Suzuki GASKET SET SV650Y User manual

Suzuki Worldwide Motorcycle-ATV Page: 1 of 88
SV650Y (SV650Y E2)
Catalogue Title:
FIG1 GASKET SET
Block No. Block Title.
Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.
Ref No
1
2
3
4
5
6
7
8
9
10
11
12
13
Part No
11401-20861
11141-20F00
11173-19F00
11241-19F00
11242-19F00
11482-19F00
11483-19F00
11484-19F01
12837-24A10
14181-22D01
09161-11008
09280-22008
09280-46006
Description
Gasket Set
• . Gasket, Cylinder Head
• . Gasket, Cylinder Head Cover
• . Gasket, Cylinder Front
• . Gasket, Cylinder Rear
• . Gasket, Clutch Cover Inner
• . Gasket, Magneto Cover
• . O Ring,clutch Cover Outer
• . Gasket, Tnsn Adjuster
• . Gasket, Exhaust Pipe
• . Washer
• . O Ring (d:3.1 Id:22.7)
• . O Ring

Suzuki Worldwide Motorcycle-ATV Page: 2 of 88
SV650Y (SV650Y E2)
Catalogue Title:
FIG1A FRONT CYLINDER HEAD
Block No. Block Title.
Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.
Ref No
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
15
15
15
15
16
17
18
19
20
20
21
22
23
24
25
26
27
Part No
11101-20F00
11101-20F10
11115-18D72
09206-08001
09103-06026
11141-20F00
04211-13189
11161-33E00
11191-13E00
09160-10082
09103-10272
07120-06403
09103-06103
07120-06123
09168-06023
09482-00456
09482-00457
09482-00458
09482-00459
09482-00460
09482-00461
13101-20F00
09280-46006
02122-06163
09402-56208
11171-19F00
11171-19F20
11173-19F00
09106-07009
09106-07010
09161-11008
11192-13E00
01550-10807
01550-10807
Description
Head Assy, Cylinder Front
Head Assy, Cylinder Front
• . Guide, Valve
• . Pin (6.2x8x11)
• . Bolt (6x39)
Gasket, Cylinder Head
Pin
Bolt, Cylinder Head Side Face
Washer, Head Cover
Washer (10.5x19x2.0)
Bolt (10x160)
Bolt
Bolt (6x70)
Bolt
Gasket (5.8x13x1.2)
Spark Plug (ngk,cr8e)
Spark Plug (denso,u24esr-n)
Spark Plug (ngk,cr9e)
Spark Plug (denso,u27esr-n)
Spark Plug (ngk,cr10e)
Spark Plug (denso,u31esr-n)
Pipe Assy, Intake Front
• . O Ring
Screw
Clamp
Cover, Cylinder Head Front
Cover, Cylinder Head Front
Gasket, Cylinder Head Cover
Bolt (7x17.5)
Bolt (7x31)
Washer
Cushion, Head Cover Bolt
Bolt
Bolt

Suzuki Worldwide Motorcycle-ATV Page: 3 of 88
SV650Y (SV650Y E2)
Catalogue Title:
FIG2 REAR CYLINDER HEAD
Block No. Block Title.
Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.
Ref No
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
16
16
16
16
16
17
18
19
20
21
21
22
23
24
25
26
27
Part No
11103-20F00
11103-20F10
11115-18D72
09206-08001
09103-06026
11141-20F00
04211-13189
11161-33E00
11191-13E00
09160-10082
09103-10272
09103-06103
07120-06403
01550-10557
07120-06123
09168-06023
09482-00456
09482-00457
09482-00458
09482-00459
09482-00460
09482-00461
13102-20F00
09280-46006
02122-06163
09402-56208
11172-19F00
11172-19F20
11173-19F00
09106-07009
09106-07010
09161-11008
11192-13E00
01550-10807
Description
Head Assy, Cylinder Rear
Head Assy, Cylinder Rear
• . Guide, Valve
• . Pin (6.2x8x11)
• . Bolt (6x39)
Gasket, Cylinder Head
Pin
Bolt, Cylinder Head Side Face
Washer, Head Cover
Washer (10.5x19x2.0)
Bolt (10x160)
Bolt (6x70)
Bolt
Bolt
Bolt
Gasket (5.8x13x1.2)
Spark Plug (ngk,cr8e)
Spark Plug (denso,u24esr-n)
Spark Plug (ngk,cr9e)
Spark Plug (denso,u27esr-n)
Spark Plug (ngk,cr10e)
Spark Plug (denso,u31esr-n)
Pipe Assy, Intake Rear
• . O Ring
Screw
Clamp
Cover, Cylinder Head Rear
Cover, Cylinder Head Rear
Gasket, Cylinder Head Cover
Bolt (7x17.5)
Bolt (7x31)
Washer
Cushion, Head Cover Bolt
Bolt

Suzuki Worldwide Motorcycle-ATV Page: 4 of 88
SV650Y (SV650Y E2)
Catalogue Title:
FIG3 CYLINDER
Block No. Block Title.
Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.
Ref No
1
1
2
2
3
4
5
6
7
Part No
11210-20F00-0F0
11210-20F10-0F0
11220-20F00-0F0
11220-20F10-0F0
11241-19F00
11242-19F00
04211-13189
08316-10063
01421-06253
Description
Cylinder, Front
Cylinder, Front
Cylinder, Rear
Cylinder, Rear
Gasket, Cylinder Front
Gasket, Cylinder Rear
Pin
Nut
Stud Bolt

Suzuki Worldwide Motorcycle-ATV Page: 5 of 88
SV650Y (SV650Y E2)
Catalogue Title:
FIG4 CRANKCASE (MODEL X/Y)
Block No. Block Title.
Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.
Ref No
1
1
1
1
2
3
3a
4
5
6
7
7
7
7a
7b
7c
7d
8
9
10
11
11a
11b
11c
11d
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
30
31
32
33
Part No
11301-20830
11301-20831
11301-20835
11301-20840
09206-11017
11315-19F00
09168-06023
01547-06503
01547-06507
07120-08553
07120-08803
07120-08803
07120-08803
01500-08903
09103-08066
11322-20F00
09103-08066
09493-28010
09280-04004
09493-28010
09280-04004
16591-06B00
11391-20F00
11391-20F10
11391-20F20
09247-12106
09168-12002
09280-12009
16438-19F00
09106-06075
09280-04004
09493-26007
01550-08123
09168-08029
09248-16012
09168-16002
11323-19F00
01547-06123
01550-06123
09168-06023
09103-10226
09103-10041
09103-12054
08319-31107
09159-10058
08319-31128
37820-33D00
09160-10060
Description
Crankcase Set
Crankcase Set
Crankcase Set
Crankcase Set
• . Pin (11x20)
• . O Ring, Crankcase
• . Gasket (5.8x13x1.2)
• . Bolt
• . Bolt
• . Bolt
• . Bolt
• . Bolt
• . Bolt
• . Bolt
• . Bolt (8x95)
• . Bolt (8x90)
• . Bolt (8x95)
• . Jet, Oil Gallery Cylinder
• . O Ring (d:1.2,id:4.0)
• . Jet, Oil Gallery Mission
• . O Ring (d:1.2,id:4.0)
• . Union, Oil Filter Stand
• . Plate, Oil
• . Plate, Oil
• . Plate, Oil
Plug (12x20)
Gasket (12.1x16.2x3.7)
O Ring (d:1.9,id:12.6)
Plate, Piston Cooling Jet
Bolt (6x12)
O Ring (d:1.2,id:4.0)
Jet (130)
Bolt
Gasket
Plug
Gasket (16x22x2)
Plate, Oil Separator
Bolt
Bolt
Gasket (5.8x13x1.2)
Bolt (10x260)
Bolt (10x215)
Bolt (12x310)
Nut
Nut
Nut
Switch Assy, Oil Pressure
Washer (10.5x22x2.3)

Suzuki Worldwide Motorcycle-ATV Page: 6 of 88
SV650Y (SV650Y E2)
Catalogue Title:
FIG4A CRANKCASE (MODEL K1/K2)
Block No. Block Title.
Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.
Ref No
1
2
3
3a
4
5
6
7
7a
7b
8
9
10
11
11a
11b
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Part No
11301-20850
09206-11017
11315-19F00
09168-06023
01547-06503
01547-06507
07120-08553
07120-08803
11322-20F00
09103-08066
09493-28010
09280-04004
09493-28010
09280-04004
16591-06B00
11391-20F20
09247-12106
09168-12002
09280-12009
16438-19F00
09106-06075
09280-04004
09493-26007
01550-08123
09168-08029
09248-16012
09168-16002
11323-19F00
01547-06123
01550-06123
09168-06023
09103-10226
09103-10041
09103-12054
09159-10058
08319-31128
37820-33D10
09160-10060
Description
Crankcase Set
• . Pin (11x20)
• . O Ring, Crankcase
• . Gasket (5.8x13x1.2)
• . Bolt
• . Bolt
• . Bolt
• . Bolt
• . Bolt (8x90)
• . Bolt (8x95)
• . Jet, Oil Gallery Cylinder
• . O Ring (d:1.2,id:4.0)
• . Jet, Oil Gallery Mission
• . O Ring (d:1.2,id:4.0)
• . Union, Oil Filter Stand
• . Plate, Oil
Plug (12x20)
Gasket (12.1x16.2x3.7)
O Ring (d:1.9,id:12.6)
Plate, Piston Cooling Jet
Bolt (6x12)
O Ring (d:1.2,id:4.0)
Jet (130)
Bolt
Gasket
Plug
Gasket (16x22x2)
Plate, Oil Separator
Bolt
Bolt
Gasket (5.8x13x1.2)
Bolt (10x260)
Bolt (10x215)
Bolt (12x310)
Nut
Nut
Switch Assy, Oil Pressure
Washer (10.5x22x2.3)

Suzuki Worldwide Motorcycle-ATV Page: 7 of 88
SV650Y (SV650Y E2)
Catalogue Title:
FIG5 CRANKCASE COVER
Block No. Block Title.
Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.
Ref No
1
2
3
4
5
6
7
8
8
9
10
11
12
13
13a
14
15
16
17
18
19
19
20
21
22
23
Part No
11340-19F00
11971-33210
11482-19F00
04211-09149
09103-06204
09103-06205
11370-19F00
11484-19F00
11484-19F01
09103-06180
09103-06207
09259-20008
09280-17003
11361-19F00
01547-06457
11351-19F00
11483-19F00
04211-09149
01547-06357
01547-06657
09168-06023
09168-06023
09259-26012
09280-22008
09248-16012
09168-16002
Description
Cover, Clutch Inner
• . Lens, Oil Level Check
Gasket, Clutch Cover Inner
Pin
Bolt
Bolt
Cover, Clutch Outer
O Ring, Clutch Cover Outer
O Ring, Clutch Cover Outer
Bolt
Bolt
Plug
O Ring (d:3.1,id:16.8)
Cover, Engine Sprocket
Bolt
Cover, Magneto
Gasket, Magneto Cover
Pin
Bolt
Bolt
Gasket (5.8x13x1.2)
Gasket (5.8x13x1.2)
Plug
O Ring (d:3.1,id:22.7)
Plug
Gasket (13.8x18.8x0.4)

Suzuki Worldwide Motorcycle-ATV Page: 8 of 88
SV650Y (SV650Y E2)
Catalogue Title:
FIG6 CRANKSHAFT
Block No. Block Title.
Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.
Ref No
1
2
2
2
2
2
2
2
2
2
2
3
3
3
4
5
6
7
7
7
7
8
9
10
11
12
13
14
15
16
17
18
18
Part No
12000-20840
12228-19F00-0A0
12228-19F00-0B0
12228-19F00-0C0
12228-19F00-0D0
12228-19F00-0E0
12228-19F00-0F0
12228-19F00-0G0
12228-19F00-0H0
12228-19F00-0I0
12228-19F00-0J0
12229-19F10-0A0
12229-19F10-0B0
12229-19F10-0C0
12160-20F00
12163-17C50
12165-27A50
12164-46E01-0A0
12164-46E01-0B0
12164-46E01-0C0
12164-46E01-0D0
21111-20F00
21112-19F00
12731-19F00
17451-19F00
12541-20F00
09126-06011
12111-20F00-0F0
12140-20F00
12151-05A00
09381-20004
12100-20F00-050
12100-20F00-100
Description
Crankshaft Set
• . Washer, Thrust (t:1.925)
• . Washer, Thrust (t:1.95)
• . Washer, Thrust (t:1.975)
• . Washer, Thrust (t:2.0)
• . Washer, Thrust (t:2.025)
• . Washer, Thrust (t:2.05)
• . Washer, Thrust (t:2.075)
• . Washer, Thrust (t:2.1)
• . Washer, Thrust (t:2.125)
• . Washer, Thrust (t:2.15)
Bearing, Crankshaft (green)
Bearing, Crankshaft (black)
Bearing, Crankshaft (brown)
Connecting Rod Assy
• . Bolt, Connecting Rod
• . Pin, Connecting Rod
Bearing, Crank Pin (green)
Bearing, Crank Pin (black)
Bearing, Crank Pin (brown)
Bearing, Crank Pin (yellow)
Gear, Primary Drive
Bolt, Primary Drive Gear
Sprocket, Cam Chain Drive
Gear, Water Pump Drive
Retainer, Crankshaft Brg Lh
Screw
Piston
Ring Set, Piston
Pin, Piston
Circlip
Piston Set (os:0.5)
Piston Set (os:1.0)

Suzuki Worldwide Motorcycle-ATV Page: 9 of 88
SV650Y (SV650Y E2)
Catalogue Title:
FIG7 STARTER CLUTCH
Block No. Block Title.
Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.
Ref No
1
2
3
4
Part No
12611-20F01
09206-12001
12600-20840
07130-08163
Description
Gear, Starter Idle
Pin
Clutch Set, Starter
Bolt

Suzuki Worldwide Motorcycle-ATV Page: 10 of 88
SV650Y (SV650Y E2)
Catalogue Title:
FIG8 CAM SHAFT / VALVE
Block No. Block Title.
Copyright © 2005 Suzuki Worldwide Motorcycle-ATV. All Rights Reserved.
Ref No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
15
Part No
12710-20F00
12720-20F00
12730-20F00
12740-20F00
12800-05820
99000-69491
12911-46E00
12912-20F00
12920-33E10
12931-33E10
12933-39E00
09289-04002
12932-17E50
12891-17E00
12892-05C00-120
12892-05C00-125
12892-05C00-130
12892-05C00-135
12892-05C00-140
12892-05C00-145
12892-05C00-150
12892-05C00-155
12892-05C00-160
12892-05C00-165
12892-05C00-170
12892-05C00-175
12892-05C00-180
12892-05C00-185
12892-05C00-190
12892-05C00-195
12892-05C00-200
12892-05C00-205
12892-05C00-210
12892-05C00-215
12892-05C00-220
Description
Cam Shaft, Intake Front
Cam Shaft, Exhaust Front
Cam Shaft, Intake Rear
Cam Shaft, Exhaust Rear
Shim Set, Tappet
• . Case, Tappet Shim
Valve, Intake
Valve, Exhaust
Spring Set, Valve
Retainer, Valve Spring
Seat, Valve Spring
Oil Seal (4.5x10x8)
Cotter, Valve
Tappet
Shim, Tappet (t:1.20)
Shim, Tappet (t:1.25)
Shim, Tappet (t:1.30)
Shim, Tappet (t:1.35)
Shim, Tappet (t:1.40)
Shim, Tappet (t:1.45)
Shim, Tappet (t:1.50)
Shim, Tappet (t:1.55)
Shim, Tappet (t:1.60)
Shim, Tappet (t:1.65)
Shim, Tappet (t:1.70)
Shim, Tappet (t:1.75)
Shim, Tappet (t:1.80)
Shim, Tappet (t:1.85)
Shim, Tappet (t:1.90)
Shim, Tappet (t:1.95)
Shim, Tappet (t:2.00)
Shim, Tappet (t:2.05)
Shim, Tappet (t:2.10)
Shim, Tappet (t:2.15)
Shim, Tappet (t:2.20)