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XF650 Freewind
User manual
Suzuki XF650 User Manual
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:
Service manual
(350 pages)
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Table Of Contents
348
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348
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348
Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Group Index
Component Parts and Work to be Done
Symbol
General Information
Contents
Warning/Caution/Note
General Precautions
SUZUKI XF650V ('97 Model) Overview
Serial Number Location
Fuel and Oil Recommendation
Fuel
Brake-In Procedures
Brake Fluid
Front Fork Oil
Information Labels
RH View
LH View
Specifications
Country or Area
Periodic Maintenance
Periodic Maintenance Schedule
Periodic Maintenance Chart
Lubrication Points
Maintenance and Tune-Up Procedures
Valve Clearance
Spark Plugs
Carbon Deposit
Spark Plug Gap
Electrode's Condition
Air Cleaner Element
Idle Speed
Throttle Cable Play
Carburetor Synchronization
Fuel Line
Clutch
Engine Oil and Oil Filter
Necessary Amount of Engine Oil
Drive Chain
Checking
Adjusting
Cleaning and Lubricating
Brake Fluid Level
Brake Pads
Brake Pedal Height
Air Bleeding the Brake Fluid Circuit
Tires
Steering
Tire Tread Condition
Tire Pressure
Front Forks
Rear Suspension
Exhaust Pipe and Muffler Bolts
Chassis Bolts and Nuts
Compression Pressure Check
Compression Test Procedure
Compression Pressure Specification
Oil Pressure Check
Oil Pressure Test Procedure
Low Oil Pressure
High Oil Pressure
Engine
Engine Components Removable with the Engine in Place
Engine Removal
Engine Reinstallation
Engine Disassembly
Engine Reassembly
Oil Seals
Crankshaft
Balancer Shaft
Gearshift Mechanism
Crankcase
Cam Driven Gear
Gearshift Shaft
Neutral Position Indicator Switch
Oil Pump
Cam Chain and Primary Drive Gear/Generator and Starter Motor
Piston and Cylinder
Cylinder Head
Camshaft
Cylinder Head Cover
Cylinder Head Cover/Rocker Arm
Cylinder Head Cover Removal
Rocker Arm Removal
Inspection and Service
Rocker Arm Installation
Cylinder Head Cover Distortion
Rocker Arm Shaft O.D.
Cylinder Head Cover Installation
Camshaft/Cylinder Head/Valves
Camshaft/Cylinder Head Removal
Valve Removal
Camshaft/Automatic De-Comp. Assembly
Camshaft Cam Wear
Camshaft Journal Wear
Cylinder Head Distortion
Valve Face Wear
Valve Stem Runout
Valve Head Radial Runout
Valve Stem Deflection
Valve Stem Wear
Valve Guide Servicing
Valve Seat Width
Valve Seat Servicing
Valve Stem End Condition
Valve Spring
Valve Installation
Cylinder Head/Camshaft Installation
Cylinder/Piston
Cylinder/Piston Removal
Cylinder Distortion
Cylinder Bore
Piston-Cylinder Clearance
Piston Ring-Groove Clearance
Piston Ring Free End Gap and Piston Ring End Gap
Piston/Cylinder Installation
Piston Pin and Pin Bore
Oil Ring
Top Ring and 2Nd Ring
Starter Motor/Generator Rotor/Gearshift
Starter Motor Removal
Generator Rotor Removal
Gearshift Shaft Removal
Starter Clutch
Starter Torque Limiter
Generator Rotor Installation
Gearshift Shaft Installation
Starter Motor Installation
Clutch Removal
Clutch Drive Plate
Clutch Driven Plate
Clutch Spring Free Length
Clutch Installation
Clutch Release Bearing
Clutch Release Pinion and Rack
Gearshift Cam/Transmission
Gearshift Cam/Transmission Removal
Gearshift Fork Groove Clearance
2Nd Drive Gear Disassembly
Transmission/Gearshift Cam Installation
Balancer Shaft/Crankshaft/Crankcase
Balancer Shaft/Crankshaft/Crankcase Removal
Balancer Shaft Disassembly
Crankshaft Disassembly
Conrod Small End I.D.
Conrod Deflection and Conrod Big End Side Clearance
Crankshaft Runout
Crankshaft Assembly
Balancer Shaft Assembly
Crankcase Bearings
Crankcase/Crankshaft/Balancer Shaft Installation
Engine Lubrication System
Oil Filter
Removal and Disassembly
Inspection
Assembly and Installation
Oil Nozzle and Oil Jet Removal
Oil Sump Filter
Fuel and Lubrication System
Fuel System
Fuel Valve
Fuel Valve Mechanism
Fuel Valve/Fuel Filter Removal
Inspection and Cleaning
Fuel Tank Removal
Carburetor
Construction
I.D. No. Location
Slow System
Main System
Diaphragm and Piston Operation
Lower Position of Piston Valve
Upper Position of Piston Valve
Piston Valve Lift Control System
Starter System
Float System
Removal
Disassembly
Pilot Screw Removal
Carburetor Cleaning
Needle Valve Inspection
Float Height Adjustment
Solenoid Valve Inspection
V.T.V. Inspection
Throttle Position Sensor Inspection
Reassembly and Remounting
Throttle Position Sensor Positioning
Carburetor Clamps
Calibrating each Gauge
Lubrication System and Cooling System
Engine Lubrication/Cylinder Head Cooling System Chart
Oil Pan
Oil Cooler
Chassis
Exterior Parts Construction
Frame Cover
Remounting
Front Wheel
Wheel Bearing
Front Axle
Wheel Rim
Spoke Nipple
Brake Disc
Front Fork
Fork Spring
Inner Tube and Outer Tube
Damper Rod Ring
Inner Tube Metal
Outer Tube Metal, Oil Seal and Dust Seal
Damper Rod Bolt
Fork Oil
Front Fork Remounting
Bearing Races
Bearing
Stem Nut
Handlebars
Rear Wheel
Wheel Bearing and Sprocket Drum Bearing
Rear Axle
Rear Sprocket
Rear Sprocket Damper
Rear Axle Nut
Rear Swingarm and Suspension
Reassembling Information
Swingarm
Cushion Lever
Shock Absorber
Swingarm Pivot Shaft
Swingarm Bearing
Cushion Lever Bearing
Final Inspection and Adjustment
Shock Absorber Spring Pre-Load Adjustment
Spring Setting Table
Shock Absorber Damping Force Adjustment
Front Brake
Brake Pad Replacement
Brake Fluid Replacement
Caliper Removal and Disassembly
Caliper Inspection
Caliper Reassembly and Remounting
Brake Disc Inspection
Master Cylinder Removal and Disassembly
Master Cylinder Inspection
Master Cylinder Reassembly and Remounting
Rear Brake
Caliper and Disc Inspection
Lowering the Seat Height
Optional Parts Supply
Special Tools
Rear Shock Absorber
Side-Stand
Side-Stand Removal and Installation
Warning Label
Electrical System
Cautions in Servicing
Connector
Coupler
Clamp
Battery
Connecting Battery
Wiring Procedure
Using Multi Circuit Tester
Location of Electrical Components
Charging System
Description
Troubleshooting
Battery Leak Current Inspection
Charging Output Inspection
Generator Coil Continuity Inspection
Generator No-Load Performance Inspection
Regulator/Rectifier Inspection
Starter System Description
Side-Stand/Ignition Interlock System Description
Starter Motor Removal and Disassembly
Starter Motor Inspection
Carbon Brush
Starter Motor Reassembly
Commutator
Armature Coil Inspection
Oil Seal Inspection
Starter Relay Inspection
Side-Stand/Ignition Interlock System Inspection
Starter Relay Circuit Diagram
Diode
Neutral Switch
Side-Stand Switch
Side-Stand/Ignition Interlock Relay
Clutch Lever Position Switch
Ignition System
Ignition Coil Primary Peak Voltage
Ignition Coil (Checking with Electro Tester)
Ignition Coil Resistance
Power Source Coil and Pick-Up Coil
Combination Meter
Speedometer Inspection
Speed Sensor Inspection
Fuel Meter Inspection
Fuel Level Gauge Removal/Installation
Fuel Level Gauge Inspection
Lamps
Headlight and Position Light
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Service Manual
Table of
Contents
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Table of Contents
Troubleshooting
Troubleshooting
206
Engine Troubleshooting
238
Carburetor Troubleshooting
241
Brake Troubleshooting
242
Electrical Troubleshooting
243
Battery Troubleshooting
244
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