SUZUKI SV650 Fl SYSTEM DIAGNOSIS SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system . ELECTRICAL PARTS CONNECTOR/COUPLER • * When connecting a connector, be sure to push it in until a click is felt. •With a lock type coupler, be sure to release the lock when isconnecting, and push it in fully till the works when connecting it. • * When disconnecting the coupler, be sure to hold the coupler body and do not pull the lead wires . • * Inspect each terminal on the connector/coupler for looseness or bending. • * Inspect each terminal for corrosion and contamination. The terminals must be clean and free of any foreign material which could impede proper terminal contact . •Inspect each lead wire circuit for poor connection by shaking it by hand lightly. If any abnormal condition is found, repair or replace. •When taking measurements at electrical connectors using a tester probe, be sure to insert the probe from the wire harness side (backside) of the connector/coupler . 0 4 40 O/ 40 16~ Id •When connecting meter probe from the terminal side of the coupler (connection from harness side not being possible), use extra care not to force and cause the male terminal to bend or the female terminal to open . Connect the probe as shown to avoid opening of female ter- minal. Never push in the probe where male terminal is supposed to fit. •Check the male connector for bend and female connector for excessive opening. Also check the coupler for locking (looseness), corrosion, dust, etc . FUSE • * When a fuse blows, always investigate the cause correct it and then replace the fuse . • * Do not use a fuse of a different capacity . • * Do not use wire or any other substitute for the fuse . ECMNARIOUS SENSORS •Since each component is a high-precision part, great care should be taken not to apply any sharp impacts during removal and installation. • * Be careful not to touch the electrical terminals of the ECM . The static electricity from your body may damage this part . FI SYSTEM DIAGNOSIS 4-3
4-4 FI SYSTEM DIAGNOSIS • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch, or electronic parts may get dam- aged. • * Battery connection in reverse polarity is strictly prohibited . Such a wrong connection will damage the components of the FI system instantly when reverse power is applied . • * Removing any battery terminal of a running engine is strictly prohibited. The moment such removal is made, damaging counter electromotive force will be applied to the ECM which may result in serious damage.

SUZUKI SV1000 ELECTRICAL SYSTEM SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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COUPLER •With a lock type coupler, be sure to release the lock before disconnecting it and push it in fully till the lock works when connecting it . • * When disconnecting the coupler, be sure to hold the coupler itself and do not pull the lead wires . • * Inspect each terminal on the coupler for being loose or bent . • * Inspect each terminal for corrosion and contamination. CLAMP • * Clamp the wire harness at such positions as indicated in “WIRE HARNESS ROUTING”. (C” -78-14) • * Bend the clamp properly so that the wire harness is clamped securely . • * In clamping the wire harness, use care not to allow it to hang down. • * Do not use wire or any other substitute for the band type clamp. FUSE • * When a fuse blows, always investigate the cause, correct it and then replace the fuse . • * Do not use a fuse of a different capacity . • * Do not use wire or any other substitute for the fuse . SEMI-CONDUCTOR EQUIPPED PART • * Be careful not to drop the part with a semi-conductor built in such as a ECM. • * When inspecting this part, follow inspection instruction strictly . Neglecting proper procedure may cause damage to this part . ELECTRICAL SYSTEM 7- 3 7-4 ELECTRICAL SYSTEM BATTERY •The MF battery used in this motorcycle does not require maintenance (e.g., electrolyte level inspection, distilled water replenishment) . • * During normal charging, no hydrogen gas is produced. However, if the battery is overcharged, hydrogen gas may be produced. Therefore, be sure there are no fire or spark sources (e.g., short circuit) nearby when charging the battery . • * Be sure to recharge the battery in a well-ventilated and open area. • Note that the charging system for the MF battery is different from that of a conventional battery. Do not replace the MF battery with a conventional battery . CONNECTING THE BATTERY •When disconnecting terminals from the battery for disassembly or servicing, be sure to disconnect the O battery lead wire, first. • * When connecting the battery lead wires, be sure to connect the OO battery lead wire first . • * If the terminal is corroded, remove the battery, pour warm water over it and clean it with a wire brush . • * After connecting the battery, apply a light coat of grease to the battery terminals. • * Install the cover over the O battery terminal. WIRING PROCEDURE • * Properly route the wire harness according to the “WIRE HARNESS ROUTING” section. (CJ8-14)

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2003 SUZUKI SV 1000 Service Manual

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Filed Under (Suzuki) by admin on 26-02-2011

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HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR : 1. The text of this manual is divided into sections . 2. The section titles are listed in the GROUP INDEX . 3 . Holding the manual as shown at the right will allow you to find the first page of the section easily . 4. The contents are listed on the first page of each section to help you find the item and page you need . COMPONENT PARTS AND WORK TO 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: Front wheel SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. ENGINE OIL SUZUKIrecommends the use of SUZUKI PERFORMANCE 4 MOTOR OIL or an oil which is rated SF or SG under the API (American Petroleum Institute) service classification. The recommended viscosity is SAE 1 OW-40 . If an SAE 1 OW-40 oil is not available, select an altematice according to the right chart . BRAKE FLUID Specification and classification: DOT 4 A WARNING 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, otherwise 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, which has been stored for a long period. FRONT FORK OIL Use fork oil L01 or an equivalent fork oil . GENERAL INFORMATION 1-5 ENGINE COOLANT Use an anti-freeze/engine coolant compatible with an aluminum radiator, mixed with distilled water only . WATER FOR MIXING Use distilled water only . Water other than distilled water can corrode and clog the aluminum radiator . ANTI-FREEZE/ENGINE COOLANT The engine coolant perform as a corrosion and rust inhibitor 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. Suzuki recommends the use of SUZUKI COOLANT anti-freeze/engine coolant. If this is not available, use an equivalent which is compatible with an aluminum radiator . LIQUID AMOUNT OF WATER/ENGINE COOLANT

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BLACK POWDER COATED ANTI-VIBRATION PEGS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 21-12-2010

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These pegs, mounts and hardware have a nickel/chrome base coat under the satin black powder coat finish. This is done to prevent any rust or corrosion at the wear points. Its is normal for some of the black powder coating to wear off (exposing the nickel/chrome base) where the pegs pivot on the mounting blocks and on the bolt heads. Again this is normal and they will not rust at these points. If desired the satin black finish can be touched up using a satin black model or spray paint.

BMW F650 CS Front belt wheel not correctly secured

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Filed Under (BMW) by admin on 23-11-2010

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2.1 Removal of the front belt wheel Remove the front belt wheel in accordance with the instructions detailed in the F 650 CS Repair Manual. Remove the securing screw of the activated charcoal filter and let the filter canister hang by one side by the hoses, or remove it and lay it aside. Clean the splines and threads of the main shaft in order to remove all traces of Loctite. If necessary, remove corrosion from the main shaft spline (use only a brass bristle brush). 2.2 Visual inspection Check the splines of the main shaft for damage. Replace the main shaft if the splines are damaged (broken, chipped, bent or damaged teeth). Refer to the F 650 CS Repair Manual for this procedure 2.3 Wear check gearbox main shaft- It is extremely important that the techni- cian always check that the dimensions of the gearbox main shaft splines are to specification before proceeding with the installation of a new front belt wheel. This note only applies to motorcycles with accumulated mileage, not to new motorcycles from the crate. If the visual inspection was satisfactory and the main shaft was not replaced for visual damage, a main shaft wear check will be necessary. This check requires the use of BMW Special Tool # 23 4 571 . The adapters are designed for micrometer gauges with stud diameters from 6.35 mm to 6.6 mm. Do not use cellulose-lacquer thinners to clean the adapters as there is a risk of damaging the measuring instruments. Make sure that the micrometer gauges and the adapters are perfectly clean

BMW F 650 CS Rear belt wheel cracks Removal And Installation Manual

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Filed Under (BMW) by admin on 12-11-2010

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Relieve the tension of the toothed belt and lift the belt off the belt wheel (refer to F 650CS Repair Manual, 00.57). 2) Remove 6 screws (see arrow in photo at right). 3) Remove the rear belt wheel. 4) Clean and degrease the tapered bores and the threads of the mounting screws 5) Carefully place the new belt wheel in position on the damper, coat the screw threads with Loctite 243 and hand tighten the securing screws. 6) Tighten the securing screws to the specified torque maintaining a diagonally opposite tightening sequence throughout (Torque to 28 NM, curing time 12 hours). 7) Measure the vertical runout of the belt wheel (refer to F 650 CS Repair Manual, 33.15). 8) Install and adjust the rear drive belt (refer to F 650 CS Repair Manual 00.57 – 00.58) 2.1 Removal of the front belt wheel Remove the front belt wheel in accordance with the instructions detailed in the F 650 CS Repair Manual. Remove the securing screw of the activated charcoal filter and let the filter canister hang by one side by the hoses, or remove it and lay it aside. Clean the splines and threads of the main shaft in order to remove all traces of Loctite. If necessary, remove corrosion from the main shaft spline (use only a brass bristle brush). 2.2 Visual inspection Check the splines of the main shaft for damage. Replace the main shaft if the splines are damaged (broken, chipped, bent or damaged teeth). Refer to the F 650 CS Repair Manual for this procedure.

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BMW R1100GS, R1150GS and R1150GS Adventure Side Cases Installation Instructions

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Filed Under (BMW) by admin on 26-10-2010

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1. Mounting blocks Note: On the low mount (for rear cross bar), attach the mounting block vertically with the opening (slot) pointing up and slightly rearward. See photo below. On the two upper mounts, attach the mounting block horizontally with the opening (slot) pointing towards the front. See photo below. Using the M5 x 16 button head screws, with M-5 split washers, attach the backing plate to the mounting block. With the backing plate inside the case and the case mounting blocks outside the case, assemble loosely, using a 3 mm Allen key. These screws will all need to be tightened after final fit up. See photo below. After each block is mounted, insert the black securing knob through the locking tab and into the center hole of the case mounting blocks, from inside the case. Use anti seize on the thread of the thumbscrews to prevent corrosion. See photo below. During riding, these screws will secure the cases to your bike. The locking tabs must be backed off (counter-clockwise), allowing the screws to firmly engage the bullet notches on the bike; then the locking tabs will be rotated clockwise to lock the screws in place and prevent them from loosening. 2. Foot peg stainless Steel “U” Brackets Mount the foot peg bracket to the front of each case with the flat side up, angle side down, using the M-5 Nylock nuts and rubber backed washers, from the inside. Put the rubber side of the washer next to the case. See photo below and photo on page 2 for the correct orientation. These nuts will be tightened, using an 8 mm wrench, after final fit up.