SV650 Motor Tear down

[daviid]

Broke a bolt in the motor @ NHMS so i need to tear the whole thing apart so we can get it out. I had already gotten one cylinder off nd the clutch cover/basket when i decided to take pics.





First remove the 3 6mm Alan Bolts from the valve cover and remove the valve cover


Next remove the cam-chain cover. There are 3 5mm Alan bolts holding it on


Remove the two 5mm alan bolts that hold the Cam Chain Tensioner


The chain should now be loose


Now remove the 6 10mm bolts from each cam shaft block, and remove each cam


I try to keep all the parts together as i remove them


You should now be looking @ this. To remove the head you need to remove the four 12mm head bolts, two 10mm head-cylinder bolts, and one 5mm alan head-cylinder bolt(exterior)


Try not to flip it as the valve spring covers will come off


You will now have the piston exposed


Remove the oil cooler (if you havent done so already)


Remove the two 10mm nuts


I then rebuild the cylinder to make sure all parts stay where they are supposed to. If you do this i recommend putting the loose cam chain guide in its proper holder (you will see it when you move it). I also forgot to take pics of where the water hoses go into the cylinder. that is a 5mm alan bolt as well.


Next remove all the 8mm bolts holding the stator cover on. You will have to wiggle the cover off and use some force as there is a giant magnet behind it. Watch out for the starter idler shaft when you remove the cover.




Next i removed the starter, it has 2 8mm bolts holding it in. this is a tight wiggle out



Next i took a 17mm socket and a IMPACT gun to the stator retaining bolt.


This is where im stuck because i forgot the stator needs to be forced off with a M20x1.5 Bolt. I got a call into fastenal, i could order one from MotionPro but ill see.

Being i couldnt find anyone locally that had the tool i needed to buy, I brought it down to the local suzuki Dealer (RideNow Powersports) There were able to pop the flywheel off in no time flat



Next i removed the pistons from the connect rod. On the side of the piston where wrist pin is a circlip. Pop that out and the wrist pin will slide out.



Next i removed the main Countershaft-Sprocket. this is a 14mm LEFT HAND thread bolt. I didnt grab a pre-shot but if you follow your cam-chain im sure you can find it.

Also i ziptied the parts in the order they came off and plastic bagged them


Next was the oil pump gear, its that yellow plastic gear. you will need circlip pliers to remove it. Remove the circlip and the gear pops off, behind it is a pin going through the shaft of the oil pump, slide that out and remove the washer. Next take out the 3 screws to the oil pump. i recommend using a socket driver. I believe Philips head #3


Next remove the oil pipe to the left of the oil gear


Next remove the output shaft gasket cover i believe its 3 10mm bolts


then remove the gear sensor. make sure you grab the little popup things, and the springs behind them and bag them


the manual says you need to remove this plate. i dont think you do, but i did anyways


Next remove all the 8mm bolts from the case exterior. then remove the 4 5mm alan head bolts on that side. the 8mm bolts are all the same size. as well as the 4 alan bolts for THAT side. when you flip it over to do the other size. the 4 5mm alan bolts are all the same size, but longer. flip the case so the left side is down. then rock the case cover. it will pop off to look like this


the crank will lift right out of place. so will the transmission arms rods. for each rod i ziptied it and the arm(s) together. the shift drum will come out next. to get the gears out you need to take out the Output shaft first, which may require the use of a hammer.


And thats that. i need to get a bolt drilled out, and heli-coiled. i will post the build next as i do it.

[UngaWunga]

Nice job. I like how you partially reassemble the pieces as you disassemble the engine and ziptie pieces together in the proper order. I've learned the hard way to do the same. It sucks when you have something disassembled, then have to wait a month for parts to come in, and then you forget where everything goes when you try to put it back together.

[Tricky Mike]

I totally missed this thread. Great write-up. What a bitch for one broken bolt.

[Kitt]

you wear gloves when you wrench? aww cute

[Jim]

great quality pictures and nicely written

[BMFR6]

nice write up dave. would have liked that when i had an sv.

[GixerJockey]

HEY CEO5878963121554789!!!

THAT'S HOW YOU DO A REBUILD THREAD!

[Crash Dummy Denno]

so let's get to the important stuff, how's Roxy doing?

[joeswamp]

Great write up and pictures. What I want to know is: What bolt did you break?? Usually I'm pretty careful when I work on my SV but this bolt seems to deserve extra precautions against overtightening.

[CEO]

Nice write up and pictures, David.

And coming from me, that's saying something

[daviid]

thanks for the compliments everyone

you wear gloves when you wrench? aww cute

You know, I've tried all sorts of moisturizers. I even went fragrance free for a whole year. Now my sister, she uses some kind of uh... uh... uh... uh... aloe vera with a little sunscreen in it, and ideally, we should all wear gloves when going to bed, but I found out that that creates a kind of an interference with my... social agenda, you know what I mean.

so let's get to the important stuff, how's Roxy doing?

shes slightly mad at me right now. she walked into my fist last night when i was bowling on my wii. other then that she is thrilled chewing a steak bone right now

Great write up and pictures. What I want to know is: What bolt did you break?? Usually I'm pretty careful when I work on my SV but this bolt seems to deserve extra precautions against overtightening.

the Shift Detent bolt. my torque wrench apparently needs a recalibration.

[Tricky Mike]

You know, I've tried all sorts of moisturizers. I even went fragrance free for a whole year. Now my sister, she uses some kind of uh... uh... uh... uh... aloe vera with a little sunscreen in it, and ideally, we should all wear gloves when going to bed, but I found out that that creates a kind of an interference with my... social agenda, you know what I mean.

Loved that scene. The two knuckleheads in the background bouncing off the van really tied it all together

[CEO]

the Shift Detent bolt. my torque wrench apparently needs a recalibration.

Similar things have happened to me

You sure you weren't just using a torque wrench near the limits of it's range (where it's not as accurate)?

I.e. for a 10 ftlb bolt, you don't want to use a torque wrench that goes from 10-90 ftlbs...

[SVRACER01]

you wear gloves when you wrench? aww cute

yeah...oil has carcinogens in it. its wise to wear gloves

[SVRACER01]

Try not to flip it as the valve spring covers will come off

you TWAT! those are the shims! not "spring covers". actually they are the "buckets" the shims are underneath them.

did you check clearances before you completely tore it down so if you needed shims you could order them, that way they would be in by the time you got back to reassembling.

[pasta-rocket]

Don't just rebuild it. Lighten the crank, titanium rods and put some big block pistons in it. Thats my 2 cents.

[brewmaster]

Dave so what I want to know is ..... what is the tube frame in the back ground for?????? Inquiring minds want to know.

[SVRACER01]

what tube frame do you see?

[Cerberus]

what tube frame do you see?

look more closely at the first 4 or so pictures

[daviid]

you TWAT! those are the shims! not "spring covers". actually they are the "buckets" the shims are underneath them.

did you check clearances before you completely tore it down so if you needed shims you could order them, that way they would be in by the time you got back to reassembling.

thanks, wasnt sure what they were called. so i just winged it

[daviid]

Don't just rebuild it. Lighten the crank, titanium rods and put some big block pistons in it. Thats my 2 cents.

lets just say that some parts arent going back in the way they came out

[daviid]

Dave so what I want to know is ..... what is the tube frame in the back ground for?????? Inquiring minds want to know.

that would be a 2008 Hempke Lated Model Stock Car. aka One of them nascar circle thingies.

[GixerJockey]

Dave... Any chance you discovered an extra radiator in that mess???

[daviid]

Dave... Any chance you discovered an extra radiator in that mess???

i got one for the SB, but im looking for a 600 or 750 radiator to replace it

[brewmaster]

that would be a 2008 Hempke Lated Model Stock Car. aka One of them nascar circle thingies.

That's cool. Bet it's a blast to beat on. Never did the roundy round thing but have driven a few cars in my fearless days.