2003 SUZUKI SV 650 COOLING AND LUBRICATION SYSTEM SERVICE MANUAL

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

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COOLING CIRCUIT INSPECTION Before removing the radiator and draining the engine coolant, inspect the cooling circuit for tightness. • * Remove the cowling. (SV650S) (C-7–7-6) • * Loosen the radiator cap stop screw 10 . (SV650) • * Remove the radiator cap O2 and connect the radiator tester to the filler. A WARNING Do not remove the radiator cap when the engine is hot. • * Give a pressure of about 120 kPa (1 .2 kgf/cm2,17.0 psi) and see if the system holds this pressure for 10 seconds . • * If the pressure should fall during this 10-second interval, it means that there is a leaking point in the system . In such a case, inspect the entire system and replace the leaking component or part. A WARNING When removing the radiator cap tester, put a rag on the filler to prevent spouting of engine coolant. CAUTION Do not allow the pressure to exceed specified pressure, or the radiator can be damaged. COOLING AND LUBRICATION SYSTEM 6-3 6-4COOLING AND LUBRICATION SYSTEM RADIATOR REMOVAL • * Remove the cowling. (SV650S) ( r- 7-7-6) • * Drain engine coolant. (r– 72-20) • * Disconnect the right and left radiator hoses from the radiator. • * Disconnect the siphon hose from the radiator. • * Disconnect the horn lead wires. rI .rr • * Remove the radiator lower mounting bolt. • * Disconnect the cooling fan motor and its thermo-switch lead wire coupler 10. • * Remove the radiator by upper mounting bolt. • * Remove the cooling fan. • * Disconnect the cooling fan thermo-switch. • * Remove the cooling fan thermo-switch. • * Remove the horn. CAUTION When removing the horn, hold the nut by spanner to prevent the horn bracket distortion. COOLING AND LUBRICATION SYSTEM 6-5 INSTALLATION • * Install the cooling fan and horn. 0 Cooling fan/horn mounting bolt: 8 N .m (0.8 kgf-m, 6 .0 Ib-ft) • * Install the cooling fan thermo-switch. ( l”76-9) • * Install the siphon hose to the radiator. • * Install the radiator in the reverse order of removal. • * Route the radiator hoses properly. (=9-22) 9-22) • * Install the drain plug with a new sealing washer and pour engine coolant. (=2-20) • * Bleed air from the cooling circuit. (r– 72-21) • * Install the cowling. (SV650S)

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SUZUKI SV650/ S PERIODIC MAINTENANCE CHART

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

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Item km miles months 1000 6000 12000 18000 24000 600 4000 7500 11000 15000 1 6 12 18 24 Air cleaner Spark plugs Tappet clearance Engine oil Engine oil filter Fuel hose Engine idle speed Carburettor synchronization Evaporative emission control system PAIR air supply system Throttle cable play Clutch cable play Radiator hoses Engine coolant Drive chain Brakes Brake hoses Brake fluid Tires Steering Front forks Rear suspension Exhaust pipe bolt & nut Chassis bolt & nuts – - – R R – I I I – - I I – - – I – - T T Replace every 4 years Replace vapor hose every 4 years – - I – I I I – - Replace every 2 years Clean & lubricate every 600 miles (1000km) Replace every 4 years Replace every 2 years R R R R – - R – I I R I I R I R – Inspect and adjust, clean

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