Suzuki DL1000 Owner's Manual
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Suzuki DL1000 Owner's Manual

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www.ClassicCycles.org
DL1000
OWNER'S MANUAL
This owner's manual contains
important safety information.
Please read it carefully.

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Summary of Contents for Suzuki DL1000

  • Page 1 DL1000 OWNER’S MANUAL This owner’s manual contains important safety information. Please read it carefully.
  • Page 2 Therefore, please follow the maintenance NOTE: Indicates special informa- instructions closely to ensure tion to make maintenance easier emission compliance. Your Suzuki or instructions clearer. dealer has experienced techni- cians that are trained to provide WARNINGs and CAUTIONs are your machine with the best possi-...

  • Page 3: Table Of Contents

    www.ClassicCycles.org TABLE OF CONTENTS THE SPORT OF MOTORCYCLING FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS CONTROLS, EQUIPMENT AND ADJUSTMENTS BREAK-IN AND INSPECTION BEFORE RIDING RIDING TIPS ACCESSORY USE AND MOTORCYCLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE PROCEDURE AND MOTORCYCLE CLEANING CONSUMER INFORMATION SPECIFICATIONS INDEX...

  • Page 4: The Sport Of Motorcycling

    THE SPORT OF MOTORCYCLING MOST ACCIDENTS CAN BE AVOIDED ............. 1-2 IF YOU DON’T HAVE A HELMET, BUY A HELMET AND WEAR IT EVERY TIME YOU RIDE ..............1-2 IF A COLLISION IS IMMINENT, DO SOMETHING ..........1-3 SPECIAL SITUATIONS REQUIRE SPECIAL CARE .......... 1-3 KNOW YOUR LIMITS ..................

  • Page 5: Most Accidents Can Be Avoided

    www.ClassicCycles.org THE SPORT OF Ride defensively. Wise motorcy- clists use a strategy of assuming MOTORCYCLING they are invisible to other drivers, even in broad daylight. Pay care- Your motorcycle and this owner’s ful attention to other motorists, manual have been designed by especially intersections, people like you who enjoy motor-...

  • Page 6: If A Collision Is Imminent, Do Something

    IF A COLLISION IS IMMINENT, maneuvers. Even a seasoned motorcyclist can improve his or DO SOMETHING her riding skills, and pick up a few Many riders fear locking up their new skills, through these courses. brakes or haven’t learned to Some insurance companies even swerve to avoid an accident.

  • Page 7: Be Extra Safety-Conscious On Bad Weather Days

    www.ClassicCycles.org for the traffic, visibility and road PRACTICE AWAY FROM conditions, your motorcycle, and TRAFFIC your experience. Your riding skill and your mechan- ical knowledge form the founda- Riding motorcycle safely tion for safe riding practices. We requires that your mental and suggest that you practice riding physical skills are fully part of the your motorcycle in a non-traffic...

  • Page 8: Carrying A Passenger

    Motorcycle Safety Foundation. tains a variety of safety tips, help- Your Suzuki dealer can help you ful hints, and practice exercises. locate fundamental This manual can increase your advanced riding skills course riding enjoyment and safety.

  • Page 9: Fuel, Engine Oil And Coolant Recommendations

    www.ClassicCycles.org FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS FUEL ........................2-2 ENGINE OIL ......................2-3 ENGINE COOLANT SOLUTION ................. 2-5...
  • Page 10 Oxygenated fuels which meet the responsibility of Suzuki and may minimum octane requirement and not be covered under the New the requirements described below Vehicle Limited Warranty or the...
  • Page 11 • Be sure that any oxygenated engine oil. Suzuki recommends fuel you use has octane rat- the use of SUZUKI PERFOR- ings of at least 87 pump MANCE 4 MOTOR OIL or equiva- octane ((R+M)/2 method). lent engine oil. Use oil with an API •...
  • Page 12 JASO T903 Energy Conserving The JASO T903 standard is an Suzuki does not recommend the index to select engine oils for 4- use of “ENERGY CONSERVING” stroke motorcycle oils. Some engine oils which have engines. Motorcycle and ATV an API classification of SH or...
  • Page 13 www.ClassicCycles.org ENGINE COOLANT SOLUTION CAUTION Use engine coolant that is com- patible with an aluminum radiator, Spilled engine coolant can mixed with distilled water at a damage painted surfaces. 50:50 mixture ratio for engine coolant solution. An engine cool- Do not spill any fluid when fill- ant mixture other than 50:50 can ing the radiator.

  • Page 14: Controls, Equipment And Adjustments

    CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS ..................3-2 KEY ........................3-5 IGNITION SWITCH ....................3-5 INSTRUMENT PANEL ..................3-7 LEFT HANDLEBAR ................... 3-14 RIGHT HANDLEBAR ..................3-16 FUEL TANK CAP ....................3-18 GEARSHIFT LEVER ..................3-19 REAR BRAKE PEDAL ..................3-19 SEAT LOCK .......................

  • Page 15: Location Of Parts

    www.ClassicCycles.org CONTROLS, EQUIPMENT AND ADJUSTMENTS LOCATION OF PARTS 1 Clutch lever 2 Left handlebar switches 3 Speedometer 4 Ignition switch 5 Indicator lights 6 Tachometer 7 Front brake fluid reservoir 8 Right handlebar switches 9 Throttle grip 0 Front brake lever A Fuel tank cap...
  • Page 16 B Tools C Gearshift lever D Side stand E Seat lock...
  • Page 17 www.ClassicCycles.org F Rear brake pedal...

  • Page 18: Key

    IGNITION SWITCH Two keys come with this motorcy- The ignition switch has 4 posi- cle. Keep the spare key in a safe tions. place. An identifying number is stamped on the plate. Use this “OFF” position number when making a replace- All electrical circuits are off.
  • Page 19 www.ClassicCycles.org “P” (PARKING) position The taillight will come on to increase visibility for temporary road side parking at night. The key can be removed and the steering will be locked. WARNING Turning the ignition switch to the “P” (PARKING) or “LOCK” position while the motorcycle is moving can be hazardous.

  • Page 20: Instrument Panel

    Speedometer 1 INSTRUMENT PANEL The speedometer indicates the road speed in miles per hour and/ or kilometers per hour. Turn Signal Indicator Light “” 2 When the turn signals are being operated either to the right or to the left, the indicator will flash at the same time.
  • Page 21 A. The display 6 indicates “FI” an authorized Suzuki dealer. If the engine stalls, try restarting the and the clock alternately, and the red indicator light 7 engine after turning the ignition switch off and on.
  • Page 22 Clock When the display 6 indicates “CHEC”, check following items; The clock has a 12-hour display. • Make sure that the engine stop Follow the procedure below to switch is in the “” position. adjust the clock. • Make sure that the transmis- sion is in neutral or the side 1.
  • Page 23 If comes on. As soon as the engine the light still does not go out, is started, the symbol “” and have your authorized Suzuki the indicator light should go out. dealer or a qualified mechanic troubleshoot your motorcycle.
  • Page 24 Fuel Meter “” 8 Odometer/Trip Meter 0 The fuel meter indicates the This display has 3 functions; amount of fuel remaining in the odometer and two trip meters. When the ignition switch is turned fuel tank. The fuel meter displays all 5 segments when the fuel tank to the “ON”...
  • Page 25 www.ClassicCycles.org To reset a trip meter to zero, push the “ADJ” button A for two sec- onds while the display indicates the trip meter 1 or 2 you want to reset. WARNING Operating the display while riding hazardous. Removing a hand from the han- To change the display, push the dlebars can reduce your ability “SEL”...
  • Page 26 Coolant Temperature Meter CAUTION “” C Running the engine with high temperature engine coolant can cause serious engine dam- age. If the mark and indicator light come on, stop the engine to let it cool. Do not run the engine until the mark and indicator light go off.

  • Page 27: Left Handlebar

    www.ClassicCycles.org LEFT HANDLEBAR CAUTION Sticking some tape or placing objects in front of the headlight can damage the headlight. Do not stick any tapes to the headlight. Do not place objects in front of the headlight. Clutch Lever 1 Turn Signal Switch “” 3 The clutch lever is used for disen- Moving the switch to the “”...
  • Page 28 Horn Button “” 4 Clutch Lever Adjustment Press the button to sound the horn. Headlight Flasher Switch 5 Press the switch to flash the headlight. The headlight high beam will be lit when the dimmer switch is in “LO” position. Hazard Warning Switch “”...

  • Page 29: Right Handlebar

    www.ClassicCycles.org RIGHT HANDLEBAR NOTE: This motorcycle has a starter interlock system for the ignition and starter circuit. The engine can only be started if: • The transmission is in neutral and the clutch is disengaged, • The transmission is in gear, the side stand is fully up, and the clutch is disengaged.
  • Page 30 Front Brake Lever Adjustment WARNING Adjusting the front brake lever position while riding can be hazardous. Removing a hand from handlebars reduce your ability to control the motorcycle. Always keep both hands on the handlebars while riding. The distance between the throttle grip and the front brake lever is adjustable to 5 positions.

  • Page 31: Fuel Tank Cap

    www.ClassicCycles.org FUEL TANK CAP 1 Fuel level 2 Filler neck WARNING Overfilling the fuel tank can cause the fuel to overflow when it expands due to heat from the engine or the sun. To open the fuel tank cap, insert Spilled fuel can catch on fire.

  • Page 32: Gearshift Lever

    GEARSHIFT LEVER REAR BRAKE PEDAL This motorcycle has a 6-speed Pressing the rear brake pedal will transmission which operates as apply the rear brake. The brake shown. To shift properly, squeeze light will come on when the rear the clutch lever and close the brake is operated.

  • Page 33: Seat Lock

    www.ClassicCycles.org SEAT LOCK WARNING Failure to install the seat prop- erly could allow the seat to move and cause loss of rider control. Latch the seat securely in its proper position. To remove the seat, insert the A small and light article such as ignition key into the lock and turn rain gear or a windbreaker can be it clockwise.

  • Page 34: Helmet Holder

    HELMET HOLDER WARNING Riding with a helmet fastened to the helmet holder can inter- fere with rider control. Never carry a helmet fastened to a helmet holder. Fix the hel- met securely atop the seat if you must carry it. Hook your helmet to the helmet holder.

  • Page 35: Side Stand

    www.ClassicCycles.org SIDE STAND WARNING Riding with the side stand incompletely retracted result in an accident when you turn left. • Check operation of the side stand/ignition interlock sys- tem before riding. • Always retract the side stand An interlock system is provided to completely before starting cut off the ignition circuit when the off.

  • Page 36: Suspension Adjustment

    SUSPENSION ADJUSTMENT The standard settings for both the front and rear suspensions are selected to meet various riding conditions such as low to high motorcycle speed and light to heavy load on the motorcycle. The suspension settings can be adjusted to fine-tune then accord- ing to your preference.
  • Page 37 www.ClassicCycles.org REAR SUSPENSION Damping Force Adjustment Spring Pre-load Adjustment rebound damping force adjuster 2 is located at the bot- rear suspension damper unit. To adjust the damp- ing force, set the adjuster to the standard setting first and then adjust it to the desired position. To set the damping force adjuster to the standard position: 1.

  • Page 38: Windshield Height Adjustment

    WINDSHIELD HEIGHT ADJUSTMENT The windshield height can be adjusted in 3 positions. To change windshield height, follow the pro- cedure below. 3. Remove the 4 bolts. 4. Move the windshield up and down to desired windshield height. 5. Reinstall the windshield in the reverse order of the removal.

  • Page 39: Break-In And Inspection Before Riding

    www.ClassicCycles.org BREAK-IN AND INSPECTION BEFORE RIDING BREAK-IN ......................4-2 INSPECTION BEFORE RIDING ................4-3...
  • Page 40 BREAK-IN AND Breaking in the New Tires New tires need proper break-in to INSPECTION BEFORE assure maximum performance, RIDING just as the engine does. Wear in the tread surface by gradually BREAK-IN increasing your cornering lean The first 800 km (500 miles) is the angles over the first 160 km (100 most important in the life of your miles) before attempting maxi-...
  • Page 41 www.ClassicCycles.org Observe Your Initial and Most INSPECTION BEFORE RIDING Critical Service WARNING The initial service (break-in main- tenance) is the most important Failure to inspect and maintain service your motorcycle will your motorcycle properly receive. During break-in opera- increases the chance of an tion, all of the engine components will have mated together and accident or equipment dam-...
  • Page 42 Check the condition of the motor- Fuel tank Tank cap locked securely cycle to help make sure that you Lighting Proper operation of all lights do not have mechanical problems – Headlight, Taillight, or get stranded somewhere when Brake light, Instrument lights, Turn signals you ride.

  • Page 43: Riding Tips

    www.ClassicCycles.org RIDING TIPS STARTING THE ENGINE ..................5-2 STARTING OFF AND SHIFTING ................ 5-3 USING THE TRANSMISSION ................5-4 RIDING ON HILLS ....................5-5 STOPPING AND PARKING ................5-5 CARRYING A PASSENGER ................5-6...

  • Page 44: Starting The Engine

    RIDING TIPS CAUTION STARTING THE ENGINE Running the engine too long Before attempting to start the without riding may cause the engine, make sure: engine to overheat. Overheat- 1. The transmission is in neutral. ing can result in damage to 2.

  • Page 45: Starting Off And Shifting

    www.ClassicCycles.org STARTING OFF AND SHIFTING WARNING WARNING Sudden side winds, which can occur when being passed by Riding this motorcycle larger vehicles, at tunnel exits excessive speed increases or in hilly areas, can upset your your chances of losing control control.

  • Page 46: Using The Transmission

    USING THE TRANSMISSION WARNING The transmission is provided to keep engine operating Downshifting when engine smoothly in its normal operating speed is too high can; speed range. The gear ratios • cause the rear wheel to skid have been carefully chosen to and lose traction due to meet the characteristics of the increased engine braking,...

  • Page 47: Riding On Hills

    www.ClassicCycles.org RIDING ON HILLS WARNING • When climbing steep hills, the motorcycle may begin to slow Inexperienced riders tend to down and show lack of power. underutilize the front brake. At this point you should shift to This can cause excessive stop- a lower gear so that the engine ping distance and lead to a col- will again be operating in its...

  • Page 48: Carrying A Passenger

    CARRYING A PASSENGER WARNING Before you invite someone to be a passenger on your motorcycle, Following another vehicle too you need to be thoroughly familiar closely can lead to a collision. with motorcycle operation. Adjust As vehicle speeds increase, tire pressures and suspension stopping distance increases according to the Tire Pressure progressively.

  • Page 49: Accessory Use And Motorcycle Loading

    www.ClassicCycles.org ACCESSORY USE AND MOTORCYCLE LOADING ACCESSORY USE ....................6-2 ACCESSORY INSTALLATION GUIDELINE ............6-2 LOADING LIMIT ....................6-3 LOADING GUIDELINES ..................6-4 MODIFICATION ....................6-4...

  • Page 50: Accessory Use

    It is not possible center of gravity as is feasible. for Suzuki to test each accessory Check that mounting on the market or combinations of brackets and other attach- all the available accessories;...

  • Page 51: Loading Limit

    www.ClassicCycles.org • Certain accessories displace LOADING LIMIT the rider from his or her normal WARNING riding position. This limits the freedom of movement of the rider and may limit control abil- Overloading or improper load- ity. ing can cause loss of motorcy- •...

  • Page 52: Loading Guidelines

    Suzuki will not be • Do not install a luggage carrier responsible in any way for per- or a luggage box protruding...

  • Page 53: Inspection And Maintenance

    www.ClassicCycles.org INSPECTION AND MAINTENANCE NOTICE ........................ 7-2 MAINTENANCE SCHEDULE ................7-2 TOOLS ......................... 7-5 FUEL TANK LIFT ....................7-5 LUBRICATION POINTS ..................7-6 BATTERY ......................7-7 AIR CLEANER ..................... 7-8 SPARK PLUG ....................7-11 ENGINE OIL ....................... 7-14 IDLE SPEED ...................... 7-18 THROTTLE CABLE PLAY ................

  • Page 54: Notice

    ANY MOTORCYCLE REPAIR dations and schedules in this ESTABLISHMENT OR INDI- VIDUAL USING ANY MOTOR- owner’s manual. Ask your CYCLE PART WHICH HAS SUZUKI dealer or a qualified BEEN CERTIFIED UNDER mechanic to do the mainte- THE PROVISIONS IN THE nance items marked with an CLEAN AIR ACT Sec.
  • Page 55 If you have any ques- tions regarding maintenance intervals, consult your SUZUKI dealer or a qualified mechanic. CAUTION Using poor quality replacement parts can cause your motorcy- cle to wear more quickly and may shorten its useful life.

  • Page 56: Maintenance Chart

    MAINTENANCE CHART Interval: This interval should be judged by odometer reading or number of months, whichever comes first. Interval 1000 6000 12000 18000 24000 miles 4000 7500 11000 14500 Element months Air cleaner element – * Exhaust pipe bolts and muffler bolts –...

  • Page 57: Tools

    www.ClassicCycles.org TOOLS 4. Remove the fasteners 3 and bolts 4. A tool kit is provided with your motorcycle. It is located under the 5. Remove the bolt 5. Remove seat. the prop 6. FUEL TANK LIFT 1. Place the motorcycle on the side stand.

  • Page 58: Lubrication Points

    LUBRICATION POINTS Proper lubrication is important for safe, smooth operation and a long life for your motorcycle. Be sure that all lubrication is performed during periodic maintenance on motorcycle. Increase fre- quency when you use your motor- cycle in severe conditions. CAUTION Lubricating switches can dam- age the switches.

  • Page 59: Battery

    www.ClassicCycles.org BATTERY CAUTION The battery is located under the seat. This battery is a sealed type Exceeding maximum battery and requires no mainte- charging rate for the battery nance. Have your dealer check can shorten its life. the battery’s state of charge peri- odically.

  • Page 60: Air Cleaner

    AIR CLEANER CAUTION The air cleaner element must be kept clean to provide good engine Clean or replace the air cleaner power and gas mileage. If you use element frequently if the motor- your motorcycle under normal cycle is used in dusty, wet or low-stress conditions, you should muddy conditions.
  • Page 61 www.ClassicCycles.org Air Cleaner Element Cleaning 3. Remove the nut 3 and bolt. 4. Remove the fuel tank. Carefully use an air hose to blow the dust from the air cleaner ele- ment. NOTE: Always apply air pressure to the mesh side of the air cleaner element only.
  • Page 62 Air Cleaner Drain Plug CAUTION Failure to position the air cleaner element properly can allow dirt to bypass the air cleaner element. This will cause engine damage. Be sure to properly install the air cleaner element. Remove the plug and drain water and oil at the periodic mainte- nance interval.

  • Page 63: Spark Plug

    Use one of the spark plugs listed below or equivalent. Consult your Suzuki dealer or a qualified mechanic if you are not sure which spark plug is correct for your type of usage. 7-11...
  • Page 64 SPARK PLUG REMOVAL To remove the spark plugs, follow the procedure below: Front Side 4. Remove the radiator mounting bolt 3 and slide the radiator forward. 1. Remove the bolts 1. 5. Pull off the spark plug cap. 6. Remove the spark plug with a spark plug wrench.
  • Page 65 www.ClassicCycles.org Rear Side Spark Plug Cleaning 1. Lift the fuel tank by referring to the FUEL TANK LIFT section. 0.6 – 0.7 mm (0.024 – 0.028 in) To maintain a hot, strong spark, keep the plug free from carbon. 2. Remove the spark plug with a Adjust the gap to 0.6 –...

  • Page 66: Engine Oil

    ENGINE OIL CAUTION Engine life depends on oil amount and quality. Daily oil level checks The engine oil level must be and periodic changes are two of between the “L” (Low) line and the most important maintenance “F” (Full) line, or engine dam- items to be performed.
  • Page 67 www.ClassicCycles.org  WARNING New and used oil can be haz- ardous. Children and pets may be harmed by swallowing new or used oil. Repeated, pro- longed contact with used engine oil may cause skin can- cer. Brief contact with used oil 3.
  • Page 68 6. Turn the oil filter 3 counter- around the rubber gasket 5 of clockwise with a Suzuki “cap the new oil filter. type” oil filter wrench or a 9. Screw on the new filter by “strap type” filter wrench of the hand until the filter gasket con- proper size.
  • Page 69 Using an oil filter with the Oil filter wrench wrong design or thread specifi- cations can cause oil leaks or engine damage. Use a genuine SUZUKI oil filter In the position at or an equivalent filter designed which the filter for your motorcycle.

  • Page 70: Idle Speed

    CAUTION Engine damage may occur if you use oil that does not meet Suzuki’s specifications. Use the oil specified in the FUEL, ENGINE OIL AND COOL- 2. Turn the throttle stop screw ANT RECOMMENDATIONS sec- knob 1 in or out so that the tion.

  • Page 71: Throttle Cable Play

    www.ClassicCycles.org THROTTLE CABLE PLAY WARNING Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handlebars. This can lead to loss of rider control. Adjust the throttle cable play so that engine idle speed does not rise due to handlebar movement.

  • Page 72: Engine Coolant

    ENGINE COOLANT COOLANT LEVEL Remove the filler cap and add mixed coolant through the filler hole. engine coolant solution WARNING should be between the “F” (full) and the “L” (low) level lines on the Engine coolant is harmful or engine coolant reservoir. If the fatal if swallowed or inhaled.

  • Page 73: Drive Chain

    “O” rings that permanently Good Worn keep grease inside. We recom- mend that you take your motorcy- cle to an authorized Suzuki dealer if the drive chain needs to be replaced. The condition and adjustment of the drive chain should be checked •...
  • Page 74 Kerosene will lubricate and which could damage the “O” clean the chain. rings in your chain. WARNING Use Suzuki chain lube or an Kerosene can be hazardous. equivalent chain lubricant that Kerosene is flammable. Chil- is specifically intended for use dren or pets may be harmed with “O”...
  • Page 75 www.ClassicCycles.org To adjust the drive chain, follow 5. At the same time that the the procedure below: chain is being adjusted, the rear sprocket must be kept in WARNING perfect alignment with the front sprocket. To assist you in per- A hot muffler can burn you.

  • Page 76: Clutch

    Use only DOT4 brake fluid from a sealed container. Never use or mix dif- ferent types of brake fluid. If there is frequent loss of fluid, take your motorcycle to a Suzuki dealer or a qualified mechanic for inspection. 7-24...

  • Page 77: Brakes

    www.ClassicCycles.org Brake Fluid CAUTION Spilled brake fluid can damage painted surfaces and plastic parts. Avoid spilling any fluid when filling the reservoir. Wipe up spills immediately. BRAKES This motorcycle has front and rear disk brakes. WARNING Failure to inspect and properly maintain the brakes increases your chance of having an acci- Check the brake fluid level in both...
  • Page 78 Use only DOT4 brake fluid from a sealed container. Never use or mix with different types of brake fluid. If there is frequent loss of fluid, take your motorcycle to a SUZUKI dealer or a qualified mechanic for inspection. 7-26...
  • Page 79 Suzuki dealer or a qualified ser- NOTE: Do not squeeze/depress vice mechanic. After replacing the brake lever/pedal when the either the front or rear brake pads, pads are not in their positions.
  • Page 80 Rear Brake Adjustment Rear Brake Light Switch The rear brake pedal must be adjusted to set the clearance between the pedal and the foot- rest. Adjust the brake pedal as fol- lows: 20 – 30 mm 20 – 30 mm To adjust the brake light switch, hold the switch body and turn the adjuster so that the brake light will...

  • Page 81: Tires

    www.ClassicCycles.org TIRES WARNING WARNING Failure to perform break-in of the tires could cause tire slip Failure to follow these warn- and loss of control. ings may result in an accident due to tire failure. The tires on Use extra care when riding on your motorcycle form the cru- new tires.
  • Page 82 Tire Pressure and Loading Tire Condition and Type Proper tire pressure and proper Tire condition and tire type affect tire loading are important factors. motorcycle performance. Cuts or cracks in the tires can lead to tire Overloading your tires can lead to tire failure and loss of motorcycle failure and loss of motorcycle con- control.
  • Page 83 WARNING improperly repaired, installed, or balanced tire can cause loss of control or shorten tire life. • Ask your SUZUKI dealer or a qualified mechanic to per- form tire repair, replacement, NOTE: The “ ” mark indicates balancing because...
  • Page 84 WARNING Failure to follow these instruc- tions about tubeless tires may result in an accident due to tire failure. Tubeless tires require different service procedures than tube tires. NOTE: The wheel has arrow • Tubeless tires require an air- marks showing the rotating direc- tight seal between the tire tion.

  • Page 85: Side Stand/Ignition Interlock System

    If the engine continues to run with the side stand down and the transmission in gear, then the side stand/igni- tion interlock system is not work- properly. Have your motorcycle inspected authorized Suzuki dealer or some other qualified service mechanic. 7-33...

  • Page 86: Front Wheel Removal

    FRONT WHEEL REMOVAL NOTE: A special tool is necessary to loosen the shaft 3. The special 1. Place the motorcycle on the tool is available at Suzuki dealer. side stand. 5. Place an accessory service stand or equivalent under the swing arm to help stabilize the rear end.
  • Page 87 If you accident. are not sure of the proper pro- cedure, have your authorized Before riding, “pump” the SUZUKI dealer or a qualified brake repeatedly until the mechanic do this. brake pads are pressed against the brake disks and proper lever stroke and firm feel are restored.

  • Page 88: Rear Wheel Removal

    Front axle tightening torque: REAR WHEEL REMOVAL 100 N·m (10.0 kgf-m, 72.5 lbf-ft) WARNING Front axle holder bolt tightening torque: A hot muffler can burn you. The 23 N·m (2.3 kgf-m, 16.5 lbf-ft) muffler will be hot enough to burn you for some time after Front brake caliper mounting bolt stopping the engine.
  • Page 89 • Torque bolts and nuts to the proper specifications. If you are not sure of the proper procedure, have your autho- rized SUZUKI dealer or a qualified mechanic do this. Rear axle nut tightening torque: 100 N·m (10.0 kgf-m, 72.5 lbf-ft) 7.

  • Page 90: Light Bulb Replacement

    LIGHT BULB REPLACEMENT WARNING The wattage rating of each bulb is shown in the following chart. Failure to extend brake pads When replacing a burned out after installing the wheel can bulb, always use the same watt- cause poor braking perfor- age rating.
  • Page 91 www.ClassicCycles.org Headlight Headlight Beam Adjustment The headlight beam can be adjusted both horizontally and vertically if necessary. 1. Disconnect the socket 1 from the headlight and remove the rubber cap 2. To adjust the beam horizontally: Turn the adjuster 1 clockwise or counterclockwise.
  • Page 92 Turn Signal Light Brake Light/Taillight To replace the turn signal light To change the brake light/taillight bulb, follow these directions. bulb, perform the following steps: 1. Turn the socket 1 counter- 1. Remove the screw and take off the lens. clockwise and remove it.

  • Page 93: Fuses

    If the new fuse the seat. One 30A spare fuse is blows in a short time, consult located under the fuse box. your Suzuki dealer or a quali- fied mechanic immediately. FUSE LIST • 30A MAIN fuse protects the...

  • Page 94: Troubleshooting

    TROUBLESHOOTING FUEL SYSTEM CHECK ..................8-2 IGNITION SYSTEM CHECK ................8-2...

  • Page 95: Troubleshooting

    If you are not sure about the sary. Retry the above proce- proper action, consult your dure with the cleaned spark Suzuki dealer about the prob- plug or new one. 4. If there is still no spark, take lem. your motorcycle an authorized Suzuki dealer.
  • Page 96 “FI”, showing signs of trouble in the fuel injection system, take your machine authorized Suzuki dealer. Refer to the “INSTRUMENT PANEL” sec- tion for an explanation of the fuel injection system indicator. 3. Check the ignition system for intermittent spark.

  • Page 97: Storage Procedure And Motorcycle Cleaning

    www.ClassicCycles.org STORAGE PROCEDURE AND MOTORCYCLE CLEANING STORAGE PROCEDURE ..................9-2 PROCEDURE FOR RETURNING TO SERVICE ..........9-3 CORROSION PREVENTION ................9-3 MOTORCYCLE CLEANING ................9-4 INSPECTION AFTER CLEANING ............... 9-6...

  • Page 98: Storage Procedure

    Suzuki recommends that you rags to prevent humidity from entering. trust this maintenance work to your Suzuki dealer. If you wish to service the machine for storage BATTERY yourself, follow the general guide- 1. Remove the battery from the lines below: motorcycle.

  • Page 99: Procedure For Returning To Service

    www.ClassicCycles.org MAINTENANCE DURING CORROSION PREVENTION STORAGE It is important to take good care of Once a month, recharge the bat- your motorcycle to protect it from tery. The standard charging rate is corrosion and keep it looking new 1.4A × 5 – 10 hours. for years to come.

  • Page 100: Motorcycle Cleaning

    Do not use hard materi- the chips or scratches have als which can scratch the gone through to the bare paint. metal, have a Suzuki dealer 2. Wash the entire motorcycle make the repair. with mild detergent or car •...
  • Page 101 Do not use high pressure discolored so as to obstruct view. When replacing the windshield, washers to clean your motorcy- use a Suzuki replacement wind- cle. Do not use parts cleaner to shield. throttle body and fuel injection sensors.

  • Page 102: Inspection After Cleaning

    INSPECTION AFTER CLEANING For extended life of your motorcy- cle, lubricate according to “GEN- ERAL LUBRICATION” section. WARNING Wet brakes can cause poor braking performance and may lead to an accident. Avoid a possible accident by expecting longer stopping dis- tances after washing your motorcycle.

  • Page 103: Consumer Information

    www.ClassicCycles.org CONSUMER INFORMATION EMISSION CONTROL WARRANTY ..............10-2 REPORTING SAFETY DEFECTS ..............10-2 TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED ...... 10-3 ON-BOARD MOTORCYCLE COMPUTER DATA INFORMATION ....10-4 SERIAL NUMBER LOCATION ................10-5 LOCATION OF LABELS ................... 10-6 10-1...

  • Page 104: Emission Control Warranty

    EMISSION CONTROL death, you should immediately WARRANTY inform the National Highway Traf- Suzuki Motor Corporation war- fic Safety Administration (NHTSA) rants to the ultimate purchaser in addition to notifying American and each subsequent purchaser Suzuki Motor Corp.

  • Page 105: Tampering With Noise Control System Prohibited

    To contact American Suzuki, own- TAMPERING WITH NOISE ers in the continental United CONTROL SYSTEM States can call toll-free 1-800- PROHIBITED 444-5077, or write to: American Federal law prohibits the following Suzuki Motor Corporation Motor- acts or the causing thereof;...

  • Page 106: On-Board Motorcycle Computer Data Information

    Removing or puncturing the air related malfunctions. cleaner case, cleaner cover, baffles, or any other component which conducts intake air. Whenever replacing parts on your motorcycle, Suzuki recommends that you use genuine Suzuki replacement parts or their equiva- lent. 10-4...

  • Page 107: Serial Number Location

    In addi- tion, once SUZUKI collects or receives data, SUZUKI may use the data for research conducted by SUZUKI, make the data avail- able for outside research if need is shown and confidentiality is assured, or make summary data...

  • Page 108: Location Of Labels

    Avoid using any alkaline or strong acid • cleaner, gasoline, brake fluid, or any other solvent. When replacing windshield, use Suzuki • replacement windshield. WARNING WARNING Failure to follow these safety...
  • Page 109 If the vehicle has been resold, obtain the owner’s manual from the previous owner or contact your local SUZUKI dealer for assistance. WARNING MAXIMUM LOAD : 10 kg (22 lbs)

  • Page 110: Specifications

    SPECIFICATIONS DIMENSIONS AND CURB MASS Overall length ..........2295 mm (90.4 in) Overall width............ 910 mm (35.8 in) Overall height ..........1395 mm (54.9 in) Wheelbase ............1535 mm (60.4 in) Ground clearance..........165 mm (6.5 in) Seat height ............840 mm (33.1 in) Curb mass ............
  • Page 111 www.ClassicCycles.org ELECTRICAL Ignition type .............Electronic ignition (Transistorized) Spark plug ............NGK CR8EK or DENSO U24ETR Battery.............12V 43.2 kC(12 Ah)/10 HR Generator ............Three-phase A.C. generator Main fuse............30A Fuse ..............15/15/10/10/15/15A Headlight ............12V 60/55W (H4) × 2 Brake light/Taillight...........12V 21/5W × 2 License plate light..........12V 5W Turn signal light ..........12V 21W ×...
  • Page 112 INDEX ACCESSORIES AND FRONT WHEEL LOADING ....... 1-4 REMOVAL ......7-34 ACCESSORY INSTALLATION FUEL ........2-2 GUIDELINE ......6-2 FUEL HOSES .......7-19 ACCESSORY USE ....6-2 FUEL SYSTEM CHECK ..8-2 AIR CLEANER ....... 7-8 FUEL TANK CAP ....3-18 FUEL TANK LIFT ....7-5 FUSES........7-41 BATTERY.......
  • Page 113 www.ClassicCycles.org KEY ........3-5 ON-BOARD MOTORCYCLE KNOW YOUR LIMITS .... 1-3 COMPUTER DATA INFORMATION ....10-4 LEFT HANDLEBAR....3-14 LIGHT BULB PRACTICE AWAY FROM REPLACEMENT ....7-38 TRAFFIC ........1-4 LOADING GUIDELINES ..6-4 PROCEDURE FOR RETURNING LOADING LIMIT ..... 6-3 TO SERVICE ......9-3 LOCATION OF LABELS ..
  • Page 114 SEAT LOCK ......3-20 TAMPERING WITH NOISE SERIAL NUMBER CONTROL SYSTEM LOCATION ......10-5 PROHIBITED......10-3 SIDE STAND......3-22 THROTTLE CABLE SIDE STAND/IGNITION PLAY ........7-19 INTERLOCK SYSTEM ..7-33 TIRES ........7-29 SPARK PLUG ...... 7-11 TOOLS ........7-5 SPECIAL SITUATIONS REQUIRE SPECIAL CARE ........
  • Page 115 OEM PARTS & ACCESSORIES Click on links below OEM parts & online schematics Cruiser Customizing J&P Cycles Motorcycle Parts Save Up to 45% on Motorcycle Tires JC Whitney Motorcycle Parts & Accessories Motorcycle Boots Motorcycle Helmets Motorcycle Jackets Find Your OEM Parts - Save Up to 25% Mega Motor Madness Shop Revzilla for the latest in Motorcycle Accessories...

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