Suzuki SV 1000S 2003 User manual

SERVICE MANUAL
I
II II II II
•

S V 10005
1 99500-39250-03E 0

IMPORTANT
All street-legal Suzuki motorcycles with engine
displacement of 50 cc or greater are subject to
Environmental Protection agency emission regulations .
These regulations set specific standards for exhaust
emission output levels as well as particular servicing
requirements . This manual includes specific information
required to properly inspect and service SV1000S in
accordance with all EPA regulations . It is strongly
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 .
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of

FOREWORD
This manual contains an introductory description
on
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 main-
tenance
. Use this section as well as other sections
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 .
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation
. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual motorcycle .
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures
. They may not represent the
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
.
may not be able to
properly perform the
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 .
SUZUKI MOTOR CORPORATION
© COPYRIGHT SUZUKI MOTOR CORPORATION 2003
GROUP /NDE
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
FI SYSTEM
4
COOLING AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
E
SERVICING INFORMATION
EMISSION CONTROL
INFORMATION
WIRING DIAGRAM
A
WARNING
Inexperienced mechanics
or mechanics
without the proper tools
and equipment

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
.
3
. Holding the manual as shown at the right will allow you to find
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
. Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided .
Example : Front wheel
0
ITEM
CA)
N .m
100
23
kgf-m
10 .0
2 .3
lb-ft
72 .5
165
1~ Brake disc
•

Dust seal
(3 Bearing
•

Center spacer
•

Coller
•

Front wheel
•

Tire valve
•

Front axle
•

Brake disc bolt
T
44P
4
•
 •
 •
of

SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing . The meaning of each symbol is also included in the table
.
SYMBOL DEFINITION
SYMBOL DEFINITION
Torque control required .
Data beside it indicates specified
torque .
LLC
Use engine coolant .
0
r
Apply oil . Use engine oil unless other-
wise specified .
FORK
Use fork oil
.
99000-99044-LO1
0
Apply molybdenum oil solution .
(Mixture of engine oil and SUZUKI
MOLY PASTE in a ratio of 1 : 1)
BF Apply or use brake fluid .
Apply SUZUKI SUPER GREASE "A" .
99000-25030 Lo a
Measure in voltage range .
Apply SUZUKI MOLY PASTE .
99000-25140
~©
a
Measure in resistance range .
©
Apply SUZUKI SILICONE GREASE .
99000-25100
Lo o
Measure in current range .
Apply SUZUKI BOND "1207B" .
99104-31 140 L o 0
Measure in diode test range .
1207B
1303
V
Apply THREAD LOCK SUPER "1303"
.
99000-32030
j
L
 1 ))
o a
Measure in continuity test range .
1342
Apply THREAD LOCK "1342" .
99000-32050
Use special tool
.
TOOL
1360
Apply THREAD LOCK SUPER "1360" .
99000-32130
Indication of service data .
DATA

ABBREVIATIONS USED IN THISMANUALA
ABDC

: After Bottom Dead Center
AC

: Alternating Current
ACL

:
Air Cleaner, Air Cleaner Box
API

: American Petroleum Institute
ATDC

: After Top Dead Center
ATM Pressure : Atmospheric Pressure
Atmospheric Pressure Sensor
(APS)
A/F

: Air Fuel Mixture
B
BBDC

: Before Bottom Dead Center
BTDC

: Before Top Dead Center
B+

: Battery Positive Voltage
C
CKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT

: Circuit
CLP Switch : Clutch Lever Position Switch
(Clutch Switch)
CMP Sensor : Camshaft Position Sensor
(CMPS)
CO

: Carbon Monoxide
CPU

: Central Processing Unit
D
DC

: Direct Current
DMC

: Dealer Mode Coupler
DOHC

:
Double Over Head Camshaft
DRL

: Daytime Running Light
E
ECM

: Engine Control Module
Engine Control Unit (ECU)
(FI Control Unit)
ECT Sensor : Engine Coolant Temperature
Sensor (ECTS), Water Temp .
Sensor (WTS)
EVAP

: Evaporative Emission
EVAP Canister : Evaporative Emission
Canister (Canister)
F
FI

: Fuel Injection, Fuel Injector
FP

: Fuel Pump
FPR

: Fuel Pressure Regulator
FP Relay

: Fuel Pump Relay
G
GEN

: Generator
GND

: Ground
GP Switch

: Gear Position Switch
H
HC

:
Hydrocarbons
IAP Sensor

: Intake Air Pressure Sensor (ZAPS)
IAT Sensor : Intake Air Temperature Sensor
(IATS)
IG

: Ignition
L
LCD

: Liquid Crystal Display
LED

: Light Emitting Diode
(Malfunction Indicator Lamp)
LH

: Left Hand
0
I
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of,
4 6

• O
0
 i
s1
 i
•

I
M
MAL-Code
Max
MIL
Min
N
NOx
0
OHC
OPS
P
PCV
R
RH
ROM
S
SAE
STC System
STP Sensor
ST Valve
STV Actuator
T
TO Sensor
TP Sensor
V
VD
Malfunction Code
(Diagnostic Code)
Maximum
Malfunction Indicator Lamp
(LED)
Minimum
Nitrogen Oxides
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)
Tip Over Sensor (TOS)
Throttle Position Sensor (TPS)
Vacuum Damper

SAE-TO-FORMER SUZUKI TERM
This table lists SAE (Society of Automotive Engineers) J1930 terms and abbreviations which may be used in
this manual in compliance with SAE recommendations, as well as their former SUZUKI names .

i t
1
•
06
46
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4
SAE TERMFULL TERM ABBREVIATION FORMER SUZUKI TERM
A
Air Cleaner ACL Air Cleaner, Air Cleaner Box
B
Barometric Pressure BARO Barometric Pressure, Atmospheric
Battery Positive Voltage B+
Pressure (APS, AP Sensor)
Battery Voltage, +B
C
Camshaft Position Sensor CMP Sensor Camshaft Position Sensor (CMPS)
Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),
D
Data Link Connector DLC
Crank
Angle
Dealer Mode Coupler
Diagnostic Test Mode
Diagnostic Trouble Code
DTM
DTC Diagnostic
Code,
Malfunction Code
E
Electronic Ignition
Engine Control Module
El
ECM Engine Control Module (ECM)
Engine Coolant Level ECL
Fl Control Unit, Engine Control Unit (ECU)
Coolant Level
Engine Coolant Temperature ECT Coolant Temperature, Engine Coolant Tem-
Engine Speed RPM
perature
Water Temperature
Engine Speed (RPM)
Evaporative Emission EVAP Evaporative Emission
Evaporative Emission Canister EVAP Canister (Canister)
Purge Valve Purge Valve Purge Valve (SP Valve)
F
Fan Control
Fuel Level Sensor
FC
Fuel Level Sensor, Fuel Level Gauge
Fuel Pump FP Fuel Pump (FP)
G
Generator GEN Generator
Ground GND Ground (GND, GRD)

•

I
SAE TERM
FULL TERM ABBREVIATION
FORMER SUZUKI TERM
H
Heated Oxygen Sensor
HO2S
Heated Oxgen Sensor (HO2S), 02 Sensor
I
Idle Speed Control
Ignition Control
ISC
IC Electronic Spark Advance (ESA)
Ignition Control Module
Intake Air Temperature
ICM
IAT Intake Air Temperature (IAT), Air Tempera-
M
Malfunction Indicator Lamp MIL
ture
LED Lamp
Manifold Absolute Pressure MAP
Malfunction Indicator Lamp (MIL)
Intake Air Pressure, Intake Vacuum
Mass Air Flow MAF Air Flow
0
On-Board Diagnostic OBD Self-Diagnosis Function
Open Loop
P
Programmable Read Only Memory
Pulsed Secondary Air Injection
OL
PROM
PAIR
Diagnostic
Pulse Air Control (PAIR)
R
Random Access Memory
Read Only Memory
RAM
ROM ROM
S
Secondary Air Injection
Secondary Throttle Control Sys-
AIR
STCS STC System (STCS)
tem
Secondary Throttle Valve
STV ST Valve (STV)
Secondary Throttle Valve Actuator STVA STV Actuator (STVA)
T
Throttle Body TB Throttle Body (TB)
Throttle Body Fuel Injection
TBI Throttle Body Fuel Injection (TBI)
Throttle Position Sensor TP Sensor TP Sensor (TPS)
V
Voltage Regulator VR Voltage Regulator
Volume Air Flow VAF Air Flow

.
GENERAL INFORMATION
6-
r
6- )
4)
CONTENTS
WARNING/CAUTION/NOTE 
1- 2
GENERAL PRECAUTIONS 
1-
2
SUZUKI SV1000SK3 ('03-MODEL)

1- 4
SERIAL NUMBER LOCATION 
1- 4
FUEL, OIL AND ENGINE COOLANT RECOMMENDATION

1- 4
FUEL (FOR USA AND CANADA) 
1- 4
FUEL (FOR OTHER COUNTRIES) 
1- 4
ENGINE OIL 
1- 5
BRAKE FLUID 
1- 5
FRONT FORK OIL 
1- 5
ENGINE COOLANT 
1- 5
WATER FOR MIXING 
1- 5
ANTI-FREEZE/ENGINE COOLANT

1- 5
LIQUID AMOUNT OF WATER/ENGINE COOLANT

1- 5
BREAK-IN PROCEDURES 
1- 6
CYLINDER IDENTIFICATION 
1- 6
INFORMATION LABELS 
1- 7
SPECIFICATIONS 
1- 8
COUNTRY AND AREA CODES 
1-10
GENERAL INFORMATION 1-1
1

1- 2
GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully . To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings
. Pay special attention to the mes-
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 . In addition to the WARN-
INGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles . If you
are unsure about how to perform a particular service operation, ask a more experienced mechanic for
advice .
GENERAL PRECAUTIONS
A
WARNING
•

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 out-
doors .
•

When working with toxic or flammable materials, make sure that the area you work in is well-
ventilated 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 .

1 40
4
1
0 I
0
0
CAUTION
GENERAL INFORMATION 1-3
•

If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-
lent .
•

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 . Lubricate them when specified .
•

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 speci-
fied 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 . Also, before installing these new parts, be sure to remove any left over material
from the mating surfaces .
• Never reuse a circlip . When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft . After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted
.
•

Use a torque wrench to tighten fasteners to the specified torque . Wipe off grease and oil if a
thread is smeared with them .
•

After reassembling, check parts for tightness and proper operation
.
•

To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and
other fluids : batteries and tires .
•

To protect Earth's natural resources, properly dispose of used motorcycle and parts .

1 -4 GENERAL INFORMATION
SUZUKI SV1000SK3 ('03-MODEL)
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 . (Vehicle Identification Number) 1O is stamped on the right side of the
steering head pipe . The engine serial number
2
is located on the right side of the crankcase . These num-
bers are required especially for registering the machine and ordering spare parts .
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 octane or higher rated by the
research method .
Gasoline containing MTBE (Methyl Tertiary Butyl Ether), less than 10% ethanol, or less than 5% methanol
with appropriate cosolvents and corrosion inhibitor is permissible .
FUEL (FOR OTHER COUNTRIES)
Gasoline used should be graded 91 octane (Research Method) or higher
.
Unleaded gasoline is recom-
mended .
4
41
01
ko

ENGINE OIL
SUZUKI recommends the use of SUZUKI PERFORMANCE 4
MOTOR OIL or an oil which is rated SF or SG under the API
(American Petroleum Institute) service classification . The rec-
ommended viscosity is SAE 1 OW-40
. If an SAE 1 OW-40 oil is not
available, select an altematice according to the right chart .
BRAKE FLUID
Specification and classification : DOT 4
A WARNING
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manu-
facturer, 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 .
FRONT FORK OIL
Use fork oil L01 or an equivalent fork oil .
GENERAL INFORMATION 1-5
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 . Therefore, the engine
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 . If this is not available, use
an equivalent which is compatible with an aluminum radiator .
LIQUID AMOUNT OF WATER/ENGINE COOLANT
Solution capacity (total) : 2 200 ml (2 .3/1 .9 US/Imp qt)
For engine coolant mixture information, refer to cooling system section, page 5-3 .
CAUTION
Mixing of anti-freeze/engine coolant should be limited to 60% . Mixing beyond it would reduce
its efficiency
. If the anti-freeze/engine coolant mixing ratio is below 50%, rust inhabiting perfor-
mance is greatly reduced . Be sure to mix it above 50% even though the atmospheric tempera-
ture does not go down to the freezing point .
MUITIGRADE
20W-50
15W-40, 15W 50
1OW 40 . 10W 50
10W 30
°C
-30 -20 -10 0 10 20 30 40
TEMP . 0 1

1 +

1

t

+

I 1
°F -22 -4 14 32 50 68 86
104

1- 6 GENERAL INFORMATION
BREAK-IN PROCEDURES
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 . The future performance and reliability of the engine depends on the care and restraint
exercised during its early life . The general rules are as follows :
•

Keep to these break-in engine speed limits :
Initial 800 km ( 500 miles) : Below 6 000 r/min
Up to 1 600 km (1 000 miles) : Below 9 000 r/min
Over 1 600 km (1 000 miles) : Below 12 500 r/min
•

Upon reaching an odometer reading of 1 600 km (1 000 miles) you can subject the motorcycle to full throt-
tle operation . However, do not exceed 12 500 r/min at any time .
CYLINDER IDENTIFICATION
The two cylinders of this engine are identified as No . 1 and No . 2 cylinder, as counted from front to rear (as
viewed by the rider on the seat)
.
6 41
4 1 6
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INFORMATION LABELS
A : Attached
(7
French
GENERAL INFORMATION 1-7
SV1000S SV1000SD
SV1000SF
1O Noise label
A For E-03, 24, 33
O2 Information label
A For E-03, 28, 33
03 Vacuum hose routing label
A For E-33
(4)
Fuel caution label
A For E-02, 24
($ Manual caution label
A For E-03, 33
© Frame caution label
AA A
O7 Warning screen label
A For E-28 (LH, RH)
Other (RH)
AA
® Warning steering label
AA A
O
Tire air pressure label
A A A
C0) Warning safety label
AA A
11 ICES Canada label
A For E-28
ID plate
A For E-03, 28, 33
A A
13 E19 ID label A
14 Safety plate
A For E-03, 28, 33

1- 8
GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length
 2 130 mm (83
.9 in)
Overall width 
745 mm (29 .3 in)
Overall height 
1 170 mm (46
.1 in)
Wheelbase  1 430 mm (56
.3 in)
Ground clearance 
150 mm ( 5 .9 in)
Seat height

810 mm (31 .9 in)
Dry mass 
189 kg (416 Ibs)
190 kg (418 Ibs)  E-33
ENGINE
Type 
4-stroke, liquid-cooled, DOHC, 90° degree V-twin
Number of cylinders 
2
Bore 
98 .0 mm (3
.858 in)
Stroke 
66 .0 mm (2 .598 in)
Displacement 
996 cm 3 (60 .8 cu . in)
Compression ratio 
11 .3 : 1
Fuel system 
Fuel injection
Air cleaner 
Non-woven fabric element
Starter system 
Electric
Lubrication system 
Wet sump
Idle speed 
1 200 ± 100 r/min
DRIVE TRAIN
Clutch 
Wet multi-plate type
Transmission 
6-speed constant mesh
Gearshift pattern 
1-down, 5-up
Primary reduction ratio 
1 .838 (57/31)
Gear ratios, Low 
2 .666 (32/12)
2nd 
1 .933 (29/15)
3rd 
1 .500 (27/18)
4th 
1 .227 (27/22)
5th 
1 .086 (25/23)
Top 
1 .000 (24/24)
Final reduction ratio 
2 .352 (40/17)
Drive chain 
RK530 SMOZ1, 108 links
t1
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•
t
•
40

0
.l
CHASSIS
Front suspension
 Telescopic, coil spring, oil damped
Rear suspension
 Link type, coil spring, oil damped
Front suspension stroke 
120 mm (4 .72 in)
Rear wheel travel  129 mm (5 .08 in)
Caster
 24 .5°
Trail  98 mm (3 .9 in)
Steering angle  30° (right & left)
Turning radius  3 .2 m (10 .50 ft)
Front brake 
Disc brake, twin
Rear brake  Disc brake
Front tire size  120/70 ZR17M/C (58W), tubeless
Rear tire size  180/55 ZR1 7M/C (73W), tubeless
ELECTRICAL
Ignition type  Electronic ignition (Transistorized)
Ignition timing  5° B . T . D . C at 1 200 r/min
Spark plug  NGK : CR8EK or DENSO : U24ETR
Battery  12 V 43 .2 kC (12 Ah)/10 HR
Generator  Three-phase A .C . Generator
Main fuse  30 A
Fuse  15/15/10/15/15/10 A
Headlight  12 V 60/55 W x 2
Position light  12 V 5 W x 2
License plate light  12 V 5 W
Turn signal light  12V21 W x 4
Brake light/Taillight  LED
Speedometer/Tachometer light  LED
Fuel level indicator light  LED
Turn signal indicator light  LED
Neutral indicator light  LED
High beam indicator light  LED
Oil pressure/Coolant temperature/Fuel injection
warning light  LED
CAPACITIES
Fuel tank  16 L (4 .2/3 .5 US/Imp gal)
 For E-33
17 L (4 .5/3
.7 US/Imp gal)  For the others
Engine oil, oil change  2 700 ml (2 .9/2
.4 US/Imp qt)
with filter change  2 900 ml (3 .1/2 .6 US/Imp qt)
overhaul  3 300 ml (3 .5/2
.9 US/Imp qt)
Front fork oil (each leg)  494 ml (16 .69/17
.39 US/Imp oz)
Coolant  2 .2 L (2 .3/1 .9 US/Imp qt)
These specifications are subject to change without notice .
GENERAL INFORMATION 1-9

1-10 GENERAL INFORMATION
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s) .
CODE COUNTRY or AREA
E-02 U . K .
E-03 U . S . A . (Except for California)
E-19 EU
E-24 Australia
E-28 Canada
E-33 California (U . S . A .)