Suzuki DL1000 Manuals

DL1000 OWNER’S MANUAL This owner’s manual contains important safety information. Please read it carefully. www.ClassicCycles.org IMPORTANT WARNING/CAUTION/NOTE Please read this manual and fol- low its instructions carefully. To emphasize special information, the symbol  and the words WARNING, CAUTION and NOTE have special meanings. Pay spe- cial attention to the messages highlighted by these signal words: NOTE: Indicates special informa- tion to make maintenance easier or instructions clearer. WARNINGs and CAUTIONs are arranged like this: FOREWORD Motorcycling is one of the most exhilarating sports and to ensure your riding enjoyment, you should become thoroughly familiar with the information presented in this Owner’s Manual before riding the motorcycle. The proper care and maintenance that your motorcycle requires is outlined in this manual. By follow- ing these instructions explicitly you will ensure a long trouble-free operating life for your motorcycle. This motorcycle also conforms to the U.S Environmental Protection Agency emission regulations which apply to new motorcycles. The proper adjustment of engine components is necessary for this motorcycle to comply with the EPA regulations. Therefore, please follow the maintenance instructions closely to ensure emission compliance. Your Suzuki dealer has experienced techni- cians that are trained to provide your machine with the best possi- ble service with the right tools and equipment. WARNING Indicates a potential hazard that could result in death or injury. CAUTION Indicates a potential hazard that could result in motorcycle damage. WARNING-or-CAUTION The first part will describe a POTENTIAL HAZARD and WHAT CAN HAPPEN if you ignore the WARNING or CAU- TION. The second part will describe HOW TO AVOID THE HAZARD. TABLE OF CONTENTS 1 2 3 4 5 6 7 8 9 10 THE SPORT OF MOTORCYCLING FUEL, ENGINE OIL AND COOLANT RECOMMENDATIONS CONTROLS, EQUIPMENT AND ADJUSTMENTS BREAK-IN AND INSPECTION BEFORE RIDING RIDING TIPS ACCESSORY USE AND MOTORCYCLE LOADING INSPECTION AND MAINTENANCE TROUBLESHOOTING STORAGE PROCEDURE AND MOTORCYCLE CLEANING CONSUMER INFORMATION SPECIFICATIONS INDEX www.ClassicCycles.org

DL1000 GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE 2 ENGINE 3 FI SYSTEM 4 COOLING AND LUBRICATION SYSTEM 5 CHASSIS 6 ELECTRICAL SYSTEM 7 SERVICING INFORMATION 8 EMISSION CONTROL INFORMATION 9 WIRING DIAGRAM 10 © COPYRIGHT SUZUKI MOTOR CORPORATION 2002 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 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. Inexperienced mechanics or mechanics without the proper tools and equipment 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. 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 lb-ft A 100 10.0 72.5 B 23 2.3 16.5 @ 1 Brake disc 2 Dust seal 3 Bearing 4 Center spacer 5 Coller 6 Front wheel 7 Tire valve A Front axle B 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. Data beside it indicates specified torque. Apply THREAD LOCK SUPER “1360”. 99000-32130 Apply oil. Use engine oil unless other- wise specified. Use engine coolant. 99000-99032-11X Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Use fork oil. 99000-99001-SS8 Apply SUZUKI SUPER GREASE “A”. 99000-25010 Apply or use brake fluid. Apply SUZUKI MOLY PASTE. 99000-25140 Measure in voltage range. Apply SUZUKI BOND “1207B” 99000-31140 Measure in current range. Apply SUZUKI BOND “1215”. 99000-31110 Measure in diode test range. Apply THREAD LOCK SUPER “1303”. 99000-32030 Measure in continuity test range. Apply THREAD LOCK SUPER “1322”. 99000-32110 Use special tool. Apply THREAD LOCK “1342”. 99000-32050 Indication of service data.

DL1000 GROUP INDEX GENERAL INFORMATION 1 PERIODIC MAINTENANCE 2 ENGINE 3 FI SYSTEM 4 COOLING AND LUBRICATION SYSTEM 5 CHASSIS 6 ELECTRICAL SYSTEM 7 SERVICING INFORMATION 8 EMISSION CONTROL INFORMATION 9 WIRING DIAGRAM 10 © COPYRIGHT SUZUKI MOTOR CORPORATION 2002 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 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. Inexperienced mechanics or mechanics without the proper tools and equipment 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. 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 lb-ft A 100 10.0 72.5 B 23 2.3 16.5 @ 1 Brake disc 2 Dust seal 3 Bearing 4 Center spacer 5 Coller 6 Front wheel 7 Tire valve A Front axle B Brake disc bolt