2002-2009 Suzuki DL1000 V-Strom Workshop Service & Parts Repair Manual 2002 2003 2004 2005 2006 2007 2008 2009
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FOREWORD
This manual contains an introductory description on
the SUZUKI DL1000 and procedures for its inspec-
tion/service and overhaul of its main components.
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 publication. If
modifications have been made since then, differ-
ences may exist between the content 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 ex-
actly 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.
Inexperienced mechanics or mechanics with-
out the proper tools and equipment may not
be able to properly perform the services de-
scribed in this manual. Improper repair may
result in injury to the mechanic and may ren-
der the motorcycle unsafe for the rider and
passenger.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2001
WARNING
!
9
EMISSION CONTROL
INFORMATION
8
SERVICING INFORMATION
7
ELECTRICAL SYSTEM
6
CHASSIS
5
COOLING AND LUBRICATION
SYSTEM
4
FI SYSTEM
3
ENGINE
2
PERIODIC MAINTENANCE
1
GROUP INDEX
GENERAL INFORMATION
99500-39237-03E
14
DL1000K9 (’09-MODEL)
13
DL1000K6/K7/K9
12
DL1000K5 ('05 MODEL)
11
DL1000K4 ('04 MODEL)
10
DL1000K3 ('03 MODEL)
SUPPLEMENTS
(’06, ’07 & ’08 MODEL)
15
WIRING DIAGRAM
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
ITEM N·m kgf-m
® 100 10.0
@ 23 2.3
Ib-ft
72.5
16.5
CD Brake disc
(2) Dust seal
@ Bearing
@ Center spacer
@Coller
@ Front wheel
({) Tire valve
® Front axle
@ Brake disc bolt
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.
-ml
Data beside it indicates specified Use engine coolant.
torque.
l!r
Apply oil. Use engine oil unless other-
Gil
Use fork oil.
wise specified. 99000-99001-SS8
m
l
Apply molybdenum oil solution.
I
(Mixture of engine oil and SUZUKI Apply or use brake fluid.
MOLY PASTE in a ratio of 1 : 1)
~
Apply SUZUKI SUPER GREASE "A".
~
Measure in voltage range.
99000-25030
~
Apply SUZUKI MOLY PASTE.
~
Measure in current range.
99000-25140
.12078]
Apply SUZUKI BOND "1207B"
~
Measure in diode test range.
99104-31140
..
Apply THREAD LOCK SUPER "1303".
ij:.~U
Measure in continuity test range.
99000-32030
•
Apply THREAD LOCK SUPER "1322" .
'{ooLl
Use special tool.
99000-32110
•
Apply THREAD LOCK "1342" .
~~
Indication of service data.
99000-32050
..
Apply THREAD LOCK SUPER "1360" .
99000-32130
ABBREVIATIONS USED IN THIS
MANUAL
A
ABDC
AC
ACL
API
ATDC
: After Bottom Dead Center
: Alternating Current
: Air Cleaner, Air Cleaner Box
: American Petroleum Institute
: After Top Dead Center
ATM Pressure: Atmospheric Pressure
Atmospheric Pressure Sensor
(APS)
A/F
B
BBDC
BTDC
B+
c
: Air Fuel Mixture
: Before Bottom Dead Center
: Before Top Dead Center
: Battery Positive Voltage
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
DMC
DOHC
DRL
: Direct Current
: Dealer Mode Coupler
: Double Over Head Camshaft
: Daytime Running Light
E
F
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)
FI
FP
FPR
FP Relay
: Fuel Injection, Fuel Injector
: Fuel Pump
: Fuel Pressure Regulator
: Fuel Pump Relay
G
GEN
GND
: Generator
: Ground
GP Switch : Gear Position Switch
H
HC : Hydrocarbons
lAP Sensor : Intake Air Pressure Sensor (lAPS)
IAT Sensor : Intake Air Temperature Sensor
(lATS)
IG : Ignition
L
LCD : Liquid Crystal Display
LED : Light Emitting Diode
(Malfunction Indicator Lamp)
LH : Left Hand
M
MAL-Code : Malfunction Code
(Diagnostic Code)
Max : Maximum
MIL : Malfunction Indicator Lamp
(LED)
Min : Minimum
N
NOx : Nitrogen Oxides
o
OHC : Over Head Camshaft
OPS : Oil Pressure Switch
p
PCV : Positive Crankcase
Ventilation (Crankcase Breather)
R
RH : Right Hand
ROM : Read Only Memory
s
T
SAE : Society of Automotive Engineers
STC System : Secondary Throttle Control
System (STCS)
STP Sensor : Secondary Throttle Position
Sensor (STPS)
ST Valve : Secondary Throttle Valve (STV)
STV Actuator : Secondary Throttle Valve Actuator
(STVA)
TO Sensor : Tip Over Sensor (TOS)
TP Sensor : Throttle Position Sensor (TPS)
V
VD : 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.
SAE TERM
FORMER SUZUKI TERM
FULL TERM ABBREVIATION
A
Air Cleaner ACl Air Cleaner, Air Cleaner Box
B
Barometric Pressure BARO Barometric Pressure, Atmospheric
Pressure (APS, AP Sensor)
Battery Positive Voltage B+ Battery Voltage, +B
C
Camshaft Position Sensor CMP Sensor Camshaft Position Sensor (CMPS)
Crankshaft Position Sensor CKP Sensor Crankshaft Position Sensor (CKPS),
Crank Angle
D
Data Link Connector DlC Dealer Mode Coupler
Diagnostic Test Mode DTM -
Diagnostic Trouble Code DTC Diagnostic Code, Malfunction Code
E
Electronic Ignition EI -
Engine Control Module ECM Engine Control Module (ECM)
FI Control Unit, Engine Control Unit (ECU)
Engine Coolant level ECl Coolant level
Engine Coolant Temperature ECT Coolant Temperature, Engine Coolant Tem-
perature
Water Temperature
Engine Speed RPM Engine Speed (RPM)
Evaporative Emission EVAP Evaporative Emission
Evaporative Emission Canister EVAP Canister -(Canister)
Exhaust Control System EXCS EXC System (EXCS)
Exhaust Control Valve EXCV EXC Valve (EXCV)
Exhaust Control Valve Actuator EXCVA EXCV Actuator (EXCVA)
Purge Valve Purge Valve Purge Valve (SP Valve)
F
Fan Control FC -
Fuel level Sensor - Fuel level Sensor, Fuel level Gauge
Fuel Pump FP Fuel Pump (FP)
SAE TERM
FORMER SUZUKI TERM
FULL TERM ABBREVIATION
G
Generator GEN Generator
Ground GND Ground (GND, GRD)
I
Idle Speed Control ISC -
Ignition Control IC Electronic Spark Advance (ESA)
Ignition Control Module ICM -
Intake Air Temperature IAT Intake Air Temperature (IAT), Air Tempera-
ture
M
Malfunction Indicator Lamp MIL LED Lamp
Malfunction Indicator Lamp (MIL)
Manifold Absolute Pressure MAP Intake Air Pressure, Intake Vacuum
Mass Air Flow MAF Air Flow
0
On-Board Diagnostic OBD Self-Diagnosis Function
Diagnostic
Open Loop OL -
P
Programmable Read Only Memory PROM -
Pulsed Secondary Air Injection PAIR Pulse Air Control (PAIR)
R
Random Access Memory RAM -
Read Only Memory ROM ROM
S
Secondary Air Injection AIR -
Secondary Throttle Control Sys- 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
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Print one or all pages of your manual
$31.99
This Service & Parts Repair Manual is an essential resource for maintaining and repairing the 2002-2009 Suzuki DL1000 V-Strom. It is a valuable tool for both professional mechanics and DIY enthusiasts, providing high-quality diagrams and detailed instructions for servicing your Suzuki.
The manual covers the following models:
- 2002 Suzuki DL1000K2 V-Strom
- 2003 Suzuki DL1000K3 V-Strom
- 2004 Suzuki DL1000K4 V-Strom
- 2005 Suzuki DL1000K5 V-Strom
- 2006 Suzuki DL1000K6 V-Strom
- 2007 Suzuki DL1000K7 V-Storm
- 2008 Suzuki DL1000K8 V-Strom
- 2009 Suzuki DL1000K9 V-Strom
The manual includes comprehensive information on general maintenance, engine, fuel injection system, cooling and lubrication system, electrical system, chassis, servicing, and emission control. It is available in PDF format, compatible with all versions of Windows and Mac, and can be viewed using Adobe Reader. With instant access, this manual is a cost-effective solution that will enhance your understanding of your Suzuki and save you time and money.
Don't miss out on the opportunity to acquire this invaluable resource for maintaining and repairing your Suzuki DL1000 V-Strom. Get your copy now and take control of your vehicle's maintenance and repair needs.
