2003 Suzuki SV650/SV650S Service Manual (495 P.)
Factory service data for SV650/SV650S covering transmission clutch, carburetor throttle body tuning, and valve adjustments. Complete technical specifications and field-replaceable unit documentation.
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Sample pages from the 2003 Suzuki SV650/SV650S Service Manual (495 P.) manual
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Models Covered & Key Technical Specifications
Suzuki SV650/SV650S (99500-36120-03E) — 2003 Precision Engineering Technical Collection | SV650 Series Section.
- Documented Heat Dissipation Data: Engine coolant capacity is configured at 1.7 L (1.8/1.5 US/Imp qt) operational Sequences.
- Measured Production Rate: For optimal performance, 645 cm³ (39.4 cu.in.) displacement limits the cylinder volume capacity Requirements.
- Technical Form Factor: Compression ratio is set to 11.5:1 for standard combustion efficiency Baseline.
- Core Tightening Data: The idle speed produces 1,300 ± 100 r/min engine operation Threshold.
- Rated Gap Specs: Fuel tank represents 16 L (4.2/3.5 US/Imp gal) storage volume Mapping.
- Principal Working Temperature: Engine oil capacity is measured at 2.7 L (2.9/2.4 US/Imp qt) with filter change Configuration.
Professional Workshop Service Manual & Technical Specifications
Detailed Service Manual: Motorcycle Suzuki SV650S 2003 - Comprehensive Service Manual for Maintenance and Repair Diagnostic-Reference
Machine-Range: SV650S, SV650 motorcycles // System-Identifier: Engine Control, Fuel Injection, Ignition Systems, Chassis components // Assembly-Group: Dual-cylinder engine featuring DOHC valve configuration, comprehensive electrical and mechanical systems.
| Identifier | Operational-Logic | Logic |
|---|---|---|
| Engine Systems | 645cc liquid-cooled V-twin with fuel injection | Complete engine specifications, torque documentation, and assembly procedures |
| Fuel Management | FI system with ECM control and multiple sensors | Fuel pressure data, injector specifications, and pressure regulator information |
| Transmission & Drivetrain | 6-speed constant mesh with 3.0:1 final ratio | Gear ratios, clutch operation, and chain specifications documented |
| Chassis & Suspension | Telescopic front forks, link-type rear with coil springs | Steering geometry, suspension settings, and bearing specifications included |
| Electrical Architecture | 12V system with generator and regulator/rectifier | Battery capacity, charging specifications, and wiring diagrams provided |
The documentation is partitioned into comprehensive sections covering engine assembly, fuel injection diagnosis, cooling and lubrication circuits, chassis components, and electrical systems. Each chapter addresses engine and transmission systems, covering fuel system procedures, addressing cooling system maintenance, detailing steering and brake operations, and examining ignition system components. The manual covers FI system diagnostics, addressing engine control module functions, detailing sensor circuit malfunction codes, examining fuel pump relay operations, and referencing ignition timing specifications.
The troubleshooting chapter addresses engine performance issues, covering fuel delivery diagnostics, addressing injection time compensation, detailing fail-safe function operations, and examining self-diagnostic procedures. Cooling system information covers radiator operations, addressing thermostat functions, detailing water pump assembly, examining engine coolant specifications, and referencing cooling fan operations. Engine disassembly procedures provide detailed removal sequences, addressing cylinder head removal, covering piston and ring inspection, examining crankshaft bearing installation, and detailing transmission gear assembly. Chassis procedures address front wheel bearing replacement, covering brake system bleeding, detailing suspension adjustment procedures, examining steering stem bearing inspection, and providing rear swingarm assembly guidance.
The document documents torque specifications for the engine fasteners to ensure proper assembly and performance integrity throughout all mechanical systems.
Maintenance information covers periodic service requirements, detailing air cleaner inspection intervals, addressing spark plug replacement schedules, examining oil change procedures, covering tappet clearance adjustment methods, and referencing compression testing procedures. The electrical system section provides wiring diagrams, covering battery connection procedures, addressing generator and charging system operations, examining ignition coil functions, and detailing all sensor circuit operations. Component inspection procedures address bearing runout limits, covering seal and gasket replacement requirements, examining fluid level verification, and providing service limit specifications for all critical engine and chassis parts.
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