1999-2002 Suzuki SV650 Carb removal.

Written By: David Koster
  • Comments: 0
1999-2002 Suzuki SV650 Carb removal.

Difficulty

Easy

Steps

13

Time Required

10 - 25 minutes

Introduction

Originally will be part of the Valve Inspection and Adjustment Guide but would be useful as a standalone guide.

When I first saw the carburetor it was a daunting looking task to me. But after doing it once I can get it off within minutes, and so can you!

Reasons you might want to take the carbs off

1: You need to replace either the front or rear head cylinder

2: You want to rebuild your carburetor

3: You want/need to clean the carbs

4: Easier time working on the valves.

Note: You can buy an impact driver kit for the JIP head bits. I personally would do it by hand but the choice is yours!

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    • If you have frame covers below your seat, remove them by removing the 4 mm allen bolts holding them on. Use a 4 mm allen wrench to turn the screws counter-clockwise until they come off.

    • Once the frame covers are off, remove the 4 mm allen seat bolts on both sides of the seat. Use the 4 mm allen wrench to turn the screws counter-clockwise until they come off.

    • The bolt in the picture is not stock.

    • Lift the front of the seat, then pull it off the frame.

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    • Turn the two 4mm allen bolts in the front tank mounts counter-clockwise with an allen wrench until they come out.

    • The bolts shown in the picture are not stock.

    • Turn the two 12mm hex bolts in the tank's hinge base counter-clockwise with a socket wrench or box end wrench until they come out.

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    • Disconnect the fuel level sensor connector, located near the tank hinge base. It will be a three wire connector and one side of the wire will be traceable to the underside of the tank.

    • Carefully lift the front of the tank to gain access to the hoses attached to the tank.

    • Do not lift the tank too much, or you risk damaging fuel lines, vacuum lines and spilling fuel.

    • There are small metal inserts that go into the front tank mounts. Make sure these do not fall out and get lost while working with the tank.

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    • Locate the petcock on the left underside of the tank. It hill have 2 hoses attached to it and will be next to the fuel level sensor.

    • Disconnect the vacuum hose from the petcock.

    • It is advisable to always remove this hose first to reduce the amount of fuel spilled.

    • Disconnect the fuel hose from the petcock

    • Disconnect the tank breather hose from the base of the tank.

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    • Carefully lift the tank up and off the frame of the bike, being sure that the fuel level sensor wire does not get caught in the frame.

    • When you set your tank aside, be mindful of the petcock hose fittings, especially the vacuum fitting on the bottom. These fittings can easily be broken by the weight of the tank and are costly to replace.

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    • There will be two hoses connected on the rear left side of the air box. There will be two clips that will hold these hoses to the air box. These will allow all the excess oil to collect in a small spong-like section. After this is disconnected slowly pull the air box from the carburator

    • I removed the clips from my motorcycle so I do not have pictures of it but beware that yours probably does.

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    • Slowly pull this out, this allows the vacuum to pull the necessary amount of gas from the tank into the carbs. As we will completely remove the carburetor from the motorcycle.

    • Do not pull mindlessly as you can damage the hose, pull at an angle and it should be easily removable.

    • This will be located at the right side of the bike.

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    • Before pulling the carbs off loosen the clamps on both the front and rear. Use your JIP-4 Screwdriver

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    • From this point on we will disconnect the carb from the head. This will make it so we can perform the next step easier

    • Slowly pull from the top "gold" handle towards you. Do this from the opposite side of where you are pulling. You will need to use some strength but not a lot. This should easily disconnect the carb from the head

    • Do not pull the carburetor off and away from the bike as of yet. There are still the throttle cables and choke cables that need to be removed. Otherwise, you could break these.

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    • Start by grabbing your JIP-4 screwdriver and slowly removing the screws. If they have never been touched before they can be hard to remove. Try your best not to strip these. After you are done with the first slowly pull the cable out of the carburator "body". Repeat the same caution for the second choke cable

    • The first picture is of the rear carb, the second picture is of the front

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    • These will be found on the front rear side of the carbs. It is also unnecessary to completely remove the nut. Just loosen them enough until they are able to be removed

    • Loosen the throttle cable nuts until they can be removed completely

    • Afterwards pull the cables out, you may need to use the screwdriver to push them out completely

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    • Be careful not to forget to remove this. This will be located at the right of the rear carb

    • Carefully push in the clip and disconnect the cable.

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    • Congratulations. You can now take out the carb completely of the motorcycle!

    • The carb has an idle adjustment screw that is in a bracket. Mine was not in such a bracket so I could not show you but be careful when pulling the carb out that you do not damage said bracket

Conclusion

To reassemble your device, follow these instructions in reverse order.

Author

David Koster

Member since: 20/11/22

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