Suzuki DL1000AL4 User manual

L4
December ’13 (TK) 21
99505-01134-01E
© COPYRIGHT SUZUKI MOTOR JAPAN
FOREWORD
This motorcycle has been designed and produced utilizing Suzuki’s most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this motorcycle.
Please read this manual and follow its instructions carefully. To emphasize special
information, the symbol and the words WARNING, CAUTION, NOTICE and
NOTE have special meanings. Pay particular attention to messages highlighted by
these signal words:

Indicates a potential hazard that could result in death or serious injury.

Indicates a potential hazard that could result in minor or moderate injury.
Indicates a potential hazard that could result in motorcycle or equipment
damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
This set-up manual is based on a motorcycle of standard specification. Some minor
differences from this manual may be found in other specifications.

1
PREPARATION
WORKSHOP
A: Packed vehicle
B: Working space
SELF PROTECTION
CAUTION
Assembling the vehicle in poor working condi-
tion can be hazardous.
Place the packed vehicle on a level floor where
it is clean and spacious.
CAUTION
Assembling the vehicle without proper clothes
and protective gear can be hazardous. You can
be injured if you do not wear proper clothes
and protective gear.
Be sure to wear proper clothes and shoes for
assembling and wear protective glasses, mask
or gloves as necessary.

2
UNCRATING THE MOTORCYCLE
Cut the strap by using scissors.
A: Strap
Remove the carton.
A: Crate
CAUTION
Metal crates may have sharp edges and may
cause injury.
Wear proper protective clothes and gear.

3
Remove the strap.
Take out the front wheel assembly from the crate base.
A: Strap
B: Front wheel assembly
Remove the strap.
Take out the various component parts packaged from
the crate base.
A: Strap
B: Component parts
Remove the bolts of the bracket.
A: Bolt

4
Remove the bolts from the crate.
A: Bolt
Lift the steel frame to separate it from the base of the
crate.
Carefully remove the various component parts pack-
aged around the motorcycle.
A: Steel frame
B: Crate base
CAUTION
Careless steel frame separation can injure a
person.
Lift the steel frame with two persons.
Wear proper protective clothes and gear.
NOTE:
Be careful not to damage the motorcycle when
separating the steel frame.

5
LOCATION OF PARTS
Check all the components which have been removed from the base of the crate.
Parts listed above are installed respectively into the positions as follows.
Item Part Name Q’ty Remarks
A
Windscreen 1
Stepped Allen screw 4 6 × 20 mm
Rubber cushion 4 OD:18.0 T:10.0
Rubber cap 4
B
Handlebars assembly 1
Clamp 2
Flange bolt 4 8 × 30 mm
Burring washer 4 OD:13.0 ID:8.5
Screw 1 5 × 45 mm
For right switch
Screw 2 5 × 25 mm
For left switch
Strap 2 L:140
CHolder 2 For master cylinder
Flange bolt 4 6 × 22 mm
D
Handlebar balancer
weight 2 Right and Left
Screw 2 6 × 105 mm
Flange rubber cushion 2 L:34.0
Spacer 2 L:50.0
Washer 2 OD:16.0 ID:6.5
T:1.6
Rubber cushion 2 L:15.0
Spacer nut 2 6 mm
E Rear view mirror 2 Right and Left
Item Part Name Q’ty Remarks
F1
Front fender 1
Stepped Allen screw 6 6 × 16 mm
Clip 1 For front brake
hose
F2
Front fender 1
Stepped Allen screw 4 6 × 16 mm
Reflex reflector assembly 2 Right and Left
Clip 1 For front brake
hose
G Front wheel assembly 1
HFront axle nut 1 24 mm
Front wheel spacer 1 Right
I Flange bolt 2
6 × 12 mm
For ABS sensor
assembly
J Case lock assembly 3
For side and rear
case
(Optional parts)
K Washer 2 OD:13.0 ID:6.5
LBattery electrolyte
container 1
M Owner’s manual set 1
N Warning label set 7 For
E-21 CC selection
O Warning label set 4 For
E-21 CD selection
NOTE:
• The parts shown as Item J in the above table are on the tray under the seat.
• The parts shown as Item F2, N and O in the above table are supplied for limited specifications.
• Use washers of Item K for mounting the license plate.
• Please hand over the parts shown as Item J and M in the above table to your customer together with motor-
cycle.
G F1,F2 A B E C D DC E
IH

6
The photograph shown indicates the parts dismounted
from the motorcycle in addition to the items shown in
the preceding page.
A: Front brake master cylinder
B: Throttle assembly
C: Clutch master cylinder
D: Left switch
E: Right switch
F: Front wheel ABS sensor assembly
G: Case lock assembly
A
A
A
BB
KK
EE
II
JJ
GG
CC
DD
F1
F1
F1
HH
N
N
OO
M
M
LL
F2
F2
F2

7
Before assembling the motorcycle, thoroughly
understand the “Safety Check Out” described on
page 52.
After completion of assembly, carefully check the
motorcycle referring to the “Safety Check Out”,
then deliver the motorcycle to the customer.
ASSEMBLY
LEFT RIGHT
REMOVING THE BRACKET
Remove the bolts to take off the front brake and clutch
master cylinder from the bracket.
A: Front brake master cylinder
B: Clutch master cylinder
C: Bolt
D: Bracket
Remove the bolts to take off the bracket from the han-
dlebar holder.
A: Bracket
B: Bolt
NOTE:
• Keep the position of front brake and clutch mas-
ter cylinder with its cap facing upwards until it is
installed.
• The bolts are not necessary to assemble the
motorcycle.
NOTE:
• Be careful not to damage the fuel tank.
• The bracket and bolts are not necessary to
assemble the motorcycle.

8
HANDLEBARS
Loosen the right switch retaining screws and throttle
housing retaining bolts.
Insert the right switch and throttle assembly onto the
handlebars.
A: Throttle assembly
B: Right switch
C: Handlebars
Install the handlebars assembly with the two clamps,
four bolts and washers.
A: Clamp
B: 8 × 30 mm flange bolt
C: Burring washer OD:13.0 mm ID:8.5 mm
D: Punch mark
E: Dot mark
Tighten the handlebar clamp bolts to the specified
torque.
Handlebar clamp bolt: 23 N·m (2.3 kgf-m)
A: 8 × 30 mm flange bolt
B: 8 × 30 mm flange bolt
NOTE:
• Install the burring washer in the direction as
shown in the illustration.
• Install each clamp with the punch mark facing
front.
• Align the dot mark on the handlebars with the
mating surface of the front side of left clamp.
NOTE:
• First tighten the bolt Aof the front side with
specified torque and then tighten the bolt Bof
the rear side.
• Make sure that the clamp has no clearance at the
front side.
FRONT

9
A: Front brake hose
B: Throttle cables
C: Right switch wiring harness
D: Clutch hose
E: Left switch wiring harness
THROTTLE
Install the throttle assembly with two Allen bolts.
A: Throttle assembly
B: Allen bolt
C: Dot mark
RIGHT SWITCH
Insert the boss of right switch housing into the hole on
the handlebars.
Install the right switch assembly with the two screws.
A: Boss
B: Hole
C: 5 × 45 mm screw
NOTE:
• The line drawings on page 47, 48, 49, 50 and 51
show the proper routing of the control cables,
hose and wirings.
• Refer to them in addition to following the instruc-
tions carefully.
NOTE:
Align the dot mark on the handlebars with the mat-
ing surface of the throttle housing.
WARNING
Improper throttle installing can interfere with
smooth throttle grip operation. It can result in
an accident.
Check to ensure that the throttle operates
freely and closes automatically.
NOTICE
Pinching the lead wires in the parts can short or
break circuit.
Check the lead wire routing when assembling
the switch.