Suzuki Sv1000S Bedienungsanleitung

SERVICE MANUAL

II II II II

•



S V 10005

1 99500-39250-03E 0

IMPORTANT

All street-legal Suzuki motorcycles with

engine

displacement

or greater are subject

Environmental Protection agency emission regulations

These regulations set specific standards for exhaust

emission output levels as well as particular servicing

requirements

. This manual includes specific information

required to properly inspect and service SV1000S in

accordance with all EPA regulations

. It is strongly

recommended that the chapter on Emission Control,

Periodic Servicing and Fl SYSTEM be thoroughly

reviewed before any type of service work is performed

Further information concerning the EPA emission

regulations and U

. Suzuki's emission control program

can be found in the U

. SUZUKI EMISSION CONTROL

PROGRAM MANUAUSERVICE BULLETIN



FOREWORD

This manual contains an introductory

description

the SUZUKI SV1000S and procedures for its

inspection/service and overhaul of its main compo-

nents

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

may

not

able

properly

perform

the

services described in this manual

Improper repair may result in injury to the

mechanic and may render the motorcycle

unsafe for the rider and passenger

SUZUKI MOTOR CORPORATION

GROUP /NDE

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FI SYSTEM

COOLING AND LUBRICATION

SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

EMISSION CONTROL

INFORMATION

WIRING DIAGRAM

WARNING

Inexperienced

mechanics

without the proper tools

and

equipment

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR

The text of this manual is divided into sections

. The section titles are listed in the GROUP INDEX

. Holding the manual as shown at the right will allow you to find

the first page of the section easily

. 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

ITEM

CA)

100

kgf-m

lb-ft

165

1~ Brake disc

•



Dust seal

(3 Bearing

•



Center spacer

•



Coller

•



Front wheel

•



Tire valve

•



Front axle

•



Brake disc bolt

44P

•



•



•

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

SYMBOL

DEFINITION

Torque control required

Data beside it indicates specified

torque

LLC

Use engine coolant

Apply oil

. Use engine oil unless other-

wise specified

FORK

Use fork oil

99000-99044-LO1

Apply molybdenum oil solution

(Mixture of engine oil and SUZUKI

MOLY PASTE in a ratio of 1

Apply or use brake fluid

Apply SUZUKI SUPER GREASE

"A"

99000-25030

Measure in voltage range

Apply SUZUKI MOLY PASTE

99000-25140

~©

Measure in resistance range

Apply SUZUKI SILICONE GREASE

99000-25100

Measure in current range

Apply SUZUKI BOND "1207B"

99104-31 140

L o

Measure in diode test range

1207B

1303

Apply THREAD LOCK SUPER "1303"

99000-32030



))

o a

Measure in continuity test range

1342

Apply THREAD LOCK "1342"

99000-32050

Use special tool

TOOL

1360

Apply THREAD LOCK SUPER "1360"

99000-32130

Indication of service data

DATA

ABBREVIATIONS USED IN THISMANUALA

ABDC



: After Bottom Dead Center



: Alternating Current

ACL



Air Cleaner, Air Cleaner Box

API



: American Petroleum Institute

ATDC



: After Top Dead Center

ATM Pressure

: Atmospheric Pressure

Atmospheric Pressure Sensor

(APS)

A/F



: Air Fuel Mixture

BBDC



Before Bottom Dead Center

BTDC



Before Top Dead Center

B+



: Battery Positive Voltage

CKP Sensor

Crankshaft Position Sensor

(CKPS)

CKT



: Circuit

CLP Switch

: Clutch Lever Position Switch

(Clutch Switch)

CMP Sensor

: Camshaft Position Sensor

(CMPS)



Carbon Monoxide

CPU



Central Processing Unit



: Direct Current

DMC



Dealer Mode Coupler

DOHC



Double Over Head Camshaft

DRL



Daytime Running Light

ECM



Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

ECT Sensor

Engine Coolant Temperature

Sensor (ECTS), Water Temp

Sensor (WTS)

EVAP



Evaporative Emission

EVAP Canister

: Evaporative Emission

Canister (Canister)



Fuel Injection, Fuel Injector



Fuel Pump

FPR



: Fuel Pressure Regulator

FP Relay



: Fuel Pump Relay

GEN



Generator

GND



Ground

GP Switch



Gear Position Switch



Hydrocarbons

IAP Sensor



Intake Air Pressure Sensor (ZAPS)

IAT Sensor

Intake Air Temperature Sensor

(IATS)



: Ignition

LCD



Liquid Crystal Display

LED



Light Emitting Diode

(Malfunction Indicator Lamp)



Left Hand



of,

4 6

•



•



MAL-Code

Max

MIL

Min

NOx

OHC

OPS

PCV

ROM

SAE

STC System

STP Sensor

ST Valve

STV Actuator

TO Sensor

TP Sensor

Malfunction Code

(Diagnostic Code)

Maximum

Malfunction Indicator Lamp

(LED)

Minimum

Nitrogen Oxides

Over Head Camshaft

Oil Pressure 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

SAE-TO-FORMER SUZUKI TERM

This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in

this manual in compliance with SAE recommendations, as well as their former SUZUKI names



•



SAE TERMFULL TERM ABBREVIATION FORMER SUZUKI TERM

Air

Cleaner

ACL

Air

Cleaner,

Air

Cleaner Box

Barometric

Pressure

BARO

Barometric

Pressure,

Atmospheric

Battery

Positive

Voltage

B+

Pressure

(APS,

Sensor)

Battery

Voltage,

Camshaft

Position

Sensor

CMP

Sensor

Camshaft

Position

Sensor

(CMPS)

Crankshaft

Position

Sensor

CKP

Sensor

Crankshaft

Position

Sensor (CKPS),

Data

Link

Connector

DLC

Crank

Angle

Dealer

Mode

Coupler

Diagnostic Test

Mode

Diagnostic

Trouble

Code

DTM

DTC

Diagnostic

Code,

Malfunction

Code

Electronic

Ignition

Engine

Control

Module

ECM

Engine

Control

Module

(ECM)

Engine

Coolant

Level

ECL

Control

Unit,

Engine

Control

Unit

(ECU)

Coolant

Level

Engine

Coolant

Temperature

ECT

Coolant

Temperature,

Engine

Coolant

Tem-

Engine

Speed

RPM

perature

Water

Temperature

Engine

Speed (RPM)

Evaporative

Emission

EVAP

Evaporative

Emission

Evaporative

Emission

Canister

EVAP

Canister

(Canister)

Purge

Valve

Purge

Valve

Purge

Valve

(SP

Valve)

Fan

Control

Fuel

Level

Sensor

Fuel

Level

Sensor,

Fuel

Level

Gauge

Fuel

Pump

Fuel

Pump

(FP)

Generator

GEN

Generator

Ground

GND

Ground

(GND,

GRD)

•



SAE TERM

FULL TERM ABBREVIATION

FORMER SUZUKI TERM

Heated Oxygen Sensor

HO2S

Heated Oxgen Sensor (HO2S), 02 Sensor

Idle Speed Control

Ignition Control

ISC

Electronic Spark Advance (ESA)

Ignition Control Module

Intake Air Temperature

ICM

IAT

Intake Air Temperature (IAT), Air Tempera-

Malfunction Indicator Lamp

MIL

ture

LED Lamp

Manifold Absolute Pressure

MAP

Malfunction Indicator Lamp (MIL)

Intake Air Pressure, Intake Vacuum

Mass Air Flow

MAF

Air Flow

On-Board Diagnostic

OBD

Self-Diagnosis Function

Open Loop

Programmable Read Only Memory

Pulsed Secondary Air Injection

PROM

PAIR

Diagnostic

Pulse Air Control (PAIR)

Random Access Memory

Read Only Memory

RAM

ROM ROM

Secondary Air Injection

Secondary Throttle Control Sys-

AIR

STCS

STC System (STCS)

tem

Secondary Throttle Valve

STV

ST Valve (STV)

Secondary Throttle Valve Actuator

STVA

STV Actuator (STVA)

Throttle Body

Throttle Body (TB)

Throttle Body Fuel Injection

TBI

Throttle Body Fuel Injection (TBI)

Throttle Position Sensor

TP Sensor

TP Sensor (TPS)

Voltage Regulator

Volume Air Flow

VAF

Air Flow

GENERAL INFORMATION

)

CONTENTS

WARNING/CAUTION/NOTE



1- 2

GENERAL PRECAUTIONS



SUZUKI SV1000SK3 ('03-MODEL)



1- 4

SERIAL NUMBER LOCATION



1- 4

FUEL, OIL AND ENGINE COOLANT RECOMMENDATION



1- 4

FUEL (FOR USA AND CANADA)



1- 4

FUEL (FOR OTHER COUNTRIES)



1- 4

ENGINE OIL



1- 5

BRAKE FLUID



1- 5

FRONT FORK OIL



1- 5

ENGINE COOLANT



1- 5

WATER FOR MIXING



1- 5

ANTI-FREEZE/ENGINE COOLANT



1- 5

LIQUID AMOUNT OF WATER/ENGINE COOLANT



1- 5

BREAK-IN PROCEDURES



1- 6

CYLINDER IDENTIFICATION



1- 6

INFORMATION LABELS



1- 7

SPECIFICATIONS



1- 8

COUNTRY AND AREA CODES



1-10

GENERAL

INFORMATION

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