Suzuki SV1000 2003-2005 Service Manual 1 General Information

• S V 10005

SERVICE MANUAL

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IMPORTANT

All street-legal Suzuki motorcycles with engine displacement of 50 cc or greater are subject to

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

PROGRAM MANUAUSERVICE BULLETIN.

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FOREWORD

This manual contains an introductory description on the SUZUKI SV1000S and procedures for its inspection/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 maintenance. 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 better 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 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 . 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 motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you .

A WARNING

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 may render the motorcycle unsafe for the rider and passenger .

SUZUKI MOTOR CORPORATION

GROUP /NDE

	GENERAL INFORMATION
	PERIODIC MAINTENANCE
	ENGINE
	FI SYSTEM	4
	COOLING AND LUBRICATION
	SYSTEM
	CHASSIS	E
	ELECTRICAL SYSTEM
	SERVICING INFORMATION
	EMISSION CONTROL
	INFORMATION
	WIRING DIAGRAM

© COPYRIGHT SUZUKI MOTOR CORPORATION 2003

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

1~ Brake disc

• Dust seal

(3 Bearing

• Center spacer

• Coller

• Front wheel

• Tire valve

• Front axle

• Brake disc bolt

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ITEM	N.m	kgf-m	lb-ft
CA)	100	10.0	72.5

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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	DEFINITION
		Torque control required .
		Data beside it indicates specified
		torque.
	0	Apply oil. Use engine oil unless other-
	r	wise specified.
		Apply molybdenum oil solution .
	0	(Mixture of engine oil and SUZUKI
		MOLY PASTE in a ratio of 1 : 1)
		Apply SUZUKI SUPER GREASE "A".
		99000-25030
		Apply SUZUKI MOLY PASTE .
		99000-25140
		Apply SUZUKI SILICONE GREASE .
	©	99000-25100
	1207B	Apply SUZUKI BOND "1207B" .
		99104-31 140
	V 1303	Apply THREAD LOCK SUPER "1303" .
		99000-32030

	1342	Apply THREAD LOCK "1342" .
		99000-32050
	1360	Apply THREAD LOCK SUPER "1360" .
		99000-32130

SYMBOL

LLC

FORK

BF

Lo a

~© a

Lo o

L o 0

j 1)) L o a

TOOL

DATA

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 .

Measure in diode test range .

Measure in continuity test range.

Use special tool.

Indication of service data .

ABDC		: After Bottom Dead Center
AC		: 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
B
C
CKP	Sensor	: Crankshaft Position Sensor
		(CKPS)
CKT		: Circuit
CLP	Switch	: Clutch Lever Position Switch
		(Clutch Switch)
CMP	Sensor	: Camshaft Position Sensor
		(CMPS)
CO		: Carbon Monoxide
CPU		: Central Processing Unit
D
DC		: Direct Current
DMC		: Dealer Mode Coupler
DOHC		: Double Over Head Camshaft
DRL		: Daytime Running Light

E

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)

F

FI	: Fuel Injection, Fuel Injector
FP	: Fuel Pump
FPR	: Fuel Pressure Regulator
FP Relay	: Fuel Pump Relay

G

GEN	: Generator
GND	: Ground
GP Switch	: Gear Position Switch
HC	: Hydrocarbons
IAP Sensor	: Intake Air Pressure Sensor (ZAPS)
IAT Sensor	: Intake Air Temperature Sensor
IG	(IATS)
	: Ignition
H
L
LCD	: Liquid Crystal Display
LED	: Light Emitting Diode
	(Malfunction Indicator Lamp)
LH	: Left Hand

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