Suzuki V-Strom DL1000 - Repair, Service Manual, Wiring Diagrams and Parts Catalog

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SUZUKI V-STROM DL1000 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING DIAGRAMS - PARTS CATALOGUE

- English Service Manual, Parts Catalogue and Wiring Diagrams, to motorcycles Suzuki V-Strom DL1000.

 
CONTENTS:

COVER

2001-2009 SERVICE MANUAL

- FOREWORD
- HOW TO USE THIS MANUAL
- To Locate What You Are Looking For
- Component Parts And Work To Be Done
- Symbol
- Abbreviations Used In This Manual
- Sae-To-Former Suzuki Term
- 01 GENERAL INFORMATION
- Warning/Caution/Note
- General Precautions
- Suzuki Dl 1000k2 (02-Model)
- Serial Number Location
- Fuel, Oil And Engine Coolant Recommendation
- fuel
- engine oil
- brake fluid
- front fork oil
- engine coolant
- water for mixing
- anti-freeze/engine coolant
- liquid amount of water/engine coolant
- Break-In Procedures
- Cylinder Identification
- Information Labels
- Specifications
- Country And Area Codes
- 02 PERIODIC MAINTENANCE
- Periodic Maintenance Schedule
- periodic maintenance chart
- lubrication points
- Maintenance And Tune-Up Procedures
- air cleaner
- spark plug
- tappet clearance
- fuel hose
- engine oil and oil filter
- engine idle speed
- throttle cable play
- throttle valve synchronization
- evaporative emission control system (e-33 only)
- pair (air supply) system
- clutch
- cooling system
- drive chain
- tire
- steering
- front fork
- rear suspension
- exhaust pipe bolt
- chassis bolt and nut
- Compression Pressure Check
- compression test procedure
- Oil Pressure Check
- oil pressure test procedure
- 03 ENGINE
- Engine Components Removable With Engine In Place
- Engine Removal And Installation
- engine removal
- engine installation
- Engine Disassembly
- engine top side
- engine bottom side
- Engine Components Inspection And Servicing
- cylinder head cover
- camshaft/cylinder head
- cylinder/piston inspection
- conrad/crankshaft
- clutch
- transmission
- gearshift fork
- primary drive gear
- starter torque limiter
- starter clutch
- gearshift
- crankcase
- crankcase-crankshaft bearing
- generator cover
- clutch cover
- gearshift cover
- Engine Reassembly
- engine bottom side
- engine top side
- 04 FI SYSTEM
- Precautions In Servicing
- connector/coupler
- fuse
- ecm/various sensors
- electrical circuit inspection procedure
- using testers
- Fi System Technical Features
- injection time (injection volume)
- compensation of injection time (volume)
- injection stop control
- fuel delivery system
- fuel pump
- fuel pressure regulator
- fuel injector
- fuel pump control system
- ecm (fi control unit)
- injection timing
- sensors
- Fi System Parts Location
- F1 System Wiring Diagram
- Self-Diagnosis Function
- user mode
- dealer mode
- tps adjustment
- Fail-Safe Function
- Fi System Troubleshooting
- customer complaint analysis
- self-diagnostic procedures
- self-diagnosis reset procedure
- malfunction code and defective condition
- "c11" cmp sensor circuit malfunction
- "c12" ckp sensor circuit malfunction
- "c13" lap sensor circuit malfunction
- "c14" tp sensor circuit malfunction
- "c15" ect sensor circuit malfunction
- "c21" iat sensor circuit malfunction
- "c22" ap sensor circuit malfunction
- "c23" to sensor circuit malfunction
- "c24" or "c2s" ignition system malfunction
- "c28" stv actuator circuit malfunction
- "c29" stp sensor circuit malfunction
- "c31" gear position (gp) switch circuit malfunction
- "c32" or "c33" fuel injection malfunction
- "c41" fp relay circuit malfunction
- "c42" ig switch circuit malfunction
- "c44" h02 sensor (h02s) circuit malfunction (except for usa)
- Fuel System
- fuel tank lift-up
- fuel tank removal
- fuel tank installation
- fuel pressure inspection
- fuel pump inspection
- fuel pump relay inspection
- fuel pump and fuel filter removal
- fuel mesh filter inspection and cleaning
- fuel pump and fuel mesh filter installation
- Throttle Body And Stv Actuator
- construction
- throttle body removal
- throttle body disassembly
- throttle body cleaning
- inspection
- throttle body reassembly
- stp sensor adjustment
- throttle body installation
- tp sensor adjustment
- fuel injector inspection
- fuel injector removal
- fuel injector installation
- fast idle inspection
- fast idle adjustment
- throttle valve synchronization
- throttle cable adjustment
- Sensor
- lap sensor inspection
- lap sensor removauinstallation
- tp sensor inspection
- tp sensor removauinstallation
- stp sensor inspection
- stp sensor removauinstallation
- ckp sensor inspection
- ckp sensor removauinstallation
- cmp sensor inspection
- cmp sensor removauinstallation
- iat sensor inspection
- iat sensor removauinstallation
- ect sensor inspection
- ect sensor removauinstallation
- ap sensor inspection
- ap sensor removauinstallation
- to sensor inspection
- to sensor removauinstallation
- h02 sensor inspection (except for usa)
- h02 sensor removaliinst allation
- 05 COOLING AND LUBRICATION SYSTEM
- Engine Coolant
- Cooling Circuit
- cooling circuit inspection
- Radiator
- removal
- inspection and cleaning
- installation
- Radiator Reservoir Tank
- removal/installation
- Radiator Cap
- inspection
- Water Hose
- inspection
- Cooling Fan
- removal
- inspection
- installation
- Cooling Fan Thermo-Switch
- removal
- inspection
- installation
- Engine Coolant Temperature Sensor
- removal
- inspection
- installation
- Thermostat
- removal
- inspection
- installation
- Water Pump
- removal and disassembly
- inspection
- reassembly and installation
- Lubrication System
- oil pressure
- oil filter
- oil pressure regulator
- oil strainer
- oil jet
- oil pump
- oil pressure switch
- Oil Cooler
- removal
- inspection and cleaning
- installation
- Engine Lubrication Flow Chart
- Engine Lubrication Circuit
- 06 CHASSIS
- Exterior Parts
- construction
- removal
- Front Wheel
- construction
- removal
- inspection and disassembly
- reassembly and remounting
- Front Fork
- construction
- removal and disassembly
- inspection
- reassembly and remounting
- Steering And Handlebar
- construction
- removal
- inspection and disassembly
- reassembly and remounting
- steering tension adjustment
- Rear Wheel
- construction
- removal
- inspection and disassembly
- reassembly and remounting
- Rear Shock Absorber
- construction
- removal
- inspection
- rear shock absorber disposal
- remounting
- suspension setting
- Rear Swingarm
- construction
- removal
- inspection and disassembly
- reassembly
- remounting
- final inspection and adjustment
- Front Brake
- construction
- brake pad replacement
- brake fluid replacement
- caliper removal and disassembly
- caliper inspection
- caliper reassembly and remounting
- brake disc inspection
- master cylinder removal and disassembly
- master cylinder inspection
- master cylinder reassembly and remounting
- Rear Brake
- construction
- brake pad replacement
- brake fluid replacement
- caliper removal and disassembly
- caliper inspection
- brake disc inspection
- caliper reassembly and remounting
- master cylinder removal and disassembly
- master cylinder inspection
- master cylinder reassembly and remounting
- Clutch Release Cylinder And Master Cylinder
- construction
- clutch fluid replacement
- clutch release cylinder removal and disassembly
- clutch release cylinder inspection
- clutch release cylinder reassembly and remounting
- clutch master cylinder removal and disassembly
- clutch master cylinder inspection
- clutch master cylinder reassembly and remounting
- Tire And Wheel
- tire removal
- inspection
- valve installation
- tire installation
- 07 ELECTRICAL SYSTEM
- Cautions In Servicing
- connector
- coupler
- clamp
- fuse
- semi-conductor equipped part
- battery
- connecting the battery
- wiring procedure
- using the multi circuit tester
- Location Of Electrical Components
- Charging System
- troubleshooting
- inspection
- Starter System And Side-Stand/Ignition Interlock System
- trouble shooting
- starter motor removal and disassembl y
- starter motor inspection
- starter motor reassembly
- starter relay inspection
- side-stand/ignition interlock system parts inspection
- Ignition System
- troubleshooting
- inspection
- Combination Meter
- removal and disassembly
- inspection
- engine coolant temperature meter and indicator
- Lamps
- headlight, brake llght/taillight and turn signal light
- Relays
- turn signal/side-stand relay
- starter relay
- fuel pump relay
- switches
- Battery
- specifications
- initial charging
- servicing
- recharging operation
- 08 SERVICING INFORMATION
- Troubleshooting
- fi system malfunction code and defective condition
- engine
- radiator (cooling system)
- chassis
- brakes
- electrical
- battery
- Wire Harness, Cable And Hose Routing
- wire harness routing
- engine electrical parts set-up
- high-tension cord routing
- throttle cable routing
- throttle body installation/hose routing
- crankcase breather hose routing
- clutch hose routing
- cooling system hose routing
- front brake hose routing
- rear brake hose routing
- fuel tank drain hose routing
- fuel tank installation
- pair (air supply) system hose routing
- seat lock cable routing
- side-stand set-up
- brake pedal/footrest set-up
- footrest set-up
- handlebar balancer installation
- Special Tools
- Tightening Torque
- engine
- fi system parts
- chassis
- tightening torque chart
- Service Data
- 09 EMISSION CONTROL INFORMATION
- Emission Control Systems
- fuel injection system
- crankcase emission control system
- exhaust emission control system (pair system)
- noise emission control system
- evaporative emission control system (only for e-33)
- Pair (Air Supply) System Inspection
- Pair (Air Supply) System Hose Routing
- Evaporative Emission Control System Inspection (Only For E-33)
- Canister Hose Routing (Only For E-33)
- 10 DL1000K3 ('03 MODEL)
- Specifications
- Service Data
- Front Fork
- Regulator/Rectifier Inspection
- 11 DL1000K4 ('04 MODEL)
- Specifications
- Service Data
- Special Tool
- Periodic Maintenance Chart
- Engine Installation
- Fi System
- Combination Meter
- Wire Harness Routing
- Cowling Setup
- 12 DL1000K5 ('05 MODEL)
- Specifications
- Service Data
- Cooling System Hose Routing
- 13 DL1000K6/K7/K8 ('06/’07/’08-MODEL)
- Specifications
- Service Data
- 14 DL1000K9 ('09 MODEL)
- Specifications
- 15 WIRING DIAGRAM


2002-2004 SPARE PARTS CATALOGUE

- V-STROM PARTS
- Illustrations
- Engine Transmission
- Electrics
- Body
- Part Numbers Lists
- K2/K3 ADDENDUM