SUZUKI DL1000 Manuals

Manuals and User Guides for SUZUKI DL1000. We have 4 SUZUKI DL1000 manuals available for free PDF download: Service Manual, Owner's Manual

Suzuki DL1000 Service Manual (444 pages)

Brand: Suzuki | Category: Motorcycle | Size: 31 MB

Foreword Group Index

2
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
- 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

Suzuki DL1000 Service Manual (450 pages)

Brand: Suzuki | Category: Motorcycle | Size: 40 MB

Suzuki DL1000 Owner's Manual (115 pages)

Suzuki DL1000

Brand: Suzuki | Category: Motorcycle | Size: 2 MB

Table of Contents

3
Controls, Equipment and Adjustments

14
- Location of Parts
  15
- Ignition Switch
  18
- Key
  18
- Instrument Panel
  20
- Left Handlebar
  27
- Right Handlebar
  29
- Fuel Tank Cap
  31
- Gearshift Lever
  32
- Rear Brake Pedal
  32
- Seat Lock
  33
- Helmet Holder
  34
- Side Stand
  35
- Front Suspension
  36
- Suspension Adjustment
  36
- Windshield Height Adjustment
  38
- Break-In and Inspection before Riding
  39
Riding Tips

43
- Riding Tips
  44
- Starting the Engine
  44
- Starting off and Shifting
  45
- Using the Transmission
  46
- Riding on Hills
  47
- Stopping and Parking
  47
- Carrying a Passenger
  48
Accessory Use and Motorcycle Loading

49
- Accessory Installation Guideline
  50
- Accessory Use
  50
- Loading Limit
  51
- Loading Guidelines
  52
- Modification
  52
Www.classiccycles.org Inspection and Maintenance

53
- Inspection and Maintenance
  53
  - Notice
    54
  - Maintenance Schedule
    54
  - Maintenance Chart
    56
  - Tools
    57
  - Fuel Tank Lift
    57
  - Lubrication Points
    58
  - Battery
    59
  - Air Cleaner
    60
  - Spark Plug
    63
  - Engine Oil
    66
  - Idle Speed
    70
  - Throttle Cable Play
    71
  - Fuel Hoses
    71
  - Engine Coolant
    72
  - Drive Chain
    73
  - Clutch
    76
  - Brakes
    77
  - Tires
    81
  - Side Stand/Ignition Interlock System
    85
  - Front Wheel Removal
    86
  - Rear Wheel Removal
    88
  - Light Bulb Replacement
    90
  - Fuses
    93
- Troubleshooting
  94
  - Troubleshooting
    95
Storage Procedure and Motorcycle Cleaning

97
- Storage Procedure
  98
- Corrosion Prevention
  99
- Procedure for Returning to Service
  99
- Motorcycle Cleaning
  100
- Inspection after Cleaning
  102
Consumer Information

103
- Emission Control Warranty
  104
- Reporting Safety Defects
  104
- Tampering with Noise Control System Prohibited
  105
- On-Board Motorcycle Computer Data Information
  106
  - Fuel
    106
- Serial Number Location
  107
- Location of Labels
  108
- Specifications
  110

Suzuki DL1000 Service Manual (29 pages)

Brand: Suzuki | Category: Motorcycle | Size: 1 MB

General Information 1

7
- General Information
  2
  - Periodic Maintenance
    2
  - Electrical System
    2
  - Servicing Information
    2
  - Wiring Diagram
    2
  - How to Use this Manual
    3
  - Abbreviations Used in this Manual
    5
  - Table of Contents
    7
- Warning/Caution/Note
  8
- General Precautions
  8
- Suzuki Dl1000K2 ('02-Model)
  10
- Serial Number Location
  10
- Fuel, Oil and Engine Coolant Recommendation
  10
  - Fuel
    10
  - Engine Oil
    11
  - Brake Fluid
    11
  - Front Fork Oil
    11
  - Engine Coolant
    11
  - Water for Mixing
    11
  - Anti-Freeze/Engine Coolant
    11
  - Liquid Amount of Water/Engine Coolant
    11
- BREAK-Ln PROCEDURES
  12
- Cylinder Identification
  12
- Information Labels
  13
- Specifications
  14
- Country and Area Codes
  16
Periodic Maintenance

17
- Periodic Maintenance Schedule
  18
  - Periodic Maintenance Chart
    18
  - Lubrication Points
    19
- Maintenance and Tune-Up Procedures
  20
  - Air Cleaner
    20
  - Spark Plug
    21
  - Tappet Clearance
    23
  - Fuel Hose
    28
  - Engine Oil and Oil Filter
    28

SUZUKI Categories

Motorcycle Automobile Motorcycle Accessories Musical Instrument Outboard Motor

More SUZUKI Manuals

SUZUKI DL1000 Manuals

Suzuki DL1000 Service Manual (444 pages)

Table of Contents

Foreword Group Index

General Information 1

Chassis

Engine

Fi System

Precautions in Servicing

Fi System Technical Features

Fi System Parts Location

Fi System Wiring Diagram

Self-Diagnosis Function

Fail-Safe Function

Fi System Troubleshooting

Fuel System

Throttle Body and Stv Actuator

Cooling and Lubrication System

Chassis

Chassis

Electrical System

Electrical

Servicing Information

Capacities

Sensor

Suzuki DL1000 Service Manual (450 pages)

Suzuki DL1000 Owner's Manual (115 pages)

Table of Contents

Table of Contents

Controls, Equipment and Adjustments

Riding Tips

Accessory Use and Motorcycle Loading

Www.classiccycles.org Inspection and Maintenance

Storage Procedure and Motorcycle Cleaning

Consumer Information

Suzuki DL1000 Service Manual (29 pages)

Table of Contents

General Information 1

Periodic Maintenance

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SUZUKI Categories