Suzuki DL1000AL4 Owner's Manual
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Suzuki DL1000AL4 Owner's Manual

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FOREWORD
This motorcycle has been designed and produced utilizing Suzuki's most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this motorcycle.
Please read this manual and follow its instructions carefully. To emphasize special
information, the symbol
and the words WARNING, CAUTION, NOTICE and
NOTE have special meanings. Pay particular attention to messages highlighted by
these signal words:
Indicates a potential hazard that could result in death or serious injury.
Indicates a potential hazard that could result in minor or moderate injury.
Indicates a potential hazard that could result in motorcycle or equipment
damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
This set-up manual is based on a motorcycle of standard specification. Some minor
differences from this manual may be found in other specifications.
99505-01134-01E
L4
December '13 (TK) 21
© COPYRIGHT SUZUKI MOTOR JAPAN

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Summary of Contents for Suzuki DL1000AL4

  • Page 1 FOREWORD This motorcycle has been designed and produced utilizing Suzuki’s most modern technology. The finest product, however, cannot perform properly unless it is cor- rectly assembled and serviced. This set-up manual has been produced to aid you in properly assembling and servicing this motorcycle.
  • Page 2 PREPARATION WORKSHOP  CAUTION Assembling the vehicle in poor working condi- tion can be hazardous. Place the packed vehicle on a level floor where it is clean and spacious. A: Packed vehicle B: Working space SELF PROTECTION  CAUTION Assembling the vehicle without proper clothes and protective gear can be hazardous.
  • Page 3 UNCRATING THE MOTORCYCLE Cut the strap by using scissors. A: Strap Remove the carton.  CAUTION Metal crates may have sharp edges and may cause injury. Wear proper protective clothes and gear. A: Crate...
  • Page 4 Remove the strap. Take out the front wheel assembly from the crate base. A: Strap B: Front wheel assembly Remove the strap. Take out the various component parts packaged from the crate base. A: Strap B: Component parts Remove the bolts of the bracket. A: Bolt...
  • Page 5 Remove the bolts from the crate. A: Bolt Lift the steel frame to separate it from the base of the crate. Carefully remove the various component parts pack- aged around the motorcycle.  CAUTION Careless steel frame separation can injure a person.

  • Page 6: Location Of Parts

    LOCATION OF PARTS Check all the components which have been removed from the base of the crate. Item Part Name Q’ty Remarks Item Part Name Q’ty Remarks Windscreen Front fender Stepped Allen screw 6 × 20 mm Stepped Allen screw 6 ×...
  • Page 7 The photograph shown indicates the parts dismounted from the motorcycle in addition to the items shown in the preceding page. A: Front brake master cylinder B: Throttle assembly C: Clutch master cylinder D: Left switch E: Right switch F: Front wheel ABS sensor assembly G: Case lock assembly...

  • Page 8: Removing The Bracket

    Before assembling the motorcycle, thoroughly understand the “Safety Check Out” described on page 52. After completion of assembly, carefully check the motorcycle referring to the “Safety Check Out”, then deliver the motorcycle to the customer. ASSEMBLY LEFT RIGHT REMOVING THE BRACKET Remove the bolts to take off the front brake and clutch master cylinder from the bracket.
  • Page 9 HANDLEBARS Loosen the right switch retaining screws and throttle housing retaining bolts. Insert the right switch and throttle assembly onto the handlebars. A: Throttle assembly B: Right switch C: Handlebars Install the handlebars assembly with the two clamps, four bolts and washers. NOTE: •...

  • Page 10: Right Switch

    NOTE: • The line drawings on page 47, 48, 49, 50 and 51 show the proper routing of the control cables, hose and wirings. • Refer to them in addition to following the instruc- tions carefully. A: Front brake hose B: Throttle cables C: Right switch wiring harness D: Clutch hose...

  • Page 11: Front Brake Master Cylinder

    FRONT BRAKE MASTER CYLINDER Install the front brake master cylinder onto the handle- bars. NOTE: • Install the holder in position according to the mark “UP”. • Align the dot mark on the handlebars with the master cylinder-to-holder fitting surface. A: Holder B: Front brake master cylinder C: 6 ×...

  • Page 12: Left Switch

    LEFT SWITCH Insert the boss of left switch housing into the hole on the handlebars. Install the left switch assembly with two screws. NOTICE Pinching the lead wires in the parts can short or break circuit. Check the lead wire routing when assembling the switch.
  • Page 13 Connect the lead wires to the clutch lever position switch. A: Clutch lever position switch B: Lead wire RIGHT CLAMP Clamp the right switch wiring harness and front brake hose union with strap. NOTE: Cut off the excess strap as shown in the photo- graph.

  • Page 14: Handlebar Balancer

    HANDLEBAR BALANCER Assemble the handlebar balancer parts as shown. A: Balancer weight B: 6 × 105 mm screw C: Flange rubber cushion L:34.0 mm D: Spacer L:50.0 mm E: Washer OD:16.0 mm ID:6.5 mm T:1.6 mm F: Rubber cushion L:15.0 mm G: 6 mm spacer nut Tighten the screw a little.
  • Page 15 TAKING OUT THE MOTORCYCLE Bind a hoist band around the handlebar clamps as shown in the photograph. NOTE: Lift the motorcycle a little by using a hoist to pre- vent the motorcycle from falling down. NOTICE Binding a hoist band to the handlebar or grips can damage the motorcycle parts.

  • Page 16: Front Fender

    FRONT FENDER Install the front fender to the front fork legs. A: Front fender B: 6 × 16 mm stepped Allen screw C: Front fork leg (FOR LIMITED SPECIFICATIONS) Install the front fender to the front fork legs. NOTE: When installing the reflex reflector assembly, tighten the reflex reflector stay.

  • Page 17: Brake Disc

    FRONT REAR BRAKE DISC To prevent brake squeaking and pad contamination, carefully clean the front and rear brake disc plates with alcohol or other non-petroleum based solvent. This will remove the rust-preventive coating and dirt. FRONT WHEEL When installing the front wheel onto the axle, special attention must be paid to the arrow of the rotational direction on the tire sidewall.
  • Page 18 Loosen the axle clamp bolts. Remove the front axle from the fork legs. A: Axle clamp bolt B: Front axle Mount the front wheel assembly properly. A: Right fork leg B: Left fork leg C: Front wheel spacer (Right) D: Front axle E: Axle nut (24 mm flange nut) Temporarily remove the right front brake caliper.
  • Page 19 LEFT Remove the supporter from the brake pad of the left front brake caliper. A: Supporter RIGHT LEFT Attach the front wheel spacer to the front wheel hub. Carefully insert the front brake disc plate between the caliper brake pads. NOTE: •...

  • Page 20: Front Brake Caliper

    Tighten the front axle nut to the specified torque while holding the front axle.  Front axle nut: 100 N·m (10.0 kgf-m) A: Axle nut FRONT BRAKE CALIPER Remove the supporter from the brake pad of the right front brake caliper. A: Supporter B: Brake caliper (Right) Set the front brake caliper so the brake disc plate is...
  • Page 21 ABS SENSOR Install the front wheel ABS sensor assembly. A: Front wheel ABS sensor assembly B: Hole C: 6 × 12 mm flange bolt Install the front wheel ABS sensor lead wire bracket to the fork leg. NOTE: The front wheel ABS sensor lead wire bracket come in contact to stopper of fork leg as shown in the photograph.
  • Page 22 Place the motorcycle on the side-stand, then remove the hoist hook. Extract the side stand. Move the front fork up and down hard 4 or 5 times. RIGHT LEFT Tighten the axle clamp bolts to the specified torque.  Front axle clamp bolt: 23 N·m (2.3 kgf-m) A: Axle clamp bolt Place the motorcycle on the stand.
  • Page 23 WINDSCREEN Install the rubber cushion to the windscreen. A: Windscreen B: Rubber cushion OD:18.0 mm T:10.0 mm Set the windscreen to the windscreen brace. NOTE: Align the hole of windscreen to most lower screw hole of windscreen brace. A: Windscreen B: 6 ×...

  • Page 24: Rear View Mirror

    REAR VIEW MIRROR Remove the lock bolt. Turn in the lock nut as far as possible. NOTE: Part D of the rear view mirror stay is opposite threaded. A: Lock bolt B: Rear view mirror stay C: Lock nut D: Opposite thread Tighten the lock bolt.

  • Page 25: License Plate

    LICENSE PLATE NOTE: When installing the license plate, use the washers as shown in the photograph. A: Washer OD:13.0 mm ID:6.5 mm B: Rear fender C: License plate (FOR LIMITED SPECIFICATIONS) NOTE: When installing the license plate, use the washers as shown in the photograph.
  • Page 26 OWNER’S MANUAL Remove the seat by using the key. A: Key B: Seat Store the owner’s manual in place. A: Owner’s manual set Reinstall the seat. Insert the seat hook into the seat hook retainer. Push the seat down to lock it. A: Seat assembly B: Seat hook C: Seat hook retainer...

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