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Suzuki DL1000 Service Manual

Suzuki DL1000
444 pages
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DL1000

Table of Contents

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Suzuki DL1000 Specifications

General IconGeneral
Displacement996cc
Compression Ratio11.3:1
Final DriveChain
StarterElectric
Bore x Stroke98.0mm x 66.0mm
Transmission6-speed
Rear SuspensionLink type, coil spring, oil damped
Front BrakesDual hydraulic disc
Rear BrakesSingle hydraulic disc
Fuel Tank Capacity22.0 L (5.8 US gal)
Ground Clearance165 mm (6.5 in)
IgnitionElectronic
Fuel SystemElectronic Fuel Injection

Summary

General Information

Safety Warnings and Precautions

Key safety information and precautions for servicing the motorcycle.

Fluid, Oil, and Coolant Recommendations

Details recommended fluids, oils, and coolants for the motorcycle.

Engine Oil Specifications

Recommended viscosity grade and API service classification for engine oil.

Brake Fluid Specification

Specifies the required brake fluid type (DOT 4) and handling precautions.

Engine Coolant and Mixing Ratio

Details engine coolant type, mixing ratio with distilled water, and handling.

Periodic Maintenance

Periodic Maintenance Schedule and Chart

Outlines recommended intervals for all periodic service work for peak performance.

Engine Oil and Oil Filter Replacement

Steps for replacing engine oil and the oil filter, including oil capacity.

Cooling System Maintenance

Procedures for checking engine coolant level and changing the coolant.

Brake System Maintenance

Maintenance for the brake system, including fluid checks, pad replacement, and caliper service.

Front Fork and Rear Suspension Maintenance

Procedures for inspecting and maintaining front fork and rear suspension components.

Engine Compression and Oil Pressure Checks

Diagnostic procedures for checking engine compression and oil pressure.

Engine

Engine Removal and Installation

Step-by-step guide for removing the engine from the frame and reinstalling it.

Engine Disassembly

Covers breaking down the engine into major sections.

Oil Filter and Pump Service

Procedures for servicing the oil filter, oil pump, and related components.

Clutch Assembly Service

Procedures for servicing the clutch assembly, including plates and bearing.

Crankcase Service

Procedures for separating the crankcase and removing crankshaft and shafts.

Engine Components Inspection and Servicing

Covers inspection of various engine parts for wear and damage.

Camshaft and Cylinder Head Inspection

Inspection of camshafts for wear, runout, and identification.

Piston and Cylinder Inspection

Inspection of cylinder bore, piston diameter, and piston ring clearances for wear.

Engine Reassembly

Step-by-step guide for reassembling the engine after disassembly.

Crankshaft and Drive Train Reassembly

Procedures for installing crankshaft, countershaft, and gearshift components.

Camshaft Installation and Timing

Procedures for installing camshafts and setting camshaft timing correctly.

Cylinder Head Installation

Steps for installing cylinder heads, including gasket and bolt torque specifications.

FI System

Precautions in Servicing FI System

Important precautions for safely servicing FI system components and connectors.

Electrical Circuit Inspection Procedures

General methods for inspecting electrical circuits for open and short circuits using testers.

Fuel Delivery System

Details the components and operation of the fuel delivery system.

Fuel Pump Service

Explains the construction and operation of the electric fuel pump.

Fuel Pressure Regulator and Injector

Describes the function of the fuel pressure regulator and fuel injector.

Sensors

Lists and describes various sensors used in the FI system.

Crankshaft Position Sensor (CKP)

Explains the CKP sensor's role in determining fuel and ignition timing.

Self-Diagnosis Function

Explains how to use the self-diagnosis feature.

Malfunction Codes and Defective Conditions

Table detailing malfunction codes, detected items, failure conditions, and check procedures.

Fail-Safe Function

Details the fail-safe modes for various sensor malfunctions and their effect on starting/running.

FI System Troubleshooting

Troubleshooting guide for common FI system issues.

Customer Complaint Analysis

Inspection form to record customer complaints for proper analysis and diagnosis.

Self-Diagnostic Procedures

Steps for performing self-diagnosis to identify malfunction codes and affected parts.

Specific Malfunction Troubleshooting

Detailed troubleshooting for specific malfunction codes.

C11 CMP Sensor Circuit Malfunction

Troubleshooting guide for camshaft position sensor circuit malfunctions, including inspection.

C12 CKP Sensor Circuit Malfunction

Troubleshooting guide for crankshaft position sensor circuit malfunctions, including inspection.

C24/C25 Ignition System Malfunction

Troubleshooting for ignition system malfunctions, referencing the Ignition System section.

Throttle Body and STV Actuator

Details the construction, removal, disassembly, and cleaning of the throttle body and STV actuator.

Fuel Injector Removal and Installation

Procedures for removing and installing the fuel injectors.

Cooling and Lubrication System

Engine Coolant

Information on engine coolant type, mixing ratio, and capacity requirements.

Cooling Circuit Inspection

Procedure for inspecting the cooling circuit for tightness and leaks using a pressure tester.

Radiator Service

Procedures for removing, inspecting, cleaning, and installing the radiator.

Water Pump Service

Procedures for removing, disassembling, inspecting, and reassembling the water pump.

Lubrication System Components

Information on lubrication system components including oil pressure, filter, and pump.

Chassis

Front Wheel Service

Procedures for front wheel removal, inspection, disassembly, and reassembly.

Front Fork Service

Comprehensive procedures for front fork removal, disassembly, inspection, and reassembly.

Steering and Handlebar Service

Procedures for servicing the steering system, including handlebar and stem adjustments.

Front Brake Service

Comprehensive procedures for front brake system maintenance and repair.

Rear Brake Service

Comprehensive procedures for rear brake system maintenance and repair.

Brake Pad Replacement

Step-by-step guide for replacing rear brake pads, including cleaning and assembly.

Brake Fluid Replacement

Procedure for replacing rear brake fluid and bleeding the brake system.

Clutch Fluid Replacement

Procedure for replacing clutch fluid and bleeding the clutch system to remove air.

Electrical System

Cautions in Servicing Electrical System

General safety precautions and procedures for servicing electrical components and connectors.

Charging System Troubleshooting

Troubleshooting guide for charging system problems like battery drain or low charging rate.

Starter System and Interlock System

Troubleshooting and inspection of the starter system and side-stand/ignition interlock system.

Ignition System Troubleshooting

Troubleshooting guide for ignition system issues causing no spark or poor spark.

Servicing Information

FI System Malfunction Code and Defective Condition

Table listing FI system malfunction codes, detected items, failure conditions, and check procedures.

Engine Troubleshooting

Troubleshooting guide for common engine performance issues like starting, idling, and power loss.

Brakes Troubleshooting

Troubleshooting guide for common brake issues like insufficient power, squeaking, and fluid leakage.

Electrical Troubleshooting

Troubleshooting guide for common electrical system issues like no spark, charging problems, and starter issues.

Tightening Torque

Table of torque specifications for various engine components.

Wiring Diagram

FI System Wiring Diagram

Comprehensive wiring diagram illustrating all electrical connections for the FI system.

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