2003 - 2005 SUZUKI SV1000 Service Manual / Repair / Maintenance Manual (57 MB) SV 1000 - NOW!!

SERVICEM NU L I II II II II •  SV10005 199500-39250-03E0

IMPORT NT ll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EP 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EP emission regulationsandU.S .Suzuki'semissioncontrolprogram canbefoundintheU.S.SUZUKIEMISSIONCONTROL PROGR MM NU USERVICEBULLETIN.  1 0  01 f 40 Of 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GENER LINFORM TIONsectionto familiarizeyourselfwiththemotorcycleanditsmaintenance .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motorcycles .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CORPOR TION ©COPYRIGHTSUZUKIMOTORCORPOR TION2003 GROUP/NDE GENER LINFORM TION PERIODICM INTEN NCE ENGINE FISYSTEM 4 COOLING NDLUBRIC TION SYSTEM CH SSIS ELECTRIC LSYSTEM E SERVICINGINFORM TION EMISSIONCONTROL INFORM TION WIRINGDI GR M W RNING Inexperienced mechanics or mechanics withoutthepropertools and equipment

HOWTOUSETHISM NU L TOLOC TEWH TYOU RE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P RTS ND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 C) 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servicing .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 pplyoil .Useengineoilunlessother- wisespecified . FORK Useforkoil . 99000-99044-LO1 0 pplymolybdenumoilsolution . (MixtureofengineoilandSUZUKI MOLYP STEinaratioof1 : 1) BF pplyorusebrakefluid . pplySUZUKISUPERGRE SE "" . 99000-25030 Lo a Measureinvoltagerange . pplySUZUKIMOLYP STE . 99000-25140 ~© a Measureinresistancerange . © pplySUZUKISILICONEGRE SE . 99000-25100 Lo o Measureincurrentrange . pplySUZUKIBOND"1207B" . 99104-31140 Lo 0 Measureindiodetestrange . 1207B 1303 V pplyTHRE DLOCKSUPER"1303" . 99000-32030 j L  1 )) oa Measureincontinuitytestrange . 1342 pplyTHRE DLOCK"1342" . 99000-32050 Usespecialtool . TOOL 1360 pplyTHRE DLOCKSUPER"1360" . 99000-32130 Indicationofservicedata . DT

BDC  : fterBottomDeadCenter C  : lternatingCurrent CL  : irCleaner, irCleanerBox PI  : mericanPetroleumInstitute TDC  : fterTopDeadCenter TMPressure : tmosphericPressure tmosphericPressureSensor ( PS) /F  : ir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) EV P  : EvaporativeEmission EV P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 I PSensor  : Intake irPressureSensor(Z PS) I TSensor : Intake irTemperatureSensor (I TS) IG  :Ignition L LCD  : LiquidCrystalDisplay LED  : LightEmittingDiode (MalfunctionIndicatorLamp) LH  : LeftHand 0 I  I  1 of, 46

• O 0  i s1  i •  I M M L-Code Max MIL Min N NOx 0 OHC OPS P PCV R RH ROM S SE STCSystem STPSensor STValve STV ctuator 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 utomotiveEngineers SecondaryThrottleControl System(STCS) SecondaryThrottlePosition Sensor(STPS) SecondaryThrottleValve(STV) SecondaryThrottleValve ctuator (STV ) TipOverSensor(TOS) ThrottlePositionSensor(TPS) VacuumDamper

S E-TO-FORMERSUZUKITERM ThistablelistsS E(Societyof utomotiveEngineers)J1930termsandabbreviationswhichmaybeusedin thismanualincompliancewithS Erecommendations,aswellastheirformerSUZUKInames .  it 1 • 06 46 1  1  4 ir Cleaner CL ir Cleaner, ir Cleaner Box B Barometric Pressure B RO Barometric Pressure, tmospheric Battery Positive Voltage B+ Pressure ( PS, P 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 ngle 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 EV P Evaporative Emission Evaporative Emission Canister EV P 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 S ETERM FULLTERM BBREVI TION FORMERSUZUKITERM H HeatedOxygenSensor HO2S HeatedOxgenSensor(HO2S),02Sensor I IdleSpeedControl IgnitionControl ISC IC ElectronicSpark dvance(ES ) IgnitionControlModule Intake irTemperature ICM IT Intake irTemperature(I T), irTempera- M MalfunctionIndicatorLamp MIL ture LEDLamp Manifold bsolutePressure MP MalfunctionIndicatorLamp(MIL) Intake irPressure,IntakeVacuum Mass irFlow MF irFlow 0 On-BoardDiagnostic OBD Self-DiagnosisFunction OpenLoop P ProgrammableReadOnlyMemory PulsedSecondary irInjection OL PROM P IR Diagnostic Pulse irControl(P IR) R Random ccessMemory ReadOnlyMemory RM ROM ROM S Secondary irInjection SecondaryThrottleControlSys- IR STCS STCSystem(STCS) tem SecondaryThrottleValve STV STValve(STV) SecondaryThrottleValve ctuator STV STV ctuator(STV ) 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 irFlow VF irFlow

. GENER LINFORM TION 6- r 6- ) 4) CONTENTS W RNING/C UTION/NOTE 1-2 GENER LPREC UTIONS 1- 2 SUZUKISV1000SK3('03-MODEL)  1-4 SERI LNUMBERLOC TION 1-4 FUEL,OIL NDENGINECOOL NTRECOMMEND TION  1-4 FUEL(FORUS  NDC N D )  1-4 FUEL(FOROTHERCOUNTRIES) 1-4 ENGINEOIL  1-5 BR KEFLUID 1-5 FRONTFORKOIL 1-5 ENGINECOOL NT 1-5 W TERFORMIXING 1-5 NTI-FREEZE/ENGINECOOL NT  1-5 LIQUID MOUNTOFW TER/ENGINECOOL NT  1-5 BRE K-INPROCEDURES  1-6 CYLINDERIDENTIFIC TION 1-6 INFORM TIONL BELS 1-7 SPECIFIC TIONS 1-8 COUNTRY ND RE CODES  1-10 GENER L INFORM TION 1-1 1

2003 - 2005 SUZUKI SV1000 Service Manual / Repair / Maintenance Manual (57 MB) SV 1000 - NOW!!

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