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
orgreateraresubject
. It is strongly
.
engine
to
.
.
0
f
1
0
1
40
Of
of
Page 3
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
Society of Automotive Engineers
Secondary Throttle Control
System (STCS)
Secondary Throttle Position
Sensor (STPS)
Secondary Throttle Valve (STV)
Secondary Throttle Valve Actuator
(STVA)
•
i
I
T
TO Sensor
TP Sensor
V
VD
Tip Over Sensor (TOS)
Throttle Position Sensor (TPS)
Vacuum Damper
Page 8
SAE-TO-FORMER SUZUKI TERM
This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in
1
i
this manual in compliance with SAE recommendations, as well as their former SUZUKI names
.
t
FULL TERMABBREVIATION
A
Air
Cleaner
B
Barometric
Battery
C
Camshaft
Crankshaft
D
Data
DiagnosticTest
Diagnostic
E
Positive
Position
Link
Connector
Trouble
Pressure
Position
SAE TERM
FORMER SUZUKI TERM
1
Voltage
Sensor
Sensor
Mode
Code
ACL
BARO
B+
CMP
CKP
DLC
DTM
DTC
Sensor
Sensor
Air
Cleaner,
Barometric
Pressure
Battery
Camshaft
Crankshaft
Crank
Dealer
Diagnostic
(APS,APSensor)
Voltage,
Position
Angle
Mode
Air
CleanerBox
Pressure,
+B
Sensor
Position
Code,
Sensor(CKPS),
Coupler
Malfunction
Atmospheric
(CMPS)
Code
4
Electronic
Engine
Engine
Engine
Engine
Evaporative
Evaporative
Purge
F
Fan
Fuel
Fuel
G
Generator
Ignition
Control
Coolant
Coolant
Speed
Valve
Control
Level
Sensor
Pump
Module
Level
Temperature
Emission
Emission
Canister
El
ECM
ECL
ECT
RPM
EVAP
EVAP
Purge
FC
FP
GEN
Canister
Valve
Engine
Fl
Coolant
Coolant
perature
Water
Engine
Evaporative
Purge
Fuel
Fuel
Generator
Control
Control
Unit,
Level
Temperature,
Temperature
Speed (RPM)
(Canister)
Valve
Level
Sensor,
Pump
(FP)
Module
Engine
Emission
(SP
Valve)
Fuel
(ECM)
Control
Engine
Level
Unit
(ECU)
Coolant
Gauge
Tem-
1
•
06
46
Ground
GND
Ground
(GND,
GRD)
Page 9
•
FULL TERMABBREVIATION
H
Heated Oxygen Sensor
I
Idle Speed Control
Ignition Control
Ignition Control Module
Intake Air Temperature
I
M
Malfunction Indicator Lamp
Manifold Absolute Pressure
Mass Air Flow
0
On-Board Diagnostic
SAE TERM
HO2S
ISC
IC
ICM
IAT
MIL
MAP
MAF
OBD
FORMER SUZUKI TERM
Heated Oxgen Sensor (HO2S), 02 Sensor
Electronic Spark Advance (ESA)
Intake Air Temperature (IAT), Air Tempera-
ture
LED Lamp
Malfunction Indicator Lamp (MIL)
Intake Air Pressure, Intake Vacuum
Air Flow
Self-Diagnosis Function
Diagnostic
Open Loop
P
Programmable Read Only Memory
Pulsed Secondary Air Injection
R
Random Access Memory
Read Only Memory
S
Secondary Air Injection
Secondary Throttle Control System
Secondary Throttle Valve
Secondary Throttle Valve Actuator
T
Throttle Body
Throttle Body Fuel Injection
OL
PROM
PAIR
RAM
ROMROM
AIR
STCS
STV
STVA
TB
TBI
Pulse Air Control (PAIR)
STC System (STCS)
ST Valve (STV)
STV Actuator (STVA)
Throttle Body (TB)
Throttle Body Fuel Injection (TBI)
Throttle Position Sensor
V
Voltage Regulator
Volume Air Flow
TP Sensor
VR
VAF
TP Sensor (TPS)
Voltage Regulator
Air Flow
Page 10
GENERAL INFORMATION
.
CONTENTS
GENERAL
INFORMATION
1-1
1
WARNING/CAUTION/NOTE
GENERAL PRECAUTIONS
SUZUKI SV1000SK3 ('03-MODEL)
SERIAL NUMBER LOCATION
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
FUEL (FOR USA AND CANADA)
FUEL (FOR OTHER COUNTRIES)
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
1- 2
2
11- 4
1- 4
1- 4
1- 4
1- 4
1- 5
1- 5
1- 5
1- 5
1- 5
1- 5
1- 5
1- 6
1- 6
1- 7
1- 8
1-10
6-
6-
4)
r
)
Page 11
1-2
GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully
and the words WARNING, CAUTION and NOTE have special meanings
sages highlighted by these signal words
A
WARNING
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
INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles
are unsure about how to perform a particular service operation, ask a more experienced mechanic for
advice
.
.
. To emphasize special information, the symbol
. Pay special attention to the mes-
.
.
.
. In addition to the WARN-
. If you
GENERAL PRECAUTIONS
WARNING
A
•
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 outdoors
.
•
When working with toxic or flammable materials, make sure that the area you work in is wellventilated 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
.
.
.
.
.
.
Page 12
1 40
4
1
GENERAL INFORMATION 1-3
CAUTION
•
If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent
.
•
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
•
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 diagonally from the inside toward outside and to the specified tightening torque
nuts, cotter pins, circlips and certain other parts as specified, be sure to replace them with
new ones
from the mating surfaces
•
Never reuse a circlip
than required to slip the circlip over the shaft
completely seated in its groove and securely fitted
•
Use a torque wrench to tighten fasteners to the specified torque
thread is smeared with them
•
After reassembling, check parts for tightness and proper operation
. Also, before installing these new parts, be sure to remove any left over material
.
.
. When installing a new circlip, take care not to expand the end gap larger
.
.
.
. After installing a circlip, always ensure that it is
.
.
. Lubricate them when specified
.
.
. Wipe off grease and oil if a
.
.
.
.
0 I
0
•
To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and
other fluids
•
To protect Earth's natural resources, properly dispose of used motorcycle and parts
0
: batteries and tires
.
.
Page 13
1
-4 GENERAL INFORMATION
SUZUKI SV1000SK3 ('03-MODEL)
4
41
RIGHT SIDE
Difference between illustrations and actual motorcycles depends on the markets
.
LEFT SIDE
SERIAL NUMBER LOCATION
The frame serial number or V.I.N
steering head pipe. The engine serial number2is located on the right side of the crankcase
bers are required especially for registering the machine and ordering spare parts
. (Vehicle Identification Number)
1O is stamped on the right side of the
. These num-
.
01
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION
FUEL (FOR USA AND CANADA)
Use only unleaded gasoline of at least 87 pump octane (R/2 + M/2) or 91
research method
Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol,
with appropriate cosolvents and corrosion inhibitor is permissible
.
.
FUEL (FOR OTHER COUNTRIES)
Gasoline used should be graded 91 octane (Research Method) or higher
mended
.
octane or higher rated by the
or less than 5% methanol
.
Unleaded gasoline is recom-
ko
Page 14
GENERAL INFORMATION 1-5
ENGINE OIL
SUZUKI
MOTOR OIL or an oil which is rated SF or SG under the API
(American Petroleum Institute) service classification
ommended viscosity is SAE 1 OW-40
available, select an altematice according to the right chart
recommends the use of SUZUKI PERFORMANCE 4
. The rec-
. If an SAE 1 OW-40 oil is not
.
MUITIGRADE
°C
TEMP
-30 -20
.
0
°F
-22 -4
20W-50
15W-40, 15W 50
1OW 40
. 10W 50
10W 30
-10 0 10 20 30
11+1t+I1
14 32 50 68 86
104
40
BRAKE FLUID
Specification and classification
A WARNING
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, 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 containers
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period
.
: DOT 4
.
.
FRONT FORK OIL
Use fork oil L01 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
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
an equivalent which is compatible with an aluminum radiator
.
. Therefore, the engine
. If this is not available, use
LIQUID AMOUNT OF WATER/ENGINE COOLANT
Solution capacity (total)
For engine coolant mixture information, refer to cooling system section, page 5-3
: 2 200 ml (2
.3/1
.9 US/Imp qt)
.
CAUTION
Mixing of anti-freeze/engine coolant should be limited to 60%
its efficiency
mance is greatly reduced
ture does not go down to the freezing point
. If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting perfor-
. Be sure to mix it above 50% even though the atmospheric tempera-
.
. Mixing beyond it would reduce
Page 15
1-6
GENERAL INFORMATION
BREAK-IN PROCEDURES
6
4
$6
41
1
6
During manufacture 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
exercised during its early life
•
Keep to these break-in engine speed limits
Initial
Up to 1 600 km (1 000 miles)
Over
•
Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throt-
tle operation
800 km(500 miles)
1 600 km (1 000 miles)
. The future performance and reliability of the engine depends on the care and restraint