Suzuki SV1000 2003-2005 Service Manual 1 General Information

Page 1
S V 10005
SERVICE MANUAL
I
1 99500-39250-03E 0
II II II II
Page 2
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
.
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
mechanics
able
to
properly
or
and
mechanics
equipment
perform
.
.
SUZUKI MOTOR CORPORATION
© COPYRIGHT SUZUKI MOTOR CORPORATION 2003
the
EMISSION CONTROL INFORMATION
WIRING DIAGRAM
Page 4
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
Page 5
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
.
0
r
0
©
DEFINITION
Torque control required
Data beside it indicates specified
.
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"
.
.
.
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
1
))
L
o a
TOOL
DATA
Measure in diode test range
Measure in continuity test range
Use special tool
Indication of service data
.
.
.
.
Page 6
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
(Clutch Switch) : Camshaft Position Sensor
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
:
Hydrocarbons
:
Intake Air Pressure Sensor (ZAPS)
: Ignition
:
Liquid Crystal Display
:
Light Emitting Diode (Malfunction Indicator Lamp)
:
Left Hand
of,
4 6
Page 7
0
O
M
MAL-Code
Max MIL
Min
N
NOx
Malfunction Code (Diagnostic Code)
Maximum Malfunction Indicator Lamp
(LED) Minimum
Nitrogen Oxides
s1
i
0
OHC OPS
P
PCV
R
RH ROM
S
SAE STC System
STP Sensor
ST Valve STV Actuator
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)
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 TERM ABBREVIATION
A Air
Cleaner B Barometric
Battery C
Camshaft Crankshaft
D Data
Diagnostic Test Diagnostic
E
Positive
Position
Link
Connector
Trouble
Pressure
Position
SAE TERM
FORMER SUZUKI TERM
1
Voltage
Mode
Code
ACL
BARO
B+
CMP CKP
DLC DTM
DTC
Air
Cleaner,
Barometric Pressure
Battery
Camshaft Crankshaft
Crank
Diagnostic
(APS,APSensor)
Voltage,
Position
Angle
Mode
Air
Cleaner Box
Pressure,
+B
Position
Code,
Sensor (CKPS),
Coupler
Malfunction
Atmospheric
Code
4
Electronic Engine
Evaporative Purge F
Fan Fuel
Fuel G
Generator
Ignition
Control
Coolant Coolant
Speed
Valve
Control
Level
Pump
Level
Temperature
Emission Emission
Canister
El ECM
ECL ECT
RPM EVAP
EVAP Purge
FC
FP
GEN
Canister
Valve
Coolant Coolant
perature Water
Purge
Fuel Fuel
Generator
Control
Control
Unit,
Level
Temperature,
Temperature
Speed (RPM)
(Canister)
Valve
Level
Sensor,
Pump
(FP)
Emission
(SP
Fuel
(ECM)
Control
Level
Unit
(ECU)
Coolant
Gauge
Tem-
1
GND
(GND,
GRD)
Page 9
FULL TERM ABBREVIATION
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 ROM ROM
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
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
.
.
. 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
Whenever you remove oil seals, gaskets, packing, 0-rings, locking washers, self-locking
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
.
octane or higher rated by the
or less than 5% methanol
.
Unleaded gasoline is recom-
ko
Page 14
GENERAL INFORMATION 1-5
ENGINE OIL
(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+I 1
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
$6
41
1
6
During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to "BREAK-IN" before subjecting the engine
to maximum stresses exercised during its early life
Keep to these break-in engine speed limits
Initial Up to 1 600 km (1 000 miles) Over
Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throt-
tle operation
800 km(500 miles)
1 600 km (1 000 miles)
. The future performance and reliability of the engine depends on the care and restraint
. The general rules are as follows
:
: Below 6 000 r/min : Below 9 000 r/min : Below 12 500 r/min
. However, do not exceed 12 500 r/min at any time
:
.
CYLINDER IDENTIFICATION
The two cylinders of this engine are identified as No viewed by the rider on the seat)
.
. 1 and No
. 2 cylinder, as counted from front to rear (as
l1
(a
Page 16
INFORMATION LABELS
GENERAL INFORMATION 1-7
V
dP
1O Noise label O2 Information label 03 Vacuum hose routing label
Fuel caution label
(4)
($ Manual caution label © Frame caution label O7 Warning screen label
® Warning steering label
Tire air pressure label
O
C0) Warning safety label
11 ICES Canada label
ID plate 13 E19 ID label 14 Safety plate
A
: Attached
SV1000S A For E-03, 24, 33 A For E-03, 28, 33
A For E-33 A For E-02, 24 A For E-03, 33
A
A For E-28 (LH, RH)
Other (RH)
A A A A
A For E-28
A For E-03, 28, 33
A For E-03, 28, 33
SV1000SD
A A
A
A A
A A
A A
SV1000SF
A
A
A
(7
French
Page 17
GENERAL INFORMATION
1- 8
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length Overall width
Overall height
Wheelbase
Ground clearance Seat height
Dry mass
ENGINE
Type
Number of cylinders Bore
 Displacement Compression ratio Fuel system Air cleaner Starter system Lubrication system Idle speed
2 130 mm (83
745 mm (29
1 170 mm (46 1 430 mm (56
150 mm(5 810 mm (31
189 kg (416 Ibs) 190 kg (418 Ibs)E-33
4-stroke, liquid-cooled, DOHC, 90° degree V-twin 2
.0 mm (3
98 66 .0 mm (2
996 cm3(60
11.3: 1 Fuel injection Non-woven fabric element Electric Wet sump 1 200 ± 100 r/min
.858 in)
.598 in)
.8 cu
. in)
t1
$4
l1
DRIVE TRAIN
 Transmission Gearshift pattern
Primary reduction ratio
Gear ratios, Low
Final reduction ratio Drive chain
2nd 3rd 4th 5th Top
  
Wet multi-plate type 6-speed constant mesh
1-down, 5-up 1
.838 (57/31)
2
.666 (32/12)
1
.933 (29/15)
1
.500 (27/18)
1
.227 (27/22)
1
.086 (25/23)
1
.000 (24/24)
2
.352 (40/17)
RK530 SMOZ1, 108 links
$
t
40
Page 18
CHASSIS
Front suspension Rear suspension Front suspension stroke
Rear wheel travel
Steering angle Turning radius
Front brake Rear brake
Front tire size Rear tire size
 
Telescopic, coil spring, oil damped
Link type, coil spring, oil damped 120 mm (4 129 mm (5
24
.5° 98 mm (3 30° (right & left) 3
.2 m (10 Disc brake, twin Disc brake 120/70 ZR17M/C (58W), tubeless 180/55 ZR1 7M/C (73W), tubeless
ELECTRICAL
Ignition type Ignition timing Spark plug Battery Generator Main fuse Fuse
 Headlight Position light License plate light
Turn signal light
Brake light/Taillight Speedometer/Tachometer light Fuel level indicator light
Turn signal indicator light
Neutral indicator light High beam indicator light Oil pressure/Coolant temperature/Fuel injection
warning light
Electronic ignition (Transistorized)
5° B
. T
. D
NGK
: CR8EK or DENSO
12 V 43 Three-phase A.C. Generator 30 A
15/15/10/15/15/10 A
12 V 60/55 W x 2
12 V 5 Wx2
12 V 5 W
12V21 W x 4
LED LED LED LED LED LED
LED
.2 kC (12 Ah)/10 HR
GENERAL INFORMATION 1-9
.72 in) .08 in)
.50 ft)
. C at 1 200 r/min
: U24ETR
0
.l
CAPACITIES
Fuel tank
Engine oil, oil change
Front fork oil (each leg) Coolant
These specifications are subject to change without notice
with filter change
overhaul
16 L (4 17 L (4
2 700 ml (2
2 900 ml (3 3 300 ml (3
2
.2/3
.5 US/Imp gal) .7 US/Imp gal)For the others
.5/3
.9/2 .1/2 .5/2
494 ml (16
.2 L (2
.3/1
.9 US/Imp qt)
.
.4 US/Imp qt) .6 US/Imp qt)
.9 US/Imp qt)
.39 US/Imp oz)
For E-33
Page 19
1-10 GENERAL INFORMATION
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s)
CODE
E-02 E-03 E-19 E-24 E-28 E-33
U
. K
U
. S . A
EU Australia Canada California (U
COUNTRY or AREA
.
. (Except for California)
. S . A
.)
.
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