Suzuki SV1000 2003-2005 Service Manual 1 General Information

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S V 10005

SERVICE MANUAL

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1 99500-39250-03E 0

II II II II

IMPORTANT

All street-legal Suzuki motorcycles with

displacementof50 Environmental Protection agency emission regulations

These regulations set specific standards for exhaust emission output levels as well as particular servicing

requirements required to properly inspect and service SV1000S in

accordance with all EPA regulations

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.S. Suzuki's emission control program can be found in the U.S. SUZUKI EMISSION CONTROL

PROGRAM MANUAUSERVICE BULLETIN

. This manual includes specific information

cc

or greater are subject

. It is strongly

.

engine

to

.

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0

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f

1

0

1

40

Of

of

FOREWORD

This manual contains an introductory 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 maintenance

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

.

. Use this section as well as other sections

.

description

on

GENERAL INFORMATION

PERIODIC MAINTENANCE

.

ENGINE

FI SYSTEM

* This manual has been prepared on the basis

of the latest specifications at the time of publication

. If modifications have been made since then, differences may exist between the content of this manual and the actual motorcycle

* Illustrations in this manual are used to show

the basic principles of operation and work

procedures 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

. They may not represent the

.

COOLING AND LUBRICATION SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

GROUP /NDE

4

E

WARNING

A

Inexperienced without the proper tools may

not

be 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

mechanics

able

to

properly

or

and

mechanics

equipment

perform

.

SUZUKI MOTOR CORPORATION

the

EMISSION CONTROL INFORMATION

WIRING DIAGRAM

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

3

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

such as the tightening torque, lubricating points and locking agent points, are provided

Example

: Front wheel

. Work instructions and other service information

.

1~ Brake disc

•

Dust seal

(3 Bearing

Center spacer

•

Coller

•

Front wheel

•

Tire valve

44P

•

4



•

Front axle

•

Brake disc bolt

T



•

0

ITEM

CA)

N

100

23

.m

kgf-m

10

.0

2

.3

lb-ft

72

.5

165

of

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servicing

. The meaning of each symbol is also included in the table

.

SYMBOL

0

r

0

©

DEFINITION

Torque control required

Data beside it indicates specified

torque

.

Apply oil wise specified

Apply molybdenum oil solution (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1)

Apply SUZUKI SUPER GREASE 99000-25030

Apply SUZUKI MOLY PASTE

99000-25140

Apply SUZUKI SILICONE GREASE 99000-25100

. Use engine oil unless other-

.

"A"

.

SYMBOL

LLC

FORK

BF

Lo

a

~©

a

Lo

o

DEFINITION

Use engine coolant

Use fork oil

99000-99044-LO1

Apply or use brake fluid

Measure in voltage range

Measure in resistance range

Measure in current range

.

1207B

1303

V

1342

1360

Apply SUZUKI BOND "1207B" 99104-31 140

Apply THREAD LOCK SUPER "1303" 99000-32030

Apply THREAD LOCK "1342" 99000-32050

Apply THREAD LOCK SUPER "1360" 99000-32130

.

L o

0

j

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1

))

L

o a

TOOL

DATA

Measure in diode test range

Measure in continuity test range

Use special tool

Indication of service data

.

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ABBREVIATIONS USED IN THIS

MANUAL

I

A

ABDC AC ACL API ATDC ATM Pressure

A/F

: After Bottom Dead Center : Alternating Current :

Air Cleaner, Air Cleaner Box

: American Petroleum Institute : After Top Dead Center : Atmospheric Pressure

Atmospheric Pressure Sensor (APS)

: Air Fuel Mixture

E

ECM

ECT Sensor:Engine Coolant Temperature

EVAP EVAP Canister

:

Engine Control Module Engine Control Unit (ECU) (FI Control Unit)

Sensor (ECTS), Water Temp Sensor (WTS)

:

Evaporative Emission

: Evaporative Emission

Canister (Canister)

.

0



I

1

B

BBDC BTDC B+

C

CKP Sensor:Crankshaft Position Sensor

CKT CLP Switch

CMP Sensor

CO CPU

D

DC DMC DOHC

DRL

:

Before Bottom Dead Center

:

Before Top Dead Center

: Battery Positive Voltage

(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

F

FI FP FPR FP Relay

G

GEN GND GP Switch:

H

HC

IAP Sensor: IAT Sensor:Intake Air Temperature Sensor

IG

L

LCD LED

LH

:

Fuel Injection, Fuel Injector

:

Fuel Pump : Fuel Pressure Regulator : Fuel Pump Relay

:

Generator

:

Ground Gear Position Switch

Hydrocarbons

:

Intake Air Pressure Sensor (ZAPS)

(IATS)

: Ignition

:

Liquid Crystal Display

:

Light Emitting Diode (Malfunction Indicator Lamp)

:

Left Hand

of,

4 6