Suzuki SV1000 2003-2005 Service Manual 8 Servicing Information

CONTENTS

SERVICING INFORMATION

8- 1

TROUBLESHOOTING~~

Fl 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 REGULATOR/RECTIFIRE INSTALLATION 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

SPECIAL TOOLS

TIGHTENING TORQUE

ENGINE Fl SYSTEM PARTS CHASSIS

TIGHTENING TORQUE CHART

SERVICE DATA

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8- 2

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.8- 2

8- 4 8- 9 8-10 8-11 8-12 8-13 8-14 8-14 8-16 8-17 8-18

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8-19 8-20 8-21 8-22 8-23 8-24 8-25

8-26 8-27

8-28 8-29

8-29

8-30 8-34

8-34 8-35 8-36 8-37 8-38

8

8-2SERVICING INFORMATION

TROUBLESHOOTING

FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION

MALFUNCTION

CODE

COO

C11

C12

C13

C14

C15

C21

C22

C23

C24 or C25

DETECTED ITEM

NO FAULT

Camshaft position sensor

Crankshaft position

sensor

Intake air pressure

sensor

Throttle position sensor

Engine coolant temperature sensor

Intake air temperature

sensor

Atmospheric pressure sensor

Tip over sensor

Ignition signal

The signal does not reach ECM for more than 3 sec receiving the starter signal

The camshaft position sensor wiring and mechanical parts (Camshaft position sensor, intake cam pin, wiring/coupler connection)

The signal does not reach ECM for more than 2 sec

receiving the starter signal

The crankshaft position sensor wiring and mechanical parts

(Crankshaft position sensor, wiring/coupler connection)

The sensor should produce following voltage

(0

Without the above range, C13 is indicated

Intake air pressure sensor, wiring/coupler connection

The sensor should produce following voltage

(0

Without the above range, C14 is indicated Throttle position sensor, wiring/coupler connection The sensor voltage should be the following

(0

Without the above range, C15 is indicated

Engine coolant temperature sensor, wiring/coupler connection

The sensor voltage should be the following (0

Without the above range, C21 is indicated Intake air temperature sensor, wiring/coupler connection

The sensor voltage should be the following (0 Without the above range, C22 is indicated

Atm

The sensor voltage should be the following for more than 2 sec

after ignition switch turns ON (0

Without the above value, C23 is indicated Tip over sensor, wiring/coupler connection Crankshaft position sensor signal is produced and ECM deter-

mines the ignition signal but signal from ignition coil is interrupted continuous by 4 times or more

C24 or C25 is indicated

Ignition coil, wiring/coupler connection, power supply from the

battery

DETECTED FAILURE CONDITION

CHECK FOR

. after

.

. after

.

.50 V < sensor voltage < 4

.20 V < sensor voltage < 4

.15 V <_ sensor voltage < 4

.15 V < sensor voltage < 4

.50 V < sensor voltage < 4

. pressure sensor, wiring/coupler connection

.20 V < sensor voltage < 4

.85 V)

.

.80 V)

.

.5 V)

.

.5 V)

.

.5 V)

.

.80 V)

.

. In this case, the code

.

SERVICING INFORMATION 8

.3

C28

C29

C31

C32 or C33

C41

C42

C44

C49

Secondary throttle valve actuator

cated STVA lead wire/coupler, STVA

Secondary throttle valve position sensor

The sensor should produce following voltage (0

Without the above range, C29 is indicated Secondary throttle position sensor, wiring/coupler connection

Gear position signal

Gear position signal voltage should be higher than the following for more than 2 seconds (Gear position switch voltage >_ 0

Without the above value, C31 is indicated Gear position sensor, wiring/coupler connection, gearshift cam,

etc

Fuel injector

Crankshaft position sensor signal is produced and ECM determines the injection signal but fuel injection signal is interrupted continuous by 4 times or more C33 is indicated

Injector, wiring/coupler connection, power supply to the injector

Fuel pump relay

No voltage is applied to fuel pump although fuel pump relay is

turned ON, or voltage is applied to fuel pump although fuel

pump relay is turned OFF Fuel pump relay, connecting lead, power source to fuel pump

relay

Ignition switch

Ignition switch signal is not input in the ECM Ignition switch, lead wire/coupler

Heated oxygen sensor (HO2S) [For E-02, 19]

During 02 feedback control, 02 sensor voltage is higher or lower than the specification No signal is detected during engine operation or no electrical

power is supplied from the battery

HO2S lead wire/coupler connection

Battery voltage supply to the HO2S

PAIR control solenoid

valve (PAIR valve)

When no operating voltage is supplied from the ECM, C49 is indicated

PAIR

No operating voltage is supplied from the ECM, C28 is indi-

. STVA can not operate

.

.10 V < sensor voltage < 4

.90 V)

.

.6 V)

.

. In this case, the code C32 or

.

. PAIR valve can not operate

valve

lead wire/coupler

.

8-4SERVICING INFORMATION

ENGINE

Complaint

Engine will not start

or is hard to start

Engine idles poorly.1

.

Symptom and possible causes

Compression too low

1

. Tappet clearance out of adjustment

2

. Worn valve guides or poor seating of valves

3

. Mistimed valves

4

. Excessively worn piston rings

5

. Worn-down cylinder bores

6

. Starter motor cranks too slowly

7

. Poor seating of spark plugs

Plugs not sparking

1

. Fouled spark plugs

2

. Wet spark plugs . Defective ignition coil or camshaft position sensor

3 4

. Open or short in high-tension cords . Defective crankshaft position sensor

5 6

. Defective ECM

7

. Open-circuited wiring connections

No fuel reaching the intake manifold

1

. Clogged fuel filter or fuel hose

2

. Defective fuel pump . Defective fuel pressure regulator

3 4

. Defective fuel injector . Defective fuel pump relay

5 6

. Defective ECM

7

. Open-circuited wiring connection

Incorrect fuel/air mixture

1

. Throttle position sensor out of adjustment

2

. Defective fuel pump

3

. Defective fuel pressure regulator

4 . Defective throttle position sensor 5

. Defective crankshaft position sensor

6

. Defective intake air pressure sensor

7

. Defective atmospheric pressure sensor

8

. Defective ECM . Defective engine coolant temp

9

10

. Defective intake air temp

. Tappet clearance out of adjustment

2

. Poor seating of valves

3

. Defective valve guides

4

. Worn down camshaft

5

. Too wide spark plug gaps . Defective ignition coil

6 7

. Defective crankshaft position sensor . Defective ECM

8 9 . Defective throttle position sensor

10

. Defective fuel pump

11

. Imbalanced throttle valve

12

. Damaged or cracked vacuum hose

. sensor

Adjust

Repair or replace

Adjust

Replace Replace

See electrical section

Retighten

Clean or replace Clean and dry

Replace Replace

Repair or replace

Clean or replace Replace Replace

Replace Replace

Replace Check and repair

Adjust Replace Replace

Replace Replace

Replace

Adjust

Replace or repair Replace

Replace

Adjust or replace

Replace Replace

Replace

Adjust

Replace

Remedy

.

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SERVICING INFORMATION

8-5

Complaint Symptom and possible causes

Engine stalls often.Incorrect fuel/air mixture

1

. Defective intake air pressure sensor or circuit

2

. Clogged fuel filter

3

. Defective fuel pump

4

. Defective fuel pressure regulator

5

. Damaged or cracked vacuum hose

6

. Defective engine coolant temp

7

. Defective thermostat

8

. Defective intake air temp . sensor

Fuel injector improperly operating

1

. Defective fuel injector

2

. No injection signal from ECM

3

. Open or short circuited wiring connection

4

. Defective battery or low battery voltage

Control circuit or sensor improperly operating

1

. Defective ECM

2

. Defective fuel pressure regulator

3

. Defective throttle position sensor

4

. Defective intake air temp . sensor

5

. Defective camshaft position sensor

6

. Defective crankshaft position sensor

7

. Defective engine coolant temp

8

. Defective fuel pump relay

Engine internal parts improperly operating

1

. Fouled spark plugs

2

. Defective crankshaft position sensor or ECM

3

. Clogged fuel hose

4

. Tappet clearance out of adjustment

. sensor

Remedy

Repair or replace

Clean or replace

Replace Replace

Replace Repair or replace Repair or replace

Replace or recharge

Replace

Replace Replace Replace

Replace Replace

Clean Replace

Clean Adjust

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8-6SERVICING INFORMATION

Complaint

Noisy engine

Noise seems to come from transmission

Noise seems to come from water pump

Engine runs poorly in high speed range

Defective engine internal/electrical parts

.

10

11 12

13

Symptom and possible causes

Excessive valve chatter

1

. Too large tappet clearance

2

. Weakened or broken valve springs

3

. Worn tappet or cam surface

4

. Worn and burnt camshaft journal

Noise seems to come from piston

1

. Worn down pistons or cylinders

2

. Combustion chambers fouled with carbon

3

. Worn piston pins or piston pin bore

4

. Worn piston rings or ring grooves

Noise seems to come from timing chain

1

. Stretched chain

2

. Worn sprockets

3

. Tension adjuster not working

Noise seems to come from clutch

1

. Worn splines of countershaft or hub

2

. Worn teeth of clutch plates

3 . Distorted clutch plates, driven and drive 4

. Worn clutch release bearing

. Weakened clutch dampers

5

Noise seems to come from crankshaft

1

. Rattling bearings due to wear

2

. Worn and burnt big-end bearings . Worn and burnt journal bearings

3 4

. Too large thrust clearance

1

. Worn or rubbing gears

2

. Worn splines

3

. Worn or rubbing primary gears

4

. Worn bearings

1

. Too much play on pump shaft bearing

2

. Worn or damaged impeller shaft

3

. Worn or damaged mechanical seal

4

. Contact between pump case and impeller

1

. Weakened valve springs

2

. Worn camshafts

3

. Valve timing out of adjustment

4

. Too narrow spark plug gaps

5

. Ignition not advanced sufficiently due to poorly working

timing advance circuit

6

. Defective ignition coil

7

. Defective crankshaft position sensor

8

. Defective ECM

9

. Clogged air cleaner element

. Clogged fuel hose, resulting in inadequate fuel supply

to injector . Defective fuel pump . Defective throttle position sensor

. Defective secondary throttle position sensor or its actu-

ato r

Adjust

.

Replace Replace

Replace

Replace Clean

Replace Replace

Replace Replace Repair or replace

Replace Replace

Replace Replace Replace the primary driven

gear

Replace Replace

Replace Replace thrust bearing

Replace Replace

Adjust

Replace ECM

Replace Replace

Replace

Clean or replace Clean and prime

Replace Replace

Replace

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Remedy

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SERVICING INFORMATION 8-7

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Complaint

Engine runs poorly in high speed range

Engine lacks power

Defective air flow system

.

Symptom and possible causes

1

. Clogged air cleaner element . Defective throttle valve

2 3

. Defective secondary throttle valve

. Sucking air from throttle body joint

4 5

. Defective ECM . Imbalanced throttle valve synchronization

6

Defective control circuit or sensor

. Low fuel pressure

1 2 . Defective throttle position sensor

. Defective intake air temp

3 4

. Defective camshaft position sensor

5

. Defective crankshaft position sensor . Defective gear position switch

6 7

. Defective intake air pressure sensor . Defective atmospheric pressure sensor

8 9

. Defective ECM

10

. Throttle position sensor out of adjustment

11

. Defective secondary throttle position sensor and/or

secondary throttle valve actuator

Defective engine internal/electrical parts

. Loss of tappet clearance

1 2

. Weakened valve springs . Valve timing out of adjustment

3 4

. Worn piston rings or cylinders . Poor seating of valves

5 6

. Fouled spark plug

7

. Incorrect spark plug

8

. Clogged injector . Throttle position sensor out of adjustment

9

. Clogged air cleaner element

10 11

. Imbalanced throttle valve synchronization

12

. Sucking air from throttle valve or vacuum hose . Too much engine oil

13 14

. Defective fuel pump or ECM . Defective crankshaft position sensor and ignition coil

15

Defective control circuit or sensor

. Low fuel pressure

1

2

. Defective throttle position sensor . Defective intake air temp

3 4

. Defective camshaft position sensor . Defective crankshaft position sensor

5 6

. Defective gear position switch

7

. Defective intake air pressure sensor . Defective atmospheric pressure sensor

8

. Defective ECM

9

. Imbalanced throttle valve synchronization

10

. Throttle position sensor out of adjustment

11

. Defective secondary throttle position sensor and/or

12

secondary throttle valve actuator

. sensor

Clean or replace Adjust or replace

Adjust or replace Repair or replace

Replace Adjust

.

Repair or replace Replace

Replace Replace

Replace Adjust

.

Replace

Adjust

.

Replace

Adjust

.

Replace Repair Clean or replace

Adjust or replace Clean or replace

Adjust

.

Clean or replace Adjust

.

Retighten or replace Drain out excess oil Replace

Replace

Repair or replace Replace

Replace Replace

Replace

Adjust Adjust

Replace

Remedy

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SERVICING INFORMATION

8

-8

Complaint

Engine overheats

Dirty or heavy exhaust smoke

Slipping clutch

Dragging clutch

Transmission will not shift

.

Transmission will not shift back

Transmission jumps out of gear

.

Defective engine internal parts

Lean fuel/air mixture

The other factors

Symptom and possible causes

1

. Heavy carbon deposit on piston crowns . Not enough oil in the engine

2 3

. Defective oil pump or clogged oil circuit . Sucking air from intake pipes

4 5

. Use of incorrect engine oil . Defective cooling system

6

. Short-circuited intake air pressure sensor/lead wire

1

2

. Short-circuited intake air temp . Sucking air from intake pipe joint

3 4

. Defective fuel injector

5

. Defective engine coolant temp

. Ignition timing too advanced due to defective timing

1

advance system (engine coolant temp position switch, crankshaft position sensor and ECM)

2

. Drive chain too tight

1

. Too much engine oil in the engine

2

. Worn piston rings or cylinders

3

. Worn valve guides . Scored or scuffed cylinder walls

4

. Worn valves stems

5 6

. Defective stem seal

7

. Worn oil ring side rails

1

. Weakened clutch springs . Worn or distorted pressure plate

2 3

. Distorted clutch plates or clutch plate

1

. Some clutch spring weakened while others are not

2

. Distorted pressure plate or clutch plate

1

. Broken gearshift cam . Distorted gearshift forks

2 3

. Worn gearshift pawl . Broken return spring on shift shaft

1

. Rubbing or sticky shift shaft

2 3

. Distorted or worn gearshift forks . Worn shifting gears on driveshaft or countershaft

1

2

. Distorted or worn gearshift forks . Weakened stopper spring on gearshift stopper

3

. sensor/lead wire

. sensor

. sensor, gear

Clean Add oil

Replace or clean Retighten or replace

Change See radiator section

Repair or replace Repair or replace

Repair or replace Replace

Replace

Adjust Check with the inspection window

.

Drain excess oil

Replace Replace Replace

Replace Replace

Replace Replace Replace

Replace Repair or replace

Replace Replace Replace

Replace

Remedy

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SERVICING INFORMATION

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RADIATOR (COOLING SYSTEM)

Complaint Complaint

Engine overheats

Engine

Engine overcools

Engine

Symptom and possible causes

.

1

. Not enough engine coolant

2

. Radiator core clogged with dirt or scale

. Radiator

2 3

. Faulty cooling fan

3

. .

4

. Defective cooling fan 5 . Clogged water passage

5

. . Air cooling circuit

6

. Air trapped in the cooling circuit

6

. Defective water pump

7

.

8

. Use of incorrect engine coolant

8

.

9

. Defective thermostat

9

. .

1.Defective cooling . Extremely cold weather

2 3

. Defective thermostat

cooling

Defective

clogged with dirt or scale

passage

engine coolant

cooling fan thermo-switch

possible causes

coolant

fan thermo-switch

RemedyRemedy

Add engine coolant

Add engine coolant Clean

.

Clean

.

Repair or replace Replace

Clean

Bleed air

Bleed air Replace

Replace

Replace Replace

Replace Put on radiator cover

Replace

.

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8 .9

8-10

SERVICING

CHASSIS

INFORMATION

Complaint

Heavy steering

Wobbly handlebars

Wobbly front wheel1. Distorted wheel rim

Front suspension too

soft

Front suspension too stiff

Noisy front suspension

Wobbly rear wheel

Rear suspension too

soft

Rear suspension too

stiff

Noisy rear suspension

1

. Overtightened steering stem nut . Broken bearing in steering stem

2 3

. Distorted steering stem

4

. Not enough pressure in tires

1

. Loss of balance between right and left front forks

2

. Distorted front fork

3

. Distorted front axle or crooked tire

4

. Loose steering stem nut . Worn or incorrect tire or wrong tire pressure

5 6

. Worn bearing/race in steering stem

2

. Worn front wheel bearings

3

. Defective or incorrect tire

4

. Loose axle or axle pinch bolt

5

. Incorrect front fork oil level

1

. Weakened springs

2

. Not enough fork oil

3

. Wrong viscous fork oil

4

. Improperly set front fork spring adjuster . Improperly set front fork damping force adjuster

5 1

. Too viscous fork oil

2

. Too much fork oil

3

. Improperly set front fork spring adjuster

4

. Improperly set front fork damping force adjuster

5

. Bent front axle

1

. Not enough fork oil

2

. Loose bolts on suspension

1

. Distorted wheel rim

2

. Worn rear wheel bearing or swingarm bearings

3

. Defective or incorrect tire

4

. Worn swingarm and rear suspensions

5

. Loose nuts or bolts on rear suspensions

1

. Weakened spring of shock absorber

2

. Leakage of oil from shock absorber

3

. Improperly set rear spring unit adjuster

4

. Improperly set damping force adjuster

1

. Bent shock absorber shaft

2

. Bent swingarm pivot shaft

3

. Worn swingarm and suspension bearings

4

. Improperly set rear suspension adjuster . Improperly set damping force adjuster

5

1

. Loose nuts or bolts on rear suspension

2

. Worn swingarm and suspension bearings

Symptom and possible causes

Remedy

Adjust

.

Replace Replace

Adjust Replace

Repair or replace Replace

Adjust Adjust or replace Replace Replace Replace

Replace Retighten

Adjust Replace

Replenish Replace

Adjust Adjust

Replace Drain excess oil

Adjust Adjust Replace Replenish Retighten

Replace Replace

Retighten Replace

Replace

Adjust Adjust

Replace Replace Replace

Adjust Adjust

Retighten Replace

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Complaint

Insufficient brake power

Brake squeaking

Excessive brake lever stroke

Leakage of brake

fluid

Brake drags

SERVICING INFORMATION

Symptom and possible causes

1

. Leakage of brake fluid from hydraulic system

2

. Worn pads

3

. Oil adhesion on friction surface of pads/shoe

4

. Worn disc . Air in hydraulic system

5 6

. Not enough brake fluid in the reservoir

1

. Carbon adhesion on pad surface

2

. Tilted pad

3

. Damaged wheel bearing

4

. Loose front-wheel axle or rear-wheel axle

5

. Worn pads or disc

6 . Foreign material in brake fluid

7

. Clogged return port of master cylinder

1

. Air in hydraulic system

2

. Insufficient brake fluid

. Improper quality of brake fluid

3 1

. Insufficient tightening of connection joints

2

. Cracked hose

3

. Worn piston and/or cup

1

. Rusty part

2

. Insufficient brake lever or brake pedal pivot lubrication

Repair or replace Replace

Clean disc and pads

Replace Bleed air Replenish

Repair surface with sandpaper

Correct pad fitting or replace

Replace

Tighten to specified torque

Replace Replace brake fluid

Disassemble and clean master

cylinder

Bleed air Replenish fluid to specified

level

Replace with correct fluid

Tighten to specified torque

Replace Replace piston and/or cup

Clean and lubricate Lubricate

Remedy

.

; bleed air

.

8-11

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8

-12 SERVICING

INFORMATION

ELECTRICAL

Complaint Symptom and possible causes

1

No sparking or poor sparking

Spark plugs soon become fouled with

carbon

Spark plugs become

fouled too soon

Spark plug electrodes overheat or burn

Generator does not charge

Generator does charge, but charging

rate is below the specification

Generator overcharges

Unstable charging

Starter button is not effective

.

. Defective ignition coil or camshaft position sensor

2

. Defective spark plugs . Defective crankshaft position sensor

3 4

. Defective ECM . Defective tip over sensor

5 6

. Open-circuited wiring connections

1

. Mixture too rich

2

. Idling speed set too high

. Incorrect gasoline

3

4

. Dirty air cleaner element

5

. Too cold spark plugs

1

. Worn piston rings

2

. Worn piston or cylinders

3

. Excessive clearance of valve stems in valve guides

4

. Worn stem oil seal

1

. Too hot spark plugs

2

. Loose spark plugs

3

. Too lean mixture

1

. Open- or short-circuited lead wires, or loose lead con-

nection

2

. Short-circuited, grounded or open generator coils . Short-circuited or punctured regulator/rectifiers

3

. Lead wires tend to get short- or open-circuited or

1

loosely connected at terminals

. Grounded or open-circuited stator coils or generator

2 3

. Defective regulator/rectifier

4

. Defective cell plates in the battery

1

. Internal short-circuit in the battery

2

. Damaged or defective resistor element in the regulator/

rectifier

3

. Poorly grounded regulator/rectifier

. Lead wire insulation frayed due to vibration, resulting in

1

intermittent short-circuiting

2 . Internally short-circuited generator 3

. Defective regulator/rectifier

1

. Run down battery

2

. Defective switch contacts . Brushes not seating properly on starter motor commu-

3

tator

4

. Defective starter relay/starter interlock switch

5

. Defective main fuse

\\

Remedy

Replace Replace

Replace Check and repair

Consult FI system Adjust fast idle or throttle stop

screw

Change Clean or replace

Replace with hot type plugs Replace

Replace Replace

Replace Replace with cold type plugs

Retighten Consult FI system

Repair or replace or retighten

Replace Replace

Repair or retighten

Replace Replace

Replace the battery Replace the battery

Replace

Clean and tighten ground connection

Repair or replace

Replace Replace

Repair or replace Replace

Repair or replace

.

Replace Replace

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BATTERY

Complaint

1

"Sulfation", acidic

white powdery substance or spots on

surfaces of cell plates Battery runs down

quickly

Battery "sulfation"1. Incorrect charging rate

.

. Cracked battery case . Battery has been left in a run-down condition for a long

2

time

1

. Trouble in charging system

2

. Cell plates have lost much of their active material as a

result of overcharging

. Internal short-circuit in the battery

3 4

. Too low battery voltage

. Too old battery

5

(When not in use battery should be checked at least once a month to avoid sulfation

. The battery was left unused in a cold climate for too

2

long

Symptom and possible causes

.

.)

SERVICING INFORMATION 8-12

Remedy

Replace the battery Replace the battery

Check the generator, regulator/ rectifier and circuit connections

and make necessary adjustments to obtain specified

charging operation

Replace the battery, and correct the charging system

Replace the battery Recharge the battery fully

Replace the battery Replace the battery

Replace the battery if badly

sulfated

.

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8-14

SERVICING INFORMATION

WIRE HARNESS, CABLE AND HOSE ROUTING

WIRE HARNESS ROUTING

Set the coupler to the

Ignition coil

Set the speed sensor coupler under the clutch hose

center of the frame

.

Handle switch (L)

/ Clutch hose

Cable guide

Clamp

Set "A" mark to

the exhaust side

.

Clamp

H02 sensor (For E-02, 19)