Suzuki SV 1000S 2003 Service Manual
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Suzuki SV 1000S 2003 Service Manual

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Summary of Contents for Suzuki SV 1000S 2003

  • Page 343 SV1000 USE THIS MANUAL WITH: SV1000S SERVICE MANUAL (99500-39250-01E) 9 9 5 0 1 - 3 9 5 4 0 - 0 1 E...

  • Page 344: Table Of Contents

    CLUTCH HOSE ROUTING ................12 FRONT BRAKE HOSE ROUTING .............13 REAR BRAKE HOSE ROUTING ...............14 BRAKE PEDAL/FOOTREST SET-UP ............15 PROP STAY SET-UP .................16 HANDLE BALANCER INSTALLATION ............16 TIGHTENING TORQUE..................17 CHASSIS ....................17 SERVICE DATA ....................19 WIRING DIAGRAM....................29 © COPYRIGHT SUZUKI MOTOR CORPORATION 2003...

  • Page 345: Specifications

    SV1000K3 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length............* 2 135 mm (84.1 in) Overall width ............* 785 mm (30.9 in) Overall height............* 1 080 mm (42.5 in) Wheelbase ............* 1 445 mm (56.9 in) Ground clearance ..........150 mm ( 5.9 in) Seat height............* 800 mm (31.5 in) Dry mass..............* 187 kg (412 lbs) ..For E-33...
  • Page 346 SV1000K3 3 CHASSIS Front suspension..........Telescopic, coil spring, oil damped Rear suspension ..........Link type, coil spring, oil damped Front suspension stroke........120 mm (4.7 in) Rear wheel travel ..........* 130 mm (5.1 in) Caster..............* 25.0° Trail ..............* 107 mm (4.2 in) Steering angle .............

  • Page 347: Periodic Maintenance

            SV1000K3 PERIODIC MAINTENANCE CHASSIS BOLT AND NUT Tighten initially at 1 000 km (600 miles, 1 month) and every 6 000 km (4 000 miles, 6 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to below and page 2-29 of SV1000S Service manual for the locations of the following nuts and bolts on the motorcycle.) ITEM N·m...

  • Page 348: Suspension Setting

        SV1000K3 5 SUSPENSION SETTING After installing the front fork, adjust the spring pre-load and damping force as follows. SPRING PRE-LOAD ADJUSTMENT There are eight grooves on the spring adjuster. Position 1 pro- vides the maximum spring pre-load and position 8 provides the minimum spring pre-load.

  • Page 349: Handlebars

                    SV1000K3 HANDLEBARS REMOVAL AND DISASSEMBLY • Remove the handlebar balancer NOTE: Do not remove the handlebar balancer mounting screw before removing the handlebar balancer. Slightly loosen the mounting screw, and then pull the balancer assembly out of handlebars. •...
  • Page 350 1 and then tighten the bolt • Install the throttle grip and cables. (Throttle cable routing: #11) • Apply SUZUKI SUPER GREASE to the throttle cables and their holes. $ 99000-25030: SUZUKI SUPER GREASE “A” (USA) 99000-25010: SUZUKI SUPER GREASE “A” (Others) •...

  • Page 351: Master Cylinder Remounting

                SV1000K3 • Install the left handlebar switch to the handlebars by engaging 5 with the handlebar hole the stopper • Install the clutch master cylinder. (#SV1000S 6-94 and below) • Install the handlebar balancers and rear view mirrors. (Handlebar balancer installation: #16) MASTER CYLINDER REMOUNTING Master...

  • Page 352: Wiring Harness, Cable And Hose Routing

    SV1000K3 9 WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Magneto lead UPPER Clamp Wiring harness Magneto Set the coupler center of the frame. Set the magneto coupler above the generator coupler. Ignition coil Set the speed sensor coupler under the clutch hose.
  • Page 353 SV1000K3 Clamp Wiring harness Neutral switch Clamp the harness without contact to the bracket. Horn Don’t slacken. Clamp Set the connector and harness between the Harness frame and reservoir tank. Rear turn signal light Set surely. Licence lamp Set the coupler inside triangle area between the frame and fender.

  • Page 354: Throttle Cable Routing

    SV1000K3 THROTTLE CABLE ROUTING Throttle cable No. 1 Brake hose Throttle cable No. 2 Guide Pass the throttle cables in front of the brake hose. Throttle cable No. 1 Harness Throttle cable No. 2 Handle switch (LH) Guide VIEW B Clutch hose Clamp SECT A...

  • Page 355: Clutch Hose Routing

    SV1000K3 CLUTCH HOSE ROUTING VIEW A After the clutch hose union 21˚ 14˚ touching to the stopper, tighten the union bolt. After positioning the clutch hose with the frame bridge, tighten the clamp bolt. Pass through the clutch hose outside of the guide. Frame bridge Clamp the clutch hose firmly.

  • Page 356: Front Brake Hose Routing

    SV1000K3 FRONT BRAKE HOSE ROUTING...

  • Page 357: Rear Brake Hose Routing

    SV1000K3 REAR BRAKE HOSE ROUTING...

  • Page 358: Brake Pedal/Footrest Set-Up

    SV1000K3 BRAKE PEDAL/FOOTREST SET-UP...

  • Page 359: Prop Stay Set-Up

    SV1000K3 PROP STAY SET-UP Fuel tank prop stay Fuel tank prop stay Clamp Fuel tank prop stay Forward Rear fender No. 2 Lift and support the fuel tank Rear fender No. 1 with its prop stay. HANDLE BALANCER INSTALLATION 5.5 N . m (0.55 kgf-m, 4.0 lb-ft) Balancer weight LH clearance...

  • Page 360: Tightening Torque

    SV1000K3 TIGHTENING TORQUE CHASSIS ITEM N·m kgf-m lb-ft Steering stem head nut 65.0 Steering stem lock nut 58.0 Front fork upper clamp bolt 16.5 Front fork lower clamp bolt 16.5 Front fork cap bolt 16.5 Front fork inner rod lock nut 11.5 Front fork damper rod bolt 16.5...
  • Page 361 SV1000K3 ITEM N·m kgf-m lb-ft Steering damper bolt 16.5 Steering damper nut 16.5 Steering stem nut 32.5...

  • Page 362: Service Data

    SV1000K3 SERVICE DATA VALVE + GUIDE Unit: mm (in) ITEM STANDARD LIMIT Valve diam. — (1.42) — (1.30) Tappet clearance (when cold) 0.10 – 0.20 — (0.004 – 0.008) 0.20 – 0.30 — (0.008 – 0.012) Valve guide to valve stem clear- 0.010 –...
  • Page 363 SV1000K3 ITEM STANDARD LIMIT Cam drive idle gear/sprocket 0.15 – 0.29 — thrust clearance (0.006 – 0.011) Cylinder head distortion 0.05 — (0.002) CYLINDER + PISTON + PISTON RING Unit: mm (in) ITEM STANDARD LIMIT Compression pressure 800 kPa 1 000 – 1 400 kPa (Automatic de-comp.
  • Page 364 SV1000K3 CONROD + CRANKSHAFT Unit: mm (in) ITEM STANDARD LIMIT Conrod small end I.D. 22.010 – 22.018 22.040 (0.8665 – 0.8668) (0.8677) Conrod big end side clearance 0.17 – 0.32 0.50 (0.007 – 0.013) (0.020) Conrod big end width 21.95 – 22.00 —...
  • Page 365 SV1000K3 THERMOSTAT + RADIATOR + FAN + COOLANT ITEM STANDARD LIMIT Thermostat valve opening tem- 86.5 – 89.5 °C — perature (188 – 193 °F) Thermostat valve lift Over 8.0 mm (0.31 in) at 100 °C (212 °F) — Radiator cap valve opening 110 kPa (1.1 kgf/cm , 15.6 psi) —...
  • Page 366 SV1000K3 INJECTOR + FUEL PUMP + FUEL PRESSURE REGURATOR ITEM SPECIFICATION NOTE 11 – 13 Ω at 20 °C (68 °F) Injector resistance Fuel pump discharge amount 168 ml and more (5.7/5.9 US/lmp oz) for 10 seconds at 300 kPa (3.0 kgf/cm , 43 psi) Fuel pressure regulator operat- Approx.

  • Page 367: Headlight

          SV1000K3 THROTTLE BODY ITEM SPECIFICATION ID No. * 16G1 (For E-33), 16G2 (Others) Bore size 52 mm Fast idle r/min 1 900 – 2 500 r/min at 25 °C (77 °F) Idle r/min 1 200 ± 100 r/min/Warmed engine Throttle cable play 2.0 –...

  • Page 368: Position Light

    SV1000K3 WATTAGE Unit: W ITEM SPECIFICATION Headlight Position light (For E-02, 19) Brake light/Taillight Turn signal light 21 × 4 Speedometer/Tachometer light Turn signal indicator light High beam indicator light Neutral indicator light Fuel indicator light Coolant temperature/oil pres- sure/FI indicator light License light BRAKE + WHEEL Unit: mm (in)
  • Page 369 SV1000K3 ITEM STANDARD LIMIT Wheel rim runout Axial — (Front & Rear) (0.08) Radial — (0.08) Wheel axle runout 0.25 Front — (0.010) 0.25 Rear — (0.010) Wheel rim size Front 17M/C × MT 3.50 — Rear 17M/C × MT 5.50 —...
  • Page 370 2 900 ml Filter change (3.1/2.6 US/lmp qt) 3 300 ml Overhaul (3.5/2.9 US/lmp qt) Front fork oil type SUZUKI FORK OIL L01 or an equivalent fork oil Front fork oil capacity (each leg) * 508 ml (17.2/17.9 US/lmp oz)

  • Page 371: Wiring Diagram

    WIRING DIAGRAM E-02, 19 R : TURN SIGNAL INDICATOR LIGHT (R) HANDLEBAR SWITCH (R) L : TURN SIGNAL INDICATOR LIGHT (L) B : HI-BEAM INDICATOR LIGHT HAZARD STARTER ENGINESTOP FRONT BRAKE N : NEUTRAL INDICATOR LIGHT SWITCH SWITCH SWITCH SWITCH F : FUEL WARNING LIGHT SPEEDOMETER IGNITION SWITCH...
  • Page 372 E-03, 24, 28, 33 R : TURN SIGNAL INDICATOR LIGHT (R) HANDLEBAR SWITCH (R) L : TURN SIGNAL INDICATOR LIGHT (L) B : HI-BEAM INDICATOR LIGHT HAZARD ENGINESTOP STARTER FRONT BRAKE N : NEUTRAL INDICATOR LIGHT SWITCH SWITCH SWITCH SWITCH F : FUEL WARNING LIGHT SPEEDOMETER IGNITION SWITCH...
  • Page 373 Prepared by May, 2003 Part No. 99501-39540-01E Printed in Japan...
  • Page 374 Printed in Japan...

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