Suzuki SV1000 2005 Service Manual
USETHE
SV1
OOOWSVIOQO
MANUAL
WITH:
SERVICE MANUAL
(99500-39251
-WE)
0
This
manual
fer
from
NOTE
*
Any
('05-model)
"
Please
manual
describes
those
of
the
differences
Sn
refer
to
.
sewice
SV7
between
specifications
the
SVlOOOK4/SK4
&fa.
OOOK4/SK4
FOREWORD
sewice
('04.model) .
the
and
service
specifications
SVIOOOK4JSK4
data
are
indicated
Senrice
Manual
for
and
sewicing
('04-model)
with
details
which
procedures
and
an
asterisk
a=
which
M-
SVIOOOKS/SK5
mark
(y
.
nof
given
in
this
G0UlVTRYANDARE.A
SPEC!F/CAfSONS(SVl000K5)
SPECIFICATIONS
SERVICE
SERVICE
CRANKCASE-CRA
Fi
SYSTEM
ECM
ECM
FAlLmSAFE
MALFUNCTION
FI
SYSTEM
FRONT
FUEL
WIRING
THROmLE
THROTTLE BODY
REAR
REAR
DATA
DATA
TERIMtNA
TERMINAL
FORK
LEVEL
HA
BRAKE
BRAKE HOSE ROUTIPJG
(SVlOOOK5)
(SVf
WRING
L
(Fur
{For
FUNCnON....
CODE AND DEFECTIVE
TROUBL
(For
INDECA
RNESS
CABLE
HOSE
CODES
(SVlOOOSK5)~m~mm~m~~m~m~m-~~-~~sm~m~mm~~mmmmmmm
...................
WSKS)
NKSHA
DIAGRAM
ESHOOJING
SVf
ROUTlNG
ROWSNG
IMSTALLAflOWOSE
FT
K4-Model)
KWodeF)
............................................................................
000SK5)
TOR
SWITCH
ROUTING
.......................................................................
...........................
.....................................................
,.
-
............
BEARING
.......................................................
SEL EG770
......................................................
..........,,...,.......,,........*..*......
r..l
hl
...............
...
.................
,
............
.......................................................................
..................
...,
................................................
CONDITION
..........
,
..,
.....
,.
..........
.....................................................................
......................................................................
INSPECTION
(For
SVIOOOK5)
(For
SVICWOK5)
(For
SV I OOOK5)
(For
SVIUOOSK5)
ROCrSING
~~.mm~mm.~.~m~pm~~~m~~m~sm~m~~mm~m~m~37
...............................a*..
........
............................................
.....
.............................
.............................................
........................................
2
3
5
7
16
=25
26
27
28
m......29
30
32
36
38
,.40
41
42
43
b
CT)PVRIEHT
9.1
171
1KI
hAMnB
t'r7OOnPA+fnhl
mn.4
StOZWKl
MOTOR
CORPORATION
COUNTRY
The
following
codes
AND
stand
AREA
for
the
applicable
CODES
country
(-ies)
and
area
(-s).
CODE
E-02
E-03
E-28
E-33
E-19
E-24
COUNTRY
USA.
California
U.K.
(Except
Canada
E.U.
Australia
or
AREA
-i
for
California)
(U.S.A.)
EFFECTIVE
SV1
OMSK5
SV1
OOOKS,SV1
SV1
WOK5
SV1000U2K5
SV1000SK5
SV?
000S2K5
SV1
OOOK5
SV1000SK5
FRAME
:
JS1
BX412200100001
000SK5
:
JSIVT54A
:
JS
18x431
:
JSIBX521100100001
:
JS1BX412100100001-
:
3S1BX612100100001
:
3ST
BX441300100001
:
JS1
BX442300100001
NO,
200
1
0000
52100001
1001
00001
1
-
-
-
-
-
-
-
-
&d
-
SPEClFlCATlONS
DM--
Overall
Overall
Overall
Wheelbase
Ground
Seat
height
Dry
mass
Type
....................
Number
Bare
.........................................................
Stroke
Displacement
Compression
Fuel system
Air
deaner
Starler
Lubricat~on
Idle
speed
Clutch
Transmis5im
Gearshift
Primary
Gear
ratim.
Final
raduetiwl
Dh
chafn
AND
OAY
length
.......................
....................................................................................
width
hergM
.....................................................................................
MASS
..
........................................................
........................................................................................
clearance
..........
...
..........................................................
.........................................................................................
...........................
of
eylindelg
.................................................................................................
..
..........................................................
..
........................................................................
...........................................................................
...................................................................................
ratio
............................
........................................................................................
..........................................................................................
system
...............................................................................
system
.....................
.................
..
...
.....................................................................
..............................................................................................
...................................................... ,.
panern
reductiwl
Low
.............................................................................
Top
ratio
................
.......................
ratlo
..............................................................................
...........................................................................
....
....
.....................................................................
..............................................................
(SVI
..
..
...........................................
000K5)
.................................
..............................................
..............................
..............................................
2
080
rnm
(81.9
785
mrn
1
080
mm
1
445
mrn
7
50
rnrn ( 5.9
800
mm
I87
kg
1
86
kg
4-stmk9,
2
Bg-Q
mm
66.0
mm
996
cma
17.6:
1
Fuel
Inledion
Nonwwen
Electric
sump
Wet
1
200
t
Wet
muttiplate
E-speedconslIlMmesh
1-dm,
1.w
(57131)
2.666
(3211
1.933
(29115)
I
,500
p7tia)
1.227
(27/22)
1.086
(25R3)
1.000
(24124)
2.352
(4011
RK50SMOZ1,
In)
(30.9
In)
(42.5
tn)
(56.9
in)
In)
(31.5
in)
(41 2 Ik)
(41
Llquld-woled,
(3.858
(2.598
(€0.8
100
5-UP
0
Ibs)
In)
in)
cu.
fMc
rhln
type
2)
7)
?i0
in)
demnt
.............................
...................
1mks
DOHC,
..
98"
E-33
.......
Olhers
degree
V-Mn
I(j
CtMssIS
Front suspension
Rear
suspsnsion
Front
suspension
Rear
wheel
Caster.
.............................
Trail
.....................................................................................................
Steering
Turning
radius
Front
brake
Rear
brake
Front
tire
Rear
tire
ELECTRICAL
. .
lgmbon
type
Ignition timing
Spark
plug
................................................................................................
Batte~
Generator
Main
fuss
Fuse ...................................................................................................
Headlight
Position light
License plate light
Turn signal light
Brake
lighnail tight
Speedometer light
TachwneTer
Fuel
level
Turn
signel indicator light
Neutral indicator
High
beam
Oil pressurelCoolant
............................................................................
.........................
stroke
travel
angle
....................................................................................
.............
..................................................................
..........................................................................
....................
..
...............................................
...
.............................................
....................................................
....
.........................................................................................
................................................................................
size
....................................................................................
size
...................
..
............................................................
........................................................................................
................................. .............................................
.......
..........................................................................................
.........................................................................................
......................
....
..............................................................
..........................................................................................
....................
..
...........................
...............................................................
..
...............................................
..................................................................................
...............
..............................................................................
lift
.................................................................................
indicator
light
light
indicator light
...
...................................................
......................................................................
...................................................................
..........................................................................
....................................................................
tempsraturalFuef
injalon
warning
IlgM
...........
Tebmpk,
Link type,
120
13U
.....
24.8"
107
32"
3.0
Disc
.....
Disc
120!7OZRi?MK:
180155ZR17MIC
ElechWric
5-
BeTD.C.
NGK
12 V 43.2
Three-phase
30
10/1011Wt5/1Q/15
12Ym%W
f2V5W
12V5W
12V21
LED
LED
LED
LED
LED
LED
LED
LED
A
mrl
rnm
(4.7
mrn
(5.
t
rnm
(4.2
/right
8.
m
(4.84
brake, Wln
brake
lgnltlon
at
CRBEK
kC
....................
W
mll
spring,
spring, oll
in)
in)
In)
left)
ft)
(WW),
(73W),
(TrarWstorlzed)
1
200
rlmin
or
DENSO
(t2Ah)HO
A.C.
gemmtor
A
dl
damped
dampd
tiheless
tubeless
U24m
HR
..
...............
L.
E-02,1$
CAPAClTlES
Fuel
tank
.........................................................................................
Englne
oil,
nil
change
w~th
Cmlant
These
overhaul
........................................................................................
ylecjhcatims
....................................................
f~lter
change
.............................................................
......................
are
subject
......
to
change
...
....................................
without
notice.
......
2
2
3
16
17
700
900
300
2.2
L
(4.2B.5
L
(4.513.7
rnl
(2.912.4
ml
(3.112.6
ml
(3
L
(2.Y1.4
USllmp
'USlrnp
512.9
Uslmp
USlrnp
USllmp
USllmp
gal)
..................
...................
gal)
qt)
qt)
qt)
qt)
E-33
Others
SPECIFICATIONS
DIME
NSlONS
Overalllength
Overall
Overall
Wheelbase
Ground
Seat
height
Dry
mass
ENGINE
Type
..................................................................................................
Number
Bore
..................................................................................................
Stroke
Dtsplacernent
Compression ratio
Fuel
system
Air cleaner
Starler
Lubrication system
Idle
sped
Clutch
Transmissian
Gearshift pattern
Primary
Gear
ratios.
Final
reduction
Drive
chain
AND
DRY
MASS
...................................................................................
widlh
....................................................................................
height
.....................................................................................
...................................................................................
clearance
............................................................................
.........................................................................................
............................................................................................
of
cylinders
.........................................................................
.................................................................................................
...................................................................................
..............................................................................
.....................................
........................
system
....................................................................................
..
...........................................................
..........................................................................
.....................
..
............................................................
................................................................................*............
.......................................................................................
...........................
reduction
ratio
Low
2nd
5th
Top.
....................
.......................................................................
...............................................................................
.......................
................................................................................
....................
ratio
............................................................................
..
..
..............................................................
(SVI
...
................................................
..
..............................................
......
..........................................
000SK5)
..................................................
2085rnm(82.1in)
745
mm
(293
1
170
mm
1
430
rnm
150
mm
800
tnm
'
187
kg
'
186
kg (410
Cstroke, Liquid-cooled,
2
W.Omm(3.858in)
660
mm
996
cm3
'
1
1.6
:
1
Fuel
Injection
Non-wwen fabric element
Electric
Wet
sump
I
200
+
Wet
multi-plate
6-sm
I
down,
1.838 (57131)
2.666
(3211
1.933
(29115)
1.500 (2711
1.227
(27122)
r
.oas
125123)
1.000
(24124)
2.352
(dOH
RKSOSMDZI
(46.1
(56.3
(
5.9
(31.5
(41
2
(2.598
(60.8
100
rSmln
constant
5-up
2)
8)
7)
,
In)
in)
in)
In)
in)
Ibs)
..................................
Ibs)
....................
In)
cu,
in)
type
rn~h
108
links
DOHC,
...
W
E-33
......
Others
degree
V-twin
CHASSIS
Front
suspensim
Rear
suspension
Frrm?
suspensim
Rear
wheel
Caster
.............
Trail
.....................................................................................................
Steering
Turning
radius
Front
brake
Rear
brake
Front tire
Rear
tlre
ELECTRICAL
Ignition
lyp
Ignition t~ming
Spark
plug
Battery
................................................................................................
Generalor
Main
fuse
Fuse
...................................................................................................
Headlight
Position light
License
Turn
signal
Brake I~ghbTail light
Speedometer llght
Tachometer
Fuel level indicator
Turn signal indicator light
Neutral
indicator
High
beam
Oil pressure1Coolant
................................................................................
................................................................................
stroke
travel
......
....................................................................................
angle
.....................................................................
................................................................................
.........................................................................
.....................................................................................
.........................................................................................
......................
size
..................................
......................................................................................
size
..
...............................................................
..,
.................................................
........................................................................................
...................................................................................
.........................................................................................
.........................................................................................
..........................................................................................
...........................................................................................
.......................................................................................
plate
ligM
...............................................................................
119111
..................................................................................
..........................................................................
..............................................................................
.................................................................................
light
light
......................................................................
....................................................................
light
ind~cator light
..........................................................................
....................................................................
temperaturelFuel
Inlection
warning
Ilght
...........
Telescopic,
Ltnk
1
15
130
24.5"
98
30"
3.2
Disc
DISC
120ffOZR171WC
180155ZR17MIC
Electronic
5"
NGK
12 V 43.2
Three-phase
30
15115HO/15/15/10
f2V60155Wx2(H4)
12Y5Wx2
12V5W
12Y21
LED
LED
LED
LED
LED
LED
LED
LED
cM1
type,
mm
mm
rnm
(righi
rn
(10.50
brake, twin
bake
B.T.D.C.
CR8EK
A
spring,
coil spring, or1
(4.5
In)
(5.1
in)
(3.9
in)
&
left)
ft)
(58W),
(73W),
ignition (Trans~storizad)
at
1
200
or
DENSO
kc
(1
2
Ah)/lO
A.C.
generam
A
W
rlrnin
01
damped
damped
tubel~ss
tubeless
U24ETR
HR
CAPmES
Fueltank
Eqine
Coolant
Them
............................................................................................
d,
al!
change
wrth
overhaul
.........................................................................
filter
change
..............................................................
.........................
..
................................................
..........................................................................................
sp&kths
am
srlbiect
to
change wilhout
natlce.
16L(4.2/3.5USnmpgal)
17
L
(4.93.7
2
2
3
300
900
300
2.2
rnl
rnl
rnt
L
(2.912.4
(3.1/2.6
(3.5/2.9
(2.3
1.9
USnrnpgal)
USllrnp
USllmp
INtmp
US/lmp
...................
..................
qt)
qt)
qt)
qt)
E-33
Oltiers
SERVICE
DATA
(SVI
000K5)
Ic,
VALVE
Valve
stem
Valve
stem
Valve
stem
+
GUIDE
0.0.
deflection
runout
IN.
EX,
IN.
8
EX.
IN. & EX.
5.475 - 5.490
(0.21
56
-
0.21
5.455
-
48
5.470
-
0.21
(0.21
-
61)
54)
Unit:
-
-
0.35
(0.01
mm
4)
(in)
b
Valve
head
thickness
Valve
head
radial
Valve
Valve
spring
spring
free
tension
CAMSHAFT
ITEM
Camshaft
Camshaft
Camshaft
journal
journal
journal
runout
length
+
CYLINDER
oil
clearance
holder
O.D.
I.D.
IN.
& EX.
IN. & EX.
IN.
&
EX.
IN.&EX.
HEAD
--
EX.
IN. & EX.
---
IN. & EX.
IN. 8 EX.
-
(0,035
(20.1-23.1kgf,44.3-51.0lbs)
at
length
STANDARD
*37.18-37.22
(0.0007
22.012
(0.8666 - 0.8671
21.972 - 21.993
(0.8650
-
0.043)
-
-
197-227
35.6
{I
.464
0.01 9 - 0.053
rnm
-
1
"465)
-
0.002 1 )
-
22.025
-
0.8659)
N
(1
-40
in)
-
0.5
(0.02)
0.03
(0.001)
41.2
(1
32)
-
Unit:
mm
LIMIT
36.88
(1.452)
0.1
50
(0.0059)
-
-
(in)
Camshaft
Cam
drive
clearance
Cylinder
head
ITEM
runowt
idle
gear/sprocket
distortion
thrust
IN.
&
EX.
STANDARD
-
0.1
5
-
0.29
-
1
LIMIT
0.10
(0.004)
0.05
(0.002)
CYLINDER
Compression
(Automatic
Compression
I
Piston
Piston
(Cylinder
Piston
Piston
Piston
de-comp.
to
cylinder
diarn.
distortion
ring
free
ring
end
ring
to
+
PISTON
lTEM
pressure
actuated)
pressure
end
gap
gm
difference
clearance
gap
clearance
+
PISTON
RING
(1
0.5
Measure
-
at
STANDARD
*
1
050
14.5
kgf/crn2,
97.980
(3.8575
10
rnm
Approx.
-
1
450
149
-
-
97.995
-
3.8581)
(0.4
in)
from
Approx.
kPa
8.8
1
0.1
-
206
the
(0.35)
(0.40)
psi)
skirt
end.
(8.5
(2
1
1
--
I
Unit:
mrn
LIMIT
'
850
kPa
kgf/cm2,
kgf/crn2,
Scratches
121
200
kPa
28 psi)
Nicks
or
97.880
(33535)
(in)
psi)
I
Piston
Piston
Piston pin
Piston
ring
ring
pin
grow
thickness
bare
O.D.
width
1.0.
Oil
2.51
10,0988
-2.53
-
0.09961
-
CONROD
Conrod
Conrod
Can
Crank
Conrod
Crank
Crankshaft
Crankshaft
Crankshaft
OIL
Oil
small
big
rod
big
pin
width
bis
end
-
pin
O.D.
journal
journal
runout
PUMP
pressure
+
CRANKSHAFT
end
I.D.
end side clearance
end
width
oil
clearance
oil
clearance
O.D.
ITEM
(at
60
"C,
140
OF)
Above
Below
22.01
0
-
22.018
(0.8665
(0.007
(0.864
(1.739
(0.001
44.976 - 45.000
11.771)7
\
*
-
(-
47.985
(1.8892
-
0.17-
-
21.95
-
-
44.1
7
-
-
6.040
-
6
-
-
"
-
0.004
0.0002
-
-
-
0.8668) (0.8677)
0.32
0.01
22.OQ
0.866)
44.22
1.741)
0.064
0:0625)
1
77171
...
-
0.023
0,0009)
48.000
1.8898)
-
STANDARD
350
kPa
(3.5
650
at
kPa
3
(6.5
000
kgflcm2,
kgf/cm2,
rlrnun
3)
.
-
"I
50
92
psi)
psi)
Unit:
mm
LIMIT
22.040
0.50
(0.020)
-
-
0.080
(0.0031
)
-
0.080
(0.0031)
-
0.05
(0.002)
LIMIT
-
Fin)
-
1
CLUTCH
Unit:
mm
tin)
THERMOSTAT
+
RADIATOR
+
FAN
+
COOLANT
r,
a
11
DalvE
Shift
fork
Drive
chain
Drive
chain
Gearshift
TRAIN
thickness
slack
lever
height
Type
Links
20-link
length
4.8 - 4.9
(0.1
89
1
20
(0.8
55
(2.2
-
0.193)
RKSOSMOZ1
10 links,
ENDLESS
-
-
30
-
1.2)
-
65
-
2.6)
-
-
-
31
9.4
(12.6)
-
-
'4
'A
I
.i
'u
INJECTOR
Injector
Fuel
Fuel
set
resistance
pump
pressure
pressure
discharge
+
FUEL
ITEM
amount
regulator
PUMP
-
operating
+
FUEL
I
for
PRESSURE
11
168
ml
70
Approx.
and
seconds
REGURATOR
SPECIFICATION
-13I1at20
more
at
300
300
kPa
"C
(5715.9
kPa
(3.0
(3.0
kgf/cm2,
(68OF)
USArnp
kgf/cm2,
43
oz)
43
psi)
psi)
THR0fT"LE
If
I.D.
No.
Bore
size
Fast idle rim
Idle
r/min
Throttle
in
cable
play
BODY
EM
*
16G4
1
900
1
200
SPECIFICATION
(For
E-33),
54
mrn
-
2
500
rlmin
A
10Q
r/rnin#armed
2.0
-
4.0
(0.08
-
0.1
16G3
at
25
mrn
6
in)
(Others)
"C
(77
T)
engine
ELECTRICAL
ITEM
Firing order
Spark
Spark performance
Crankshaft
tance
Ignition
Crankshaft
voltage
Ignition
Generator
Generator
Generator
(When
Regulated
Starter
1
plug
position
coil
resistance
position
coil
primary
coil
resistance
Max.
output
no-load
engine
relay resistance
is
cold)
voltage
sensor
sensor
peak
voltage
resis-
peak
voltage
TY
pe
Gap
I
prnary
1
Secondary
Approx.
45 V
Over
and
14.0
SPEC!
8
130
5.0
V
200
0.2
400
more
-
15.5
FlCATlON
1.2
NGK:
DENSO:
0.6
(0.024
(0.3)
at
-
240
2.8
-
24
-
and
more
V
and
more
-
0.7
S2
W
at
5
(AC)
at
V
at
5
3-6rR
CR8EK
V24ETR
-
0.7
-
0.028)
1
atm.
f2
4.2
il
36
kR
000
rlrnin
5
000
000
rlrnin
rlmin
Unit:
rnm
NOTE
BI-G
4
]
@tap-@tap
I+>
tap
Plug
cap
When
When
cranking
cranking
Y-Y
-
linl
,
I
I
Fuse
size
U
Capacity
/
Headlight
Fuel
Ignition
Turn
Fan
signal
motor
HI
LO
I
12
V
43.2
kC
(12
10
A
10
A
IOA
f
5
A
10
A
15
A
Ah)/lO
HR
I
I
I
II
b
WATTAGE
ITEM
Headlight
Position light (For
Brake
Turn signal light
Speedometerfrachometer light
Turn
High
Neutral indicator light
Fuel indicator light
Coolant
FI indicator l~ght
License
IightlTaillight
signal indicator light
beam
indicator light
temperaturelOil pressure/
light
E-02,
19)
HI
LO
SPECIFICAIION
60
55
5
LED
21
x4
LED
LED
LED
LED
LED
LED
5
Unit:
W
b
w
w
BRAKE
I
Rear
Brake
Brake
(Front & Rear)
Master cylinder bore
Master
Brake caliper cylinder
bore
Brake
diam.
Brake fluid
+
WHEEL
ITEM
brake
pedal height
disc
thickness
disc runout
cylinder piston
caliper
piston
type
diarn.
Leading
Trailing
Leading
Trailing
1
1
Front
Rear
Front
Rear
Front
Rear
Front
Rear
Front
Rear
I
1
STANDARD
5.0
rt:
0.2
(0.1
97
0.008)
-
15.870
(0.6248
15.827
10.6231
13.957
10.5495 - 0.55061
30.230
(1.1902
33.960
(1.3370
38.1 80
(1
30.1 67 - 30.200
(1.1876- 1.1890)
33.901 - 33.934
(1.3346
38.1
(1.5005
DOT
-
15.91
-
0.6265)
-
15.854
-
0.6242)
-
13.984
-
30.280
-
1.1921)
-
34.01
-
1.3389)
-
38.230
-5031 - 1.5051)
-
1.3360)
15
-38.148
-
1.501
4
3
0
9)
Unit:
LIMIT
-
4.5
(0.1 8)
0.30
(0.01
-
-
-
-
-
-
-
-
-
-
mrn
--
2)
(in)
SUSPENSION
m
Front
fork
stroke
Front
fork
Front
fork
(without
corn
Front
Front
Front fork
Front
Rear
length
Rear
force
Rear
Swingarm
spring,
p
ressed)
fork
fork
fork
shock
shock
adjuster
wheel
spring
oil
oil
oil
spring
damping
free
level
inner
type
capacity
adjuster
absorber
absorber
travel
pivot
shaft
length
tube
(each
force
adjuster
spring
damping
runout
fully
leg)
pre-set
SUZUKl
Rebound
FORK
COmPres-
sion
Rebound
Cornpres-
sion
I
STANDARD
(1
OIL
LO1
7.211
7th
1
508
7.9
groove
1
from
turn
turn
1
(1
314
from
120
(4.7)
305
2.0)
1
49
15-81
or
rnl
USllmp
from
and
stiffest
out
from
202
(8.0)
out
from
and
314
stiffest
1
30
(5.11
.I
-
an
equivalent
oz)
top
114
turns
position
stiffest
stiffest
turns
~osition
fork
out
position
position
out
oil
Unit:
LIMIT
-
298
(1
1.7)
-
-
-
-
-
-
-
-
-
-
0.3
10.01
mrn
1
(in)
I
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