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3 Engine .pdf



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ENGINE

ENGINE

CONTENTS
ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN
PLACE

3- 2

ENGINE REMOVAL AND INSTALLATION

3- 3

ENGINE REMOVAL
ENGINE INSTALLATION

S

ENGINE DISASSEMBLY
ENGINE TOP SIDE
ENGINE BOTTOM SIDE

3- 3
3-14
3-23
3-23
3-30

ENGINE COMPONENTS INSPECTION AND SERVICING 3-40
CYLINDER HEAD COVER
CAMSHAFT/CAMSHAFT JOURNAL
CYLINDER HEAD AND VALVE
CYLINDER
PISTON AND PISTON RING
CONROD AND CRANKSHAFT
CRANKCASE
CRANKSHAFT JOURNAL BEARING
CRANKCASE BEARING AND OIL SEAL
CLUTCH
PRIMARY DRIVEN GEAR ASSEMBLY
GEARSHIFT SHAFT/GEARSHIFT ARM
TRANSMISSION
STARTER CLUTCH
GENERATOR AND SIGNAL GENERATOR
OIL PUMP
CLUTCH RELEASE
ENGINE REASSEMBLY
ENGINE BOTTOM SIDE
ENGINE TOP SIDE

3-40
3-41
3-44
3-53
3-54
3-56
3-60
3-64
3-69
3-72
3-73
3-74
3-75
3-82
3-83
3-84
3-84
3-85
3-85
3-97

3-1

3-2 ENGINE

'4

ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE
Engine components which can be removed while the engine is installed on the chassis are listed below . For
the installing and removing procedures, refer to respective paragraphs describing each component .
ENGINE LEFT SIDE
PARTS
Engine sprocket
Generator
Gear position switch
Clutch release
Starter idle gear

REMOVAL
3-8
3-30,3-36
3-37
3-7

INSTALLATION
3-18
3-89,3-96
3-88
3-19

3-30

3-96

REMOVAL

INSTALLATION

3-31
3-33,3-73
3-35
3-33
3-34
6-14

3-93
3-73,3-93
3-90
3-92
3-91
6-17

REMOVAL
5-17
3-24
3-25,3-27
3-26,3-29
3-27,3-29
3-27,3-30
3-26,3-28
6-12
2-15
3-61
3-30

INSTALLATION
5-29
3-109
3-102, 3-105
3-100
3-99
3-97
3-104, 3-107
6-13
2-15
3-61
3-97

ENGINE RIGHT SIDE
PARTS
Clutch
Primary driven gear
Primary drive gear
Oil pump
Gearshift shaft
Water pump
ENGINE CENTER
PARTS
Throttle body
Cylinder head covers
Camshafts
Cylinder heads
Cylinders
Pistons
Cam chain tension adjusters
Thermostat
Oil filter
Oil pressure switch
Starter motor

i



ENGINE 3-3

ENGINE REMOVAL AND INSTALLATION
ENGINE REMOVAL
Before taking the engine out of the frame, wash the engine
using a steam cleaner . Engine removal is sequentially explained
in the following steps . Reinstall the engine by reversing the
removal procedure .

r/

• Remove the cowling . (SV650S) (=7-6)
• Remove the front and rear seat . (r r'7-4)
• Lift and support the fuel tank with the prop stay . (F-75-6)

• Disconnect the battery O lead wire and

• Drain engine oil . (=2-14)
i~. 4F

• Drain engine coolant . ( F-7- 2-20)

44

OO

lead wire .




3-4 ENGINE

• Loosen the throttle body clamp screws 10 at the air cleaner
box side .

• Disconnect the IAP sensor coupler CU and hose

• Disconnect the IAT sensor coupler

U.

4.

• Disconnect the front side of crankcase breather hose
rear side of crankcase breather hose © .

O

and

0
• Disconnect the PAIR hose 07 and coupler © .



ENGINE

• Disconnect the cooling fan thermo-switch lead wire coupler .

• Disconnect the radiator outlet hose .
• Disconnect the reserve tank hose .
• Remove the radiator mounting bolts .

• Disconnect the radiator inlet hose .

• Disconnect the horn coupler

• Remove the radiator

O and

cooling fan coupler C2 .

(I .

CAUTION
Be careful not to bent the radiator fin .

• Remove the throttle body . (f -r5-17)

3 -5



3-6 ENGINE

• Loosen the No .1 (Front) cylinder exhaust pipe connector bolt .
• Remove the No .1 (Front) cylinder exhaust pipe bolts O.

• Loosen the No .2 (Rear) cylinder exhaust pipe connector bolt .

• Remove the muffler mounting bolt and nut .
• Remove the exhaust pipe mounting bolts and nut .
• Remove the exhaust pipe/muffler .



ENGINE

• Remove the engine sprocket cover 1~ .
• Remove the gearshift lever OO .

• Remove the clutch release assembly ©, its support plate
and spring ($) .

• Remove the clutch push rod © .
• Remove the clutch cable from the generator cover .

NOTE:
If it is necessary to replace the clutch cable or clutch release
lever, pry up and bend down the stopper OO of the clutch release
lever.

• Flatten the lock washer
• Remove the engine sprocket nut O7 and lock washer .

3 .7




3 -8 ENGINE

• Remove the cotter pin . (For E-03, 28, 33)
• Loosen the rear axle nut D .
• Loosen the left and right chain adjusters (Z .

• Push the rear wheel forward and make sure that the drive
chain has enough slack .
• Disengage the drive chain with the rear sprocket .
• Remove the engine sprocket 30 .

• Remove the oil cooler .

• Disconnect the oil pressure switch lead wire ® .
• Disconnect the starter motor lead wire ($) .

• Disconnect the No .2 (Rear) spark plug cap © .
• Disconnect the ECT sensor lead wire 70 .

0





ENGINE

• Disconnect the No .1 (Front) spark plug cap 10 .

I

• Disconnect the ground lead wire

OO .

r

• Disconnect the generator lead wire coupler (1 .
• Disconnect the CKP sensor lead wire coupler ® .
• Disconnect the clamp .

• Disconnect the GP sensor lead wire coupler (5) .
• Remove the side-stand switch lead wire coupler C) .

,/

• Support the engine using an engine jack .
CAUTION
Do not support at the oil filter .

3-9


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