Suzuki DL1000 K2 Service Manual
Contents
1. 2 27 COMPRESSION PRESSURE CHECK 2 29 COMPRESSION TEST PROCEDURE 2 29 OIL PRESSURE CHECK 2 30 OIL PRESSURE TEST PROCEDURE 2 30 2 2 PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy Mileages are expressed in terms of kilome ters miles and time for your convenience NOTE More frequent servicing may be performed on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART Interval km miles months Item Air cleaner element Exhaust pipe bolts and muffler bolts Valve clearance Spark plugs Fuel hose Replace every 4 years Engine oil R R Engine oil filter R Idle speed Throttle cable play Throttle valve synchronization E 33 only Evaporative emission control system E 33 only Replace vapor hose every 4 years PAIR air supply system Engine coolant Replace every 2 years Radiator hose Clutch hose Replace every 4 years Clutch fluid Replace every 2 years Drive chain and lublicate every 1 000 km 600 Brakes2. 1 8 COUNTRY AND AREA CODES 1 10 1 2 GENERAL INFORMATION WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the symbol and the words WARNING CAUTION and NOTE have special meanings Pay special attention to the mes sages highlighted by these signal words Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that could result in motorcycle damage NOTE Indicates special information to make maintenance easier or instructions clearer Please note however that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing or lack of servicing of the motorcycle In addition to the WARN INGS and CAUTIONS stated you must use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle When 2 or more persons work together pay attention to the safety of each other When it is necessary to run the engine indoors make sure that exhaust gas is forced out doors When working with toxic or fla
3. Replace every 4 years Brake fluid Replace every 2 years Tires Steering Front fork Rear suspension Chassis bolts and nuts T NOTE l Inspect and clean adjust replace or lubricate as necessary R Replace T Tighten PERIODIC MAINTENANCE 2 3 LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle Major lubrication points are indicated below Clutch lever holder AGH Side stand pivot AGH Footrest pivot Drive chain and spring hook Brake pedal pivot and footrest pivot NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions 2 4 PERIODIC MAINTENANCE MAINTENANCE AND TUNE UP PRO CEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements AIR CLEANER Inspect every 6 000 km 4 000 miles 6 months and replace every 18 000 km 11 000 miles 18 months Remove the seat L7 6 4 Remove the fuel tank 7774 52 e Remove the air cleaner box Remove the air cleaner element 2 Carefully use air hose to blow the dust from the cleaner
4. 2 10 PERIODIC MAINTENANCE INTAKE SIDE ose ose Svt 0 91 ose ose sve Ort 920 126 ose 098 sve Ort see oct IIEL 08 pasn ezis uius ww 012 9215 WIS jueseJd 22 0 s 05 5 uunjoo jeiuozuou ezis uius Cue pee ezis ulus queseid 0700 SI 3NION3 Jadde ainseayy 0170 9071 ost Svt ore see 522 Sve Ort see 06 5272 501 101 See 05 5 sze Ove 960 160 Sct Oct SLE 06 0 98 0 EXEJE 1HVHO SIHL ISN OL MOH BSE SEE ORE OEE ae oer oe we ore eee we ose ost Svt Ort ore See soe ove 96 2 062 Set 525 025 sve ove S0 E 00 8 S80 18 0 oct Sle ove sos 00 962 080 92 0 Ort 902 00 Sec 06c 90 soe ove sez 90190 00 Sec 06c sez og z GL 022 SLZ 02 592 09 ssec oLz 592 09 992 082 560 10 Se 090 990 962 590 190 06 090 970 Sec 570 170 08 07 0 95 0 GL or se sec 062 Sie 022 092 N 99 09 soe osz sve 0 0 920 sse osz we orz 020 00
5. A e 2 N e iD N SLE 018 00 62 o e o e Sec CIE ve ove ose ESSE Ove see Sve ove see E see OEE see ore 525 Sec 062 082 9 wc SvE lt we BEEBE e 06 SEG 8 5151819 e e e ose Srt Ort gee 055 325 St sre ove see O Sct EE SLE 56 98 orz 8 992 011 901 ore SO L O t 001 960 960 160 060 980 S80 180 818 osz srg 092 e e 9 d Borm Koc j e 8888882283 8 5 9 Orc Sec e T 2 E SOE Svo e e e o 8 N 2 SEE oee sze oze SU e or 092 00017 26821 ON WIHS l3ddVL 1S0 vHX3 319 1 NOILO313S WIHS L3ddV L e o e bo eo N e rd 2 e H ore Sec 3 e e e iD N e A e o e N N e oec 01817 00821 LAS WIHS 13ddV L NOILLdO ove 0 180 l3ddVl Qaunsv3w
6. Src Porc owe ave Lore see Lee owe are Lore os oe 092 992 sse osz LNSAWLSAPAV ON AONVHV319 031512395 Pore ars ore ove ore soe we ser we see we me me fm e _ bi 01817 00821 LAS WIHS LoddVL 009 17 26851 ON WIHS 13ddVL 60 0 50 0 70 0 00 0 13ddVl aaunsv3w orc 592 092 SSZ 092 sve Ore Sec 055 Xi44ns NOlLdO 33V LNI 318V L NOLLO313S WIHS 13ddV L PERIODIC MAINTENANCE 2 11 EXHAUST SIDE 906 eq 9215 ullus ost 06 2 9215 WIYS jueseJg ose ose ww 85 0 5 ove 31dWvxa uuunioo jejuozuou ezis uurus juese1d eoruea YNEN ezis WIYS jueseud eunseo w 1 07100 SI ANIDNG yedde eunseojw St ose 15 e e x 28888 e e 8 e SIH L ASN OL 081 91 5 m e 921 121 021 911 SUIT UL sius rs feefee fo 8 e e S e sce Oct Oct SLE ze sre Ole e ove soc 10 e e wo e o See 3 e S oe
7. SYMBOL DEFINITION Torque control required Data beside it indicates specified torque Apply THREAD LOCK SUPER 1360 99000 32130 Apply oil Use engine oil unless other wise specified Use engine coolant 99000 99032 11X Apply molybdenum oil solution Mixture of engine oil and SUZUKI MOLY PASTE in ratio of 1 1 Use fork oil 99000 99001 558 Apply SUZUKI SUPER GREASE 99000 25010 Apply or use brake fluid Apply SUZUKI MOLY PASTE 99000 25140 i Measure in voltage range Apply SUZUKI BOND 12078 99000 31140 gt gt Measure in current range Apply SUZUKI BOND 1215 99000 31110 Measure in diode test range Apply THREAD LOCK SUPER 1303 99000 32030 Measure in continuity test range Apply THREAD LOCK SUPER 1322 99000 32110 C o 9 Use special tool Apply THREAD LOCK 1342 99000 32050 gt gt Indication of service data ABBREVIATIONS USED IN THIS MANUAL A ABDC AC ACL API ATDC ATM Pressure A F BBDC BTDC CKT CLP Switch CMP Sensor DC DMC DOHC DRL After Bottom Dead Center Alternating Current Air Cleaner Air Cleaner Box American Petroleum Institute After Top Dead Center Atmospheric Pressure Atmospheric Pressu
8. 8 WW XIdaNS 2 12 PERIODIC MAINTENANCE FUEL HOSE Inspect every 6 000 km 4 000 miles 6 months Replace every 4 years Inspect the fuel feed hose for damage and fuel leakage If any defects are found the fuel hoses must be replaced ENGINE OIL AND OIL FILTER ENGINE OIL Replace initially at 1 000 km 600 miles 1 month and every 6 000 km 4 000 miles 6 months thereafter OIL FILTER Replace initially at 1 000 km 600 miles 1 month and every 18 000 km 11 000 miles 18 months thereafter Oil should be changed while the engine is warm Oil filter replacement at the above intervals should be done together with the engine oil change ENGINE OIL REPLACEMENT Keep the motorcycle upright Place an oil pan below the engine and drain oil by removing the drain plug and filler cap Tighten the drain plug D to the specified torque and pour fresh oil through the oil filler The engine will hold about 2 7 L 2 9 2 4 US Imp qt of oil Use an API classification of SF or SG oil with SAE 10W 40 viscosity V Oil plug 23 N m 2 3 kg m 16 5 Ib ft Start up the engine and allow it to run for several minutes at idling speed Turn off the engine and wait about one minute then check the oil level through the inspection window X If the level is below mark L add oil to F level If the level is above mark F drain oil to
9. F level OIL FILTER REPLACEMENT Remove the engine under cover 1 Drain engine oil in the same manner of engine oil replacement procedure Remove the oil filter by using the oil filter wrench Special tool Apply engine oil lightly to the gasket of the new filter before installation Install the new filter turning it by hand until you feel that the fil ter gasket contacts the mounting surface Then tighten it 2 turns using the oil filter wrench 09915 40610 Oil filter wrench NOTE To properly tighten the filter use the special tool Never tighten the filter by hand Pour fresh engine oil and check the oil level in the same man ner of engine oil replacement procedure Engine oil capacity Oil change 2 7 L 2 9 2 4 US Imp qt Filter change 2 9 L 3 1 2 6 US Imp qt Overhaul engine 3 3 L 3 5 2 9 US Imp qt CAUTION ONLY USE A GENUINE SUZUKI MOTORCYCLE OIL FILTER Other manufacturer s oil filters may differ in thread specifications thread diameter and pitch fil tering performance and durability which may lead to engine damage or oil leaks Also do not use a genuine Suzuki automobile oil filter on this motorcycle PERIODIC MAINTENANCE 2 13 After contcting the gasket tighten 2 turns
10. are required especially for registering the machine and ordering spare parts FUEL OIL AND ENGINE COOLANT RECOMMENDATION FUEL FOR CANADIAN MODEL Use only unleaded gasoline of at least 87 pump octane 8 5 or 91 octane higher rated by the research method Gasoline containing MTBE Methyl Tertiary Butyl Ether less than 1096 ethanol or less than 596 methanol with appropriate cosolvents and corrosion inhibitor is permissible FUEL FOR OTHER COUNTRIES Gasoline used should be graded 91 octane Research Method or higher Unleaded gasoline is recom mended GENERAL INFORMATION 1 5 sd 15W 40 15W 50 0 t 40 10W 50 30 20 10 0 10 20 40 22 4 14 32 50 68 86 104 ENGINE OIL Use a premium quality 4 stroke motor oil to ensure longer ser vice life of your motorcycle Use only oils which are rated SF or SG under the API service classification The recommended vis cosity is SAE 10W 40 If an SAE 10W 40 motor oil is not avail able select an alternative according to the following chart MULTIGRADE BRAKE FLUID Specification and classification DOT 4 Since the brake system of this motorcycle is filled with a glycol based brake fluid by the manu facturer do not use or mix different types of fluid such as silicone based and petroleum based fluid for refilling the system otherwise serious damage will result Do not use any brake fluid taken from old or used or unsealed
11. them to the specified torque V Spark plug 11 N m 1 1 kgf m 8 0 Ib ft NOTE When fitting the spark plug caps front and rear face the triangle mark on the water proof cover to each cylinder exhaust side TAPPET CLEARANCE Inspect every 24 000 km 15 000 miles 24 months Remove the seat 7776 4 Lift and support the fuel tank C 7 4 51 Remove the fuel tank side covers cowlings and inner cover 26 6 Remove the radiator L7 5 4 e Remove the spark plugs 72 5 Remove the cylinder head covers The tappet clearance specification is different for intake and exhaust valves Tappet clearance must be checked and adjusted 1 at the time of periodic inspection 2 when the valve mechanism is serviced and 3 when the camshafts are disturbed by removing them for servicing Tappet clearance when cold IN 0 10 0 20 mm 0 004 0 008 in EX 0 20 0 30 mm 0 008 0 012 in NOTE The tappet clearance should be taken when each cylinder is at Top Dead Center TDC of compression stroke The cams IN amp EX on the front cylinder at position amp show the front cylinder at TDC of compression stroke The cams IN amp EX on the rear cylinder at position B show the rear cylinder at TDC of compression stroke The clearance specification is for COLD state To turn the crankshaft for clearance checking be sure to use a 17 mm wrench and rotate in the normal runn
12. to change without notice 1 10 GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s COUNTRY or AREA U K U S A Except for California EU Australia Canada California U S A PERIODIC MAINTENANCE 2 1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE 2 2 PERIODIC MAINTENANCE CHART 2 2 LUBRICATION enar 2 3 MAINTENANCE AND TUNE UP PROCEDURES 2 4 AIR CLEANER 2 4 SPARK E 2 5 TAPPET CLEARANCE 2 7 PUBL HOSE E 2 12 ENGINE OIL AND OIL FILTER rnt anre karina 2 12 ENGINE IDLE SPEED tant dada Ya 2 14 THROTTLE CABLE PLAY 2 14 THROTTLE VALVE SYNCHRONIZATION 2 15 PAIR AIR SUPPLY SYSTEM 2 15 eire P 2 16 COOLING SYSTEM 2 17 DRIVE CHAIN a 2 19 BRAKE cM 2 21 pud 2 25 STEERING 2 25 FRONT FORK 2 26 REAR SUSPENSION 2 26 EXHAUST PIPE BOLT rnt mri arua 2 26 CHASSIS BOLT AND NUT
13. OVAL Remove the seat 276 4 Lift and support the fuel tank L7 4 51 Remove the spark plug cap Remove the spark plug with a spark plug wrench HEAT RANGE Check to see the heat range of the plug Standard Cold type CR8EK CR9EK or CR10EK U24ETR U27ETR or CARBON DEPOSIT Check to see if there are carbons deposit on the plugs If car bon is deposited remove it with a spark plug cleaner machine or carefully using a tool with a pointed end SPARK PLUG GAP Measure the plug gap with a thickness gauge If out of specifi cation adjust it to the following gap 09900 20803 Thickness gauge Spark plug gap Standard 0 6 0 7 mm 0 024 0 028 in ELECTRODES CONDITION Check to see the worn or burnt condition of the electrodes If it is extremely worn or burnt replace the plug And also replace the plug if it has a broken insulator damaged thread CAUTION Confirm the thread size and reach when replacing the plug If the reach is too short carbon will be deposited on the screw portion of the plug hole and engine dam age may result SPARK PLUG AND PLUG CAP INSTALLATION CAUTION Before using a spark plug wrench carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage the aluminum threads Install the spark plugs to the cylinder heads by finger tight and then tighten
14. SUZUKI SERVICE MANUAL FOREWORD This manual contains an introductory description on the SUZUKI DL1000 and procedures for its inspec tion service and overhaul of its main components Other information considered as generally known is not included Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its main tenance Use this section as well as other sections to use as a guide for proper inspection and service This manual will help you know the motorcycle bet ter so that you can assure your customers of fast and reliable service This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have been made since then differences may exist between the con tent of this manual and the actual motorcycle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual motorcycle exactly in detail This manual is written for persons who have enough knowledge skills and tools including special tools for servicing SUZUKI motorcy cles If you do not have the proper knowledge and tools ask your authorized SUZUKI motorcycle dealer to help you Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual Improper repair may result in injury to the mechanic and ma
15. containers Never re use brake fluid left over from a previous servicing which has been stored for a long period FRONT FORK OIL Use fork oil 558 or an equivalent fork oil ENGINE COOLANT Use an anti freeze engine coolant compatible with an aluminum radiator mixed with distilled water only WATER FOR MIXING Use distilled water only Water other than distilled water can corrode and clog the aluminum radiator ANTI FREEZE ENGINE COOLANT The engine coolant perform as a corrosion and rust inhibitor as well as anti freeze Therefore the engine coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point Suzuki recommends the use of SUZUKI COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an aluminum radiator LIQUID AMOUNT OF WATER ENGINE COOLANT Solution capacity total 2 200 ml 2 3 1 9 US Imp qt For engine coolant mixture information refer to cooling system section page 5 2 CAUTION Mixing of anti freeze engine coolant should be limited to 60 Mixing beyond it would reduce its efficiency If the anti freeze engine coolant mixing ratio is below 50 rust inhabiting perfor mance is greatly reduced Be sure to mix it above 5096 even though the atmospheric tempera ture does not go down to the freezing point 1 6 GENERAL INFORMATION BREAK IN PROCEDURES During manufact
16. ele ment CAUTION Always use air pressure on the throttle body side of the air cleaner element If air pressure is used on the other side dirt will be forced into the pores of the air cleaner element thus restricting air flow through the air cleaner element Install the O ring 3 properly Reinstall the cleaned or new air cleaner element in the reverse order of removal CAUTION If driving under dusty condition clean the air cleaner element more frequently The surest way to accelerate engine wear is to use the engine without the element or to use a ruptured element Make sure that the air cleaner is in good condition at all times Life of the engine depends largely on this component PERIODIC MAINTENANCE 2 5 NOTE When cleaning the air cleaner element drain water from the air cleaner by removing the drain plug SPARK PLUG Inspect every 6 000 km 4 000 miles 6 months and replace every 12 000 km 7 500 miles 12 months NO 1 FRONT SPARK PLUG REMOVAL Remove the spark plug mounting bolts and B Move the radiator forward Remove the spark plug cap D NOTE Be careful not to damage the radiator fins The hot radiator and the hot engine can burn you Wait until the radiator and the engine are cool enough to touch Remove the spark plug with a spark plug wrench 2 6 PERIODIC MAINTENANCE NO 2 REAR SPARK PLUG REM
17. ench For E 28 These labels are attached on the right frame GENERAL INFORMATION 1 7 1 8 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall 2 295 mm 90 4 in Overall width 865 mm 34 1 in Overall height icri treten 1 335 mm 52 6 in Wheelbase 1 535 mm 60 4 in Ground clearance 165 mm 6 5 in Seat i dietus 840 mm 33 1 in Diy MaS x Ea 207 kg 456 lbs 209 kg 461 Ibs E 33 ENGINE Bp TE Four stroke Liquid cooled DOHC 90 degree V twin Number of cylinders 2 ss ideis D P 98 0 3 858 66 0 2 598 Piston 996 cm 60 8 cu Compression 11 3 1 System i eei Fuel injection system geld Non woven fabric element Starter Electric starter Lubrication system Wet sump DRIVE TRAIN iio aet i Wet multi plate type TRANSMISSIO 6 speed constant mesh Gearshift pattern 1 down 5 Prima
18. ing direction spark plugs should be removed PERIODIC MAINTENANCE 2 7 2 8 PERIODIC MAINTENANCE Remove the generator cover plug and timing inspection plug 2 Turn the crankshaft to set the No 1 Front cylinder at TDC of compression stroke Align the F T line on the generator rotor to the index mark of valve timing inspection hole and also bring the camshafts to the position as shown in page 2 7 To inspect the No 1 Front cylinder tappet clearance use a thickness gauge between the tappet and the cam If the clear ance is out of specification adjust it into the specified range 09900 20803 Thickness gauge Turn the crankshaft 270 degrees 34 turns to set the No 2 Rear cylinder at TDC of compression stroke Align the T line on the generator rotor to the index mark of valve timing inspection hole and also bring the camshafts to the position as shown in page 2 7 Inspect the No 2 Rear cylinder tappet clearance as the same manner of No 1 Front cylinder and adjust the clear ance if necessary 09900 20803 Thickness gauge PERIODIC MAINTENANCE 2 9 TAPPET CLEARANCE ADJUSTMENT The clearance is adjusted by replacing the existing tappet shim by a thicker or thinner shim Remove the intake or exhaust camshafts 773 20 Remove the tappet and shim by fingers or magnetic hand Check the figures printed on the shim These figures indicate the thick
19. mmable materials make sure that the area you work in is well ventilated and that you follow all of the material manufacturer s instructions Never use gasoline as a cleaning solvent To avoid getting burned do not touch the engine engine oil radiator and exhaust system until they have cooled After servicing the fuel oil water exhaust or brake systems check all lines and fittings related to the system for leaks GENERAL INFORMATION CAUTION 13 If parts replacement is necessary replace the parts with Suzuki Genuine Parts or their equiva lent When removing parts that are to be reused keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation Be sure to use special tools when instructed Make sure that all parts used in reassembly are clean Lubricate them when specified Use the specified lubricant bond or sealant When removing the battery disconnect the negative cable first and then the positive cable When reconnecting the battery connect the positive cable first and then the negative cable and replace the terminal cover on the positive terminal When performing service to electrical parts if the service procedures not require use of bat tery power disconnect the negative cable the battery When tightening the cylinder head and case bolts and nuts tighten the larger sizes first Always tighten the bolts and nuts diag
20. ness of the shim as illustrated Select a replacement shim that will provide a clearance within the specified range For the purpose of this adjustment a total of 25 sizes of tappet shim are available ranging from 2 30 to 3 50 mm in steps of 0 05 mm Fit the selected shim to the valve stem end with numbers toward tappet Be sure to check shim size with micrometer to ensure its size Refer to the tappet shim selection table Pages 2 10 and 11 for details NOTE Be sure to apply engine oil to tappet shim top and bottom faces When seating the tappet shim be sure to face figure printed surface to the tappet CAUTION Reinstall the camshafts as the specified manner 73 105 After replacing the tappet shim and camshafts rotate the engine so that the tappet is depressed fully This will squeeze out oil trapped between the shim and the tappet that could cause an incorrect measurement then check the clearance again to confirm that it is within the specified range After finishing the tappet clearance adjustment reinstall the following items When installing the cylinder head cover do not forget the gas ket A Page Cylinder head cover 3 111 Spark plug and plug 2 7 Valve timing inspection plug 3 111 Generator cover 9 3 112
21. onally from the inside toward outside and to the speci fied tightening torque Whenever you remove oil seals gaskets packing O rings locking washers self locking nuts cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any left over material from the mating surfaces Never reuse a circlip When installing a new circlip take care not to expand the end gap larger than required to slip the circlip over the shaft After installing a circlip always ensure that it is completely seated in its groove and securely fitted Use a torque wrench to tighten fasteners to the specified torque Wipe off grease and oil if a thread is smeared with them After reassembling check parts for tightness and proper operation To protect the environment do not unlawfully dispose of used motor oil engine coolant and other fluids batteries and tires To protect Earth s natural resources properly dispose of used motorcycle and parts 14 GENERAL INFORMATION SUZUKI DL1000K2 02 MODEL RIGHT SIDE LEFT SIDE Difference between photographs and actual motorcycles depends on the markets SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number D is stamped on the right side of the steering head pipe The engine serial number 2 is located on the right side of the crankcase These num bers
22. re Sensor APS Air Fuel Mixture Before Bottom Dead Center Before Top Dead Center Battery Positive Voltage Crankshaft Position Sensor CKPS Circuit Clutch Lever Position Switch Clutch Switch Camshaft Position Sensor CMPS Carbon Monoxide Central Processing Unit Direct Current Dealer Mode Coupler Double Over Head Camshaft Daytime Running Light ECM ECT Sensor EVAP EVAP Canister Fl FP FPR FP Relay G GEN GND GP Switch H HC IAP Sensor IAT Sensor IG L LCD LED LH Engine Control Module Engine Control Unit ECU FI Control Unit Engine Coolant Temperature Sensor ECTS Water Temp Sensor WTS Evaporative Emission Evaporative Emission Canister Canister Fuel Injection Fuel Injector Fuel Pump Fuel Pressure Regulator Fuel Pump Relay Generator Ground Gear Position Switch Hydrocarbons Intake Air Pressure Sensor IAPS Intake Air Temperature Sensor IATS Ignition Liquid Crystal Display Light Emitting Diode Malfunction Indicator Lamp Left Hand T V MAL Code Max MIL Min NOx OHC OPS ROM SAE STC System STP Sensor ST Valve STV Actuator TO Sensor TP Sensor VD Malfunction Code Diagnostic Code Maximum Malfunction Indicator Lamp LED Minimum Nitrogen Oxides Over Head Camshaft Oil Press
23. ry reduction 1 838 57 31 Final reduction ratio 2 411 41 17 Gear ratios 3 000 36 12 2hg E 1 933 29 15 SIG ER 1 500 27 18 LE 1 227 27 22 sj 1 086 25 23 TOD deii attain eats 0 913 21 23 Drive RK525 SMCZT 112 links GENERALINFORMATION 1 9 CHASSIS Front 0 Inverted telescopic coil spring oil damped Rear suspension Link type coil spring oil damped Steering angle eiie deos 40 right amp left innen e Di tdi o 26 30 Hc M M 111 mm 4 3 in Turning radius 2 7 m 8 86 ft Front Brake te bi rio veil ot Disc brake twin Rear Drake e cbe eee Disc brake Front tIre SIZe ire 110 80 R19M C 59H tubeless 150 70 R17M C 69H tubeless Front fork stroke 160 mm 6 3 in Rear wheel travel 159 mm 6 2 in ELECTRICAL Ignition type Electronic ignition ECM Transistorized Ignition timing eee 4 B T D C at 1 200 r min Spark 0 iude hd esee CR8EK or DENSO U24ETR Bat
24. tery uo eee tete 12 V 43 2 12 Ah 10 HR Generator annaus Three phase A C Generator nae 30 15 15 15 15 15 10 Headlight i 12 V 60 55 H4 POSITION io orte nes 12V 5W x 2 Except for 03 24 28 33 Turn signal gnti 12V 10W License lightstand eei 12V5W Brake 12 V 21 5 W 2 Speedometer Tachometer light LED Neutral indicator light LED High beam indicator LED Turn signal indicator light LED Over drive indicator light LED Fuel injector warning light LED Engine coolant temperature warning light LED Oil pressure warning LED CAPACITIES PUGH TANK uenerit ei 22 L 5 8 4 8 US Imp gal Engine oil oil change 2 700 ml 2 9 2 4 US Imp qt with filter 2 900 ml 3 1 2 6 US Imp qt overhaul enne 3 300 ml 3 5 2 9 US Imp qt Engine coolant including reserve 2 200 ml 2 3 1 9 US Imp oz Front fork oil each leg 505 ml 17 1 17 8 US Imp oz These specifications are subject
25. ure Switch Positive Crankcase Ventilation Crankcase Breather Right Hand Read Only Memory Society of Automotive Engineers Secondary Throttle Control System STCS Secondary Throttle Position Sensor STPS Secondary Throttle Valve STV Secondary Throttle Valve Actuator STVA Tip Over Sensor TOS Throttle Position Sensor TPS Vacuum Damper GENERAL INFORMATION 1 1 GENERAL INFORMATION CONTENTS WARNING CAUTION NOTE 5er in nda pL y Rue nsa 1 2 GENERAL PRECAUTIONS 1 2 SUZUKI DL1000K2 02 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL OIL AND ENGINE COOLANT RECOMMENDATION 1 4 1 4 ENGINE Dit TP NIE 1 5 BRAKE FLUID RR AU IERI Medie 1 5 FRONT FORK OIL 1 5 ENGINE COOLANT inia 1 5 WATER FOR MIXING 1 5 ANTI FREEZE ENGINE COOLANT 1 5 LIQUID AMOUNT OF WATER ENGINE COOLANT 1 5 BREAK IN PROCEDURES sissississssoareccswscessseouncvssadinssosnsveresssdedstovuacvane 1 6 CYLINDER IDENTIFICATION cciscssusissicncsiseaiertisastidivesuuceteasstsiaicensidvave 1 6 INFORMATION 5 1 7 SPECIFICATIONS
26. ure only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life The general rules are as follows Keep to these break in engine speed limits Initial 800 500 miles Below 4 500 r min Up 1 600 km 1 000 miles Below 7 000 r min Over 1 600 km 1 000 miles Below 9 500 r min Upon reaching an odometer reading of 1 600 km 1 000 miles you can subject the motorcycle to full throt tle operation However do not exceed 9 500 r min at any time CYLINDER IDENTIFICATION The two cylinders of this engine are identified as No 1 and No 2 cylinder as counted from front to rear as viewed by the rider on the seat INFORMATION LABELS Noise label For 03 24 33 Information label For 03 28 33 ICES Canada label For E 28 Vacuum hose routing label For E 33 Fuel caution label For E 02 24 Manual notice label For 03 33 Tire pressure label Warning safety label Rear carrier warning label Frame caution label Steering warning label Screen warning label ID label For E 02 19 24 9 99 9 9 069 Safety label For 03 28 33 42 For E 28 Fr
27. y render the motorcycle unsafe for the rider and passenger SUZUKI MOTOR CORPORATION COPYRIGHT SUZUKI MOTOR CORPORATION 2002 GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE SYSTEM COOLING AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION EMISSION CONTROL INFORMATION WIRING DIAGRAM HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 1 The text of this manual is divided into sections 2 The section titles are listed in the GROUP INDEX 3 Holding the manual as shown at the right will allow you to find the first page of the section easily 4 The contents are listed on the first page of each section to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instructions and other service information such as the tightening torque lubricating points and locking agent points are provided Example Front wheel Brake disc 2 Dust seal 3 Bearing Center spacer 5 Coller 6 Front wheel Tire valve Front axle Brake disc bolt SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servic ing The meaning of each symbol is also included in the table SYMBOL DEFINITION
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