Suzuki sv1000S User manual

SERVICE MANUAL
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II II II II
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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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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
•
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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
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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
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•

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 .
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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)

•
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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