Suzuki DL1000 Service Manual

6
CHASSIS 6-1
CHASSIS
CONTENTS
EXTERIOR PARTS ......................................................................................................................................6- 2
CONSTRUCTION ............................................................................................................................6- 2
REMOVAL .......................................................................................................................................6- 4
FRONT WHEEL ...........................................................................................................................................6- 8
CONSTRUCTION ............................................................................................................................6- 8
REMOVAL .......................................................................................................................................6- 9
INSPECTION AND DISASSEMBLY ...............................................................................................6- 9
REASSEMBLY AND REMOUNTING .............................................................................................6-11
FRONT FORK ..............................................................................................................................................6-14
CONSTRUCTION ............................................................................................................................6-14
REMOVAL AND DISASSEMBLY ...................................................................................................6-15
INSPECTION ...................................................................................................................................6-18
REASSEMBLY AND REMOUNTING .............................................................................................6-19
STEERING AND HANDLEBAR ..................................................................................................................6-24
CONSTRUCTION ............................................................................................................................6-24
REMOVAL .......................................................................................................................................6-25
INSPECTION AND DISASSEMBLY ...............................................................................................6-28
REASSEMBLY AND REMOUNTING .............................................................................................6-29
STEERING TENSION ADJUSTMENT ............................................................................................6-32
REAR WHEEL .............................................................................................................................................6-33
CONSTRUCTION ............................................................................................................................6-33
REMOVAL .......................................................................................................................................6-34
INSPECTION AND DISASSEMBLY ...............................................................................................6-35
REASSEMBLY AND REMOUNTING .............................................................................................6-38
REAR SHOCK ABSORBER .......................................................................................................................6-42
CONSTRUCTION ............................................................................................................................6-42
REMOVAL .......................................................................................................................................6-43
INSPECTION ...................................................................................................................................6-44
REAR SHOCK ABSORBER DISPOSAL ........................................................................................6-44
REMOUNTING ................................................................................................................................6-45
SUSPENSION SETTING .................................................................................................................6-46
REAR SWINGARM ......................................................................................................................................6-47
CONSTRUCTION ............................................................................................................................6-47
REMOVAL .......................................................................................................................................6-48
INSPECTION AND DISASSEMBLY ...............................................................................................6-49
REASSEMBLY ................................................................................................................................6-52
REMOUNTING ................................................................................................................................6-54
FINAL INSPECTION AND ADJUSTMENT .....................................................................................6-55
FRONT BRAKE ...........................................................................................................................................6-56
CONSTRUCTION ............................................................................................................................6-56
BRAKE PAD REPLACEMENT .......................................................................................................6-57
BRAKE FLUID REPLACEMENT ....................................................................................................6-58
CALIPER REMOVAL AND DISASSEMBLY ..................................................................................6-59
CALIPER INSPECTION ..................................................................................................................6-60
CALIPER REASSEMBLY AND REMOUNTING .............................................................................6-61
BRAKE DISC INSPECTION ...........................................................................................................6-62
MASTER CYLINDER REMOVAL AND DISASSEMBLY ...............................................................6-63
MASTER CYLINDER INSPECTION ...............................................................................................6-64
MASTER CYLINDER REASSEMBLY AND REMOUNTING ..........................................................6-64
REAR BRAKE .............................................................................................................................................6-66
CONSTRUCTION ............................................................................................................................6-66
BRAKE PAD REPLACEMENT .......................................................................................................6-67
BRAKE FLUID REPLACEMENT ....................................................................................................6-68
CALIPER REMOVAL AND DISASSEMBLY ..................................................................................6-69
CALIPER INSPECTION ..................................................................................................................6-70
BRAKE DISC INSPECTION ...........................................................................................................6-71
CALIPER REASSEMBLY AND REMOUNTING .............................................................................6-72
MASTER CYLINDER REMOVAL AND DISASSEMBLY ...............................................................6-73
MASTER CYLINDER INSPECTION ...............................................................................................6-74
MASTER CYLINDER REASSEMBLY AND REMOUNTING ..........................................................6-75
CLUTCH RELEASE CYLINDER AND MASTER CYLINDER .....................................................................6-77
CONSTRUCTION ............................................................................................................................6-77
CLUTCH FLUID REPLACEMENT ..................................................................................................6-78
CLUTCH RELEASE CYLINDER REMOVAL AND DISASSEMBLY ..............................................6-78
CLUTCH RELEASE CYLINDER INSPECTION ..............................................................................6-79
CLUTCH RELEASE CYLINDER REASSEMBLY AND REMOUNTING ........................................6-79
CLUTCH MASTER CYLINDER REMOVAL AND DISASSEMBLY ................................................6-81
CLUTCH MASTER CYLINDER INSPECTION ...............................................................................6-82
CLUTCH MASTER CYLINDER REASSEMBLY AND REMOUNTING ..........................................6-82
TIRE AND WHEEL ......................................................................................................................................6-84
TIRE REMOVAL ..............................................................................................................................6-84
INSPECTION ...................................................................................................................................6-84
VALVE INSTALLATION .................................................................................................................6-85
TIRE INSTALLATION .....................................................................................................................6-85

Suzuki DL1000 Specifications

General

Brand	Suzuki
Model	DL1000
Category	Motorcycle
Language	English