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Suzuki
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DL1000
Suzuki DL1000 Service Manual
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1-10
G
ENE
RA
L INF
OR
MA
TION
COUNTRY AND AREA CODES
The
followi
ng c
odes
stand
for th
e appl
icabl
e cou
ntry(-ie
s) and
are
a(-s).
COD
E
COU
NTRY
or AREA
E-02
E-03
E-19
E-24
E-28
E-33
U.
K.
U
.
S. A
. (
Exce
pt
f
or
Cali
f
orni
a)
EU
Aus
t
ra
li
a
Can
ada
Cal
if
orni
a (
U
. S
. A.
)
15
17
Table of Contents
Foreword Group Index
2
Table of Contents
2
How to Use this Manual
3
Abbreviations Used in this Manual
5
General Information 1
7
General Information
8
Suzuki Dl1000K2 ('02-Model)
10
Serial Number Location
10
Fuel, Oil and Engine Coolant Recommendation
10
Fuel
10
Anti-Freeze/Engine Coolant
11
Brake Fluid
11
Engine Coolant
11
Engine Oil
11
Front Fork Oil
11
Liquid Amount of Water/Engine Coolant
11
Water for Mixing
11
BREAK-Ln PROCEDURES
12
Cylinder Identification
12
Information Labels
13
Specifications
14
General Precautions
8
Warning/Caution/Note
8
Chassis
15
Country and Area Codes
16
Periodic Maintenance Schedule
18
Periodic Maintenance Chart
18
Lubrication Points
19
Engine
20
Spark Plug
21
Tappet Clearance
23
Engine Oil and Oil Filter
28
Fuel Hose
28
Engine Idle Speed
30
Throttle Cable Play
30
Pair (Air Supply) System
31
Throttle Valve Synchronization
31
Clutch
32
Cooling System
33
Drive Chain
35
Brake
37
Steering
41
Tire
41
Exhaust Pipe Bolt
42
Front Fork
42
Rear Suspension
42
Chassis Bolt and Nut
43
Compression Pressure Check
45
Compression Test Procedure
45
Oil Pressure Check
46
Oil Pressure Test Procedure
46
Maintenance and Tune-Up Procedures
20
Air Cleaner
20
Engine
47
Engine Components Removable with Engine in Place
48
Engine Removal and Installation
49
Engine Removal
49
Engine Installation
58
Engine Disassembly
65
Engine Top Side
65
Engine Bottom Side
71
Engine Components Inspection and Servicing
80
Cylinder Head Cover
80
Camshaft/Cylinder Head
81
Camshaft Runout
83
Cylinder/Piston Inspection
93
Piston Diameter
94
Piston Ring Thickness
95
Conrod/Crankshaft
96
Clutch
100
Transmission
102
Gearshift Fork
108
Primary Drive Gear
109
Starter Torque Limiter
110
Starter Clutch
111
Gearshift
112
Crankcase
112
Crankcase-Crankshaft Bearing
117
Generator Cover
123
Clutch Cover
123
Gearshift Cover
123
Engine Reassembly
124
Engine Bottom Side
124
Engine Top Side
138
Fi System
159
Precautions in Servicing
161
Connector/Coupler
161
Ecm/Various Sensors
162
Fuse
162
Electrical Circuit Inspection Procedure
164
Using Testers
167
Fi System Technical Features
168
Injection Time (Injection Volume)
168
Compensation of Injection Time (Volume)
169
Injection Stop Control
169
Fuel Delivery System
170
Fuel Pump
171
Fuel Pressure Regulator
172
Fuel Injector
172
Fuel Pump Control System
173
Ecm (Fi Control Unit)
174
Injection Timing
174
Sensors
175
Fi System Parts Location
179
Fi System Wiring Diagram
181
Self-Diagnosis Function
182
User Mode
182
Dealer Mode
183
Tps Adjustment
184
Fail-Safe Function
185
Fi System Troubleshooting
186
Customer Complaint Analysis
186
Self-Diagnostic Procedures
188
Self-Diagnosis Reset Procedure
188
Malfunction Code and Defective Condition
189
C11" Cmp Sensor Circuit Malfunction
191
C12" Ckp Sensor Circuit Malfunction
192
C13" Iap Sensor Circuit Malfunction
193
C14" Tp Sensor Circuit Malfunction
195
C15" Ect Sensor Circuit Malfunction
197
C21" Iat Sensor Circuit Malfunction
198
C22" Ap Sensor Circuit Malfunction
199
C23" to Sensor Circuit Malfunction
201
C24" or "C25" IGNITION SYSTEM MALFUNCTION
202
C28" Stv Actuator Circuit Malfunction
202
C29" Stp Sensor Circuit Malfunction
203
C31" Gear Position (Gp) Switch Circuit Malfunction
205
C32" or "C33" FUEL INJECTION MALFUNCTION
206
C41" Fp Relay Circuit Malfunction
207
C42" Ig Switch Circuit Malfunction
207
C44" Ho
208
Sensor (Ho 2 S) Circuit Malfunction
208
Fuel System
210
Fuel Tank Lift-Up
210
Fuel Tank Removal
211
Fuel Tank Installation
211
Fuel Pressure Inspection
212
Fuel Pump Inspection
213
Fuel Pump Relay Inspection
214
Fuel Pump and Fuel Filter Removal
214
Fuel Mesh Filter Inspection and Cleaning
216
Fuel Pump and Fuel Mesh Filter Installation
216
Throttle Body and Stv Actuator
218
Construction
218
Throttle Body Removal
219
Throttle Body Disassembly
220
Throttle Body Cleaning
224
Inspection
224
Throttle Body Reassembly
224
Stp Sensor Adjustment
227
Throttle Body Installation
228
Tp Sensor Adjustment
228
Fuel Injector Inspection
228
Fuel Injector Removal
229
Fuel Injector Installation
229
Fast Idle Inspection
229
Fast Idle Adjutment
230
Throttle Valve Synchronization
231
Throttle Cable Adjustment
232
Cooling and Lubrication System
237
Chassis
258
Chassis
313
Electrical System
344
Electrical
360
Servicing Information
379
Capacities
426
Sensor
233
Iap Sensor Inspection
233
Iap Sensor Removal/Installation
233
Stp Sensor Inspection
233
Stp Sensor Removal/Installation
233
Tp Sensor Inspection
233
Tp Sensor Removal/Installation
233
Ckp Sensor Inspection
234
Ckp Sensor Removal/Installation
234
Cmp Sensor Inspection
234
Cmp Sensor Removal/Installation
234
Iat Sensor Inspection
234
Iat Sensor Removal/Installation
234
Ap Sensor Inspection
235
Ap Sensor Removal/Installation
235
Ect Sensor Inspection
235
Ect Sensor Removal/Installation
235
Ho 2 Sensor Inspection
235
To Sensor Inspection
235
To Sensor Removal/Installation
235
Ho 2 Sensor Removal/Installation
236
Cooling and Lubrication
237
Engine Coolant
238
Cooling Circuit
239
Cooling Circuit Inspection
239
Radiator
240
Removal
240
Inspection and Cleaning
241
Inspection
242
Installation
242
Radiator Cap
242
Radiator Reservoir Tank
242
Removal/Installation
242
Inspection
243
Water Hose
243
Cooling Fan
244
Inspection
244
Installation
244
Removal
244
Cooling Fan Thermo-Switch
245
Inspection
245
Installation
245
Removal
245
Engine Coolant Temperature Sensor
246
Inspection
246
Instalation
246
Removal
246
Inspection
247
Removal
247
Thermostat
247
Installation
248
Removal and Disassembly
249
Water Pump
249
Inspection
251
Reassembly and Installation
251
Lubrication System
254
Oil Cooler
254
Oil Filter
254
Oil Jet
254
Oil Pressure
254
Oil Pressure Regulator
254
Oil Pressure Switch
254
Oil Pump
254
Oil Strainer
254
Removal
254
Inspection and Cleaning
255
Installation
255
Engine Lubrication Flow Chart
256
Engine Lubrication Circuit
257
Construction
259
Exterior Parts
259
Removal
261
Construction
265
Front Wheel
265
Inspection and Disassembly
266
Removal
266
Reassembly and Remounting
268
Construction
271
Front Fork
271
Removal and Disassembly
272
Inspection
275
Reassembly and Remounting
276
Construction
281
Steering and Handlebar
281
Removal
282
Inspection and Disassembly
285
Reassembly and Remounting
286
Steering Tension Adjustment
289
Construction
290
Rear Wheel
290
Removal
291
Inspection and Disassembly
292
Reassembly and Remounting
295
Construction
299
Rear Shock Absorber
299
Removal
300
Inspection
301
Rear Shock Absorber Disposal
301
Remounting
302
Suspension Setting
303
Construction
304
Rear Swingarm
304
Removal
305
Inspection and Disassembly
306
Reassembly
309
Remounting
311
Final Inspection and Adjustment
312
Construction
313
Front Brake
313
Brake Pad Replacement
314
Brake Fluid Replacement
315
Caliper Removal and Disassembly
316
Caliper Inspection
317
Caliper Reassembly and Remounting
318
Brake Disc Inspection
319
Master Cylinder Removal and Disassembly
320
Master Cylinder Inspection
321
Master Cylinder Reassembly and Remounting
321
Construction
323
Rear Brake
323
Brake Pad Replacement
324
Brake Fluid Replacement
325
Caliper Removal and Disassembly
326
Caliper Inspection
327
Brake Disc Inspection
328
Service Limit
328
Caliper Reassembly and Remounting
329
Master Cylinder Removal and Disassembly
330
Master Cylinder Inspection
331
Master Cylinder Reassembly and Remounting
332
Clutch Release Cylinder and Master Cylinder
334
Construction
334
Clutch Fluid Replacement
335
Clutch Release Cylinder Removal and Disassembly
335
Clutch Release Cylinder Inspection
336
Clutch Release Cylinder Reassembly and Remounting
336
Clutch Master Cylinder Removal and Disassembly
338
Clutch Master Cylinder Inspection
339
Clutch Master Cylinder Reassembly and Remounting
339
Inspection
341
Tire and Wheel
341
Tire Removal
341
Tire Installation
342
Valve Installation
342
Electrical System
344
Cautions in Servicing
345
Clamp
345
Connector
345
Coupler
345
Fuse
345
Semi-Conductor Equipped Part
345
Battery
346
Connecting the Battery
346
Using the Multi Circuit Tester
346
Wiring Procedure
346
Location of Electrical Components
347
Charging System
349
Troubleshooting
349
Inspection
350
Starter System and Side-Stand/Ignition Interlock System
353
Trouble Shooting
353
Starter Motor Removal and Disassembly
354
Starter Motor Inspection
355
Starter Motor Reassembly
355
Starter Relay Inspection
356
Side-Stand/Ignition Interlock System Parts Inspection
357
Battery
360
Fuse
360
Ignition System
360
Spark Plug
360
Troubleshooting
360
Inspection
362
Combination Meter
365
Removal and Disassembly
365
Inspection
366
Engine Coolant Temperature Meter and Indicator
368
Headlight
372
Headlight, Brake Light/Taillight and Turn Signal Light
372
Lamps
372
Turn Signal Light
372
Fuel Pump Relay
373
Relays
373
Starter Relay
373
Turn Signal/Side-Stand Relay
373
Switches
374
Battery
376
Initial Charging
376
Specifications
376
Recharging Operation
378
Servicing
378
Servicing Information
379
Fi System Malfunction Code and Defective Condition
380
Troubleshooting
380
Engine
382
Radiator (Cooling System)
387
Chassis
388
Brakes
389
Electrical
390
Battery
391
Wire Harness Routing
392
Wire Harness, Cable and Hose Routing
392
Engine Electrical Parts Set-Up
395
High-Tension Cord Routing
396
Throttle Cable Routing
397
Throttle Body Installation/Hose Routing
398
Crankcase Breather Hose Routing
399
Clutch Hose Routing
400
Cooling System Hose Routing
401
Front Brake Hose Routing
402
Rear Brake Hose Routing
403
Fuel Tank Drain Hose Routing
404
Fuel Tank Installation
405
Pair (Air Supply) System Hose Routing
406
Seat Lock Cable Routing
407
Brake Pedal/Footrest Set-Up
408
Side-Stand Set-Up
408
Footrest Set-Up
409
Handlebar Balancer Installation
409
Special Tools
410
Engine
413
Tightening Torque
413
Fi System Parts
414
Chassis
415
Tightening Torque Chart
416
Service Data
417
Drive Train
421
Throttle Body
422
Brake Light/Taillight
424
High Beam Indicator Light
424
License Light
424
Neutral Indicator Light
424
Oil Pressure Warning Light
424
Over Drive Indicator Light
424
Speedometer/Tachometer Light
424
Turn Signal Indicator Light
424
Fuel Tank
426
Emission Control Information
427
Emission Control Systems
428
Fuel Injection System
428
Crankcase Emission Control System
429
Exhaust Emission Control System (Pair System)
430
EVAPORATIVE EMISSION CONTROL SYSTEM (Only for E-33)
431
Noise Emission Control System
431
Pair (Air Supply) System Inspection
432
Pair Control Solenoid Valve
433
Pair (Air Supply) System Hose Routing
434
Heated Oxgen Sensor (Ho S) Inspection
435
Heated Oxgen Sensor Wire Routing
436
EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION (Only for E-33)
437
CANISTER HOSE ROUTING (Only for E-33)
438
Wiring Diagram
439
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Owner's Manual
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Suzuki DL1000 Specifications
General
Brand
Suzuki
Model
DL1000
Category
Motorcycle
Language
English
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