately 70-75 HP at the crank (specific dyno figures vary). Manual will provide OEM specs.

Torque:

Around 45-50 lb-ft at the crank. Manual will provide OEM specs.

Fuel System

Carburetor Type:

Mikuni CV (Constant Velocity) carburetors, typically 39mm twin.

Fuel Delivery:

Carbureted with accelerator pump for improved throttle response.

Ignition System

Type:

CDI (Capacitor Discharge Ignition).

Cooling System

Type:

Liquid-cooled.

🔧 Transmission

Standard

Type:

6-speed, constant mesh.

Optional

Type:

N/A for this generation, manual transmission was standard.

Features

Clutch Type:

Wet, multi-plate, cable-actuated.

Final Drive:

Chain drive.

📐 Dimensions

Exterior

Length:

Detailed in manual, but typically around 2070 mm for naked, 2130 mm for faired.

Width:

Detailed in manual, but typically around 720 mm for naked, 750 mm for faired.

Height:

Detailed in manual, but typically around 1035 mm for naked, 1175 mm for faired.

Weights

Dry Weight:

Around 165-170 kg. Manual will have precise figures.

Wet Weight:

Around 185-190 kg. Manual will have precise figures.

Fuel Tank Capacity:

17 Liters (approx. 4.5 US gallons). Manual will confirm.

🛡️ Safety Features

Ratings

Crash Test Results:

N/A for motorcycles; safety is assessed through design, handling, and braking capabilities.

Active Features

Braking System:

Dual front disc brakes, single rear disc brake. ABS was not a common option for these early models. Manual provides detailed braking system service.

Passive Features

Frame Type:

Chassis construction is integral to safety and handling. The tubular steel frame (often referred to as a 'trellis' frame) provides rigidity. Manual details frame inspection.

Lighting:

Halogen headlight, LED taillight. Manual covers bulb replacement and wiring.

💡 Technology Features

Infotainment

Features:

Basic instrumentation including speedometer, tachometer, odometer, trip meter, and indicator lights. No complex infotainment systems present on these early models.

Driver Assistance

Features:

No electronic rider aids like traction control or advanced ABS (though some later models offered ABS). Focus is on mechanical systems and rider skill.

Connectivity

Features:

N/A; no modern connectivity features available.

🔧 Maintenance

Service Intervals

Oil Change:

Typically every 4,000-6,000 km (2,500-3,700 miles) or annually. Manual will specify exact interval.

Air Filter:

Inspect at 6,000 km (3,700 miles), replace as needed. Manual provides detailed inspection and replacement procedures.

Spark Plugs:

Replace typically every 12,000-16,000 km (7,500-10,000 miles). Manual lists recommended spark plug types and gap.

Valve Clearance:

Check at higher mileage intervals (e.g., 24,000 km or 15,000 miles). Manual provides precise checking and adjustment procedures.

Fluid Specifications

Engine Oil:

API SG or higher, JASO MA rated 10W-40 viscosity recommended. Manual will specify exact Suzuki-approved oil and capacity (typically around 3.4 L with filter change).

Coolant:

Mixture of antifreeze and distilled water (50/50 ratio). Manual will specify type and capacity.

Brake Fluid:

DOT 4 recommended for brake and clutch systems. Manual will specify exact type and replacement intervals.

Fork Oil:

Specific viscosity and quantity detailed in manual, often SAE 10W or similar.

Known Issues

Common Complaints:

Some owners report occasional issues with regulator/rectifier failure (heat-related), stator output degradation over time, and potential carb synchronization drift. Early models might have had minor fit and finish critiques compared to later iterations. Manual aids in diagnosing and rectifying these.

Wear And Tear Items:

Chain and sprockets, brake pads, tires, fork seals are common wear items that require periodic inspection and replacement as outlined in the manual's maintenance schedule.

📚 Vehicle History

Brand Heritage

Manufacturer:

Suzuki Motor Corporation, a Japanese multinational corporation renowned for its range of motorcycles, automobiles, and marine engines.

Model Evolution

Introduction Year:

1998 globally, with early models establishing the SV650's reputation.

Key Developments:

The first generation (1999-2002 US model years) set the standard for the SV650 line, characterized by its innovative V-twin engine and sporty yet accessible chassis. Subsequent generations introduced fuel injection, different frame materials, and styling updates.

Production

Manufacturing Location:

Primarily Japan, though assembly locations may vary by market. Specific details are not in the product description.

🏆 Awards & Recognition

Recognitions

Industry Acclaim:

The Suzuki SV650, particularly in its early iterations, received widespread critical acclaim for its excellent V-twin engine, agile handling, and strong value proposition, often being lauded as a benchmark in its class by motorcycle publications.

Ratings

Performance Reviews:

Consistently rated highly for its sporty performance combined with user-friendliness, making it a popular choice for both experienced riders and those upgrading from smaller displacement motorcycles.

Certifications

Manual Quality:

Described as 100% complete and intact, ensuring no missing or corrupt sections.