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Suzuki DL1000 VStrom 2002 - 2009 Service Repair Manual + Wir
Suzuki DL1000 VStrom 2002 - 2009Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Suzuki. Read and print pages, or copy the entire manual to your hard drive.
444 Pages
MODEL YEAR:
2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
MODEL COVERS:
Suzuki DL1000 VStrom
MANUAL COVERS:
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
PERIODIC MAINTENANCE SCHEDULE ............................................2- 2
PERIODIC MAINTENANCE CHART ...........................................2- 2
LUBRICATION POINTS ...............................................................2- 3
MAINTENANCE AND TUNE-UP PROCEDURES ...............................2- 4
AIR CLEANER .............................................................................2- 4
SPARK PLUG ..............................................................................2- 5
TAPPET CLEARANCE ................................................................2- 7
FUEL HOSE .................................................................................2-12
ENGINE OIL AND OIL FILTER ....................................................2-12
ENGINE IDLE SPEED ..................................................................2-14
THROTTLE CABLE PLAY ...........................................................2-14
THROTTLE VALVE SYNCHRONIZATION ..................................2-15
PAIR (AIR SUPPLY) SYSTEM ....................................................2-15
CLUTCH .......................................................................................2-16
COOLING SYSTEM .....................................................................2-17
DRIVE CHAIN ..............................................................................2-19
BRAKE .........................................................................................2-21
TIRE .............................................................................................2-25
STEERING ...................................................................................2-25
FRONT FORK ..............................................................................2-26
REAR SUSPENSION ...................................................................2-26
EXHAUST PIPE BOLT .................................................................2-26
CHASSIS BOLT AND NUT ..........................................................2-27
COMPRESSION PRESSURE CHECK .................................................2-29
COMPRESSION TEST PROCEDURE .........................................2-29
OIL PRESSURE CHECK ......................................................................2-30
OIL PRESSURE TEST PROCEDURE
ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ...3- 2
ENGINE REMOVAL AND INSTALLATION .........................................3- 3
ENGINE REMOVAL .....................................................................3- 3
ENGINE INSTALLATION .............................................................3-12
ENGINE DISASSEMBLY .....................................................................3-19
ENGINE TOP SIDE ......................................................................3-19
ENGINE BOTTOM SIDE ..............................................................3-25
ENGINE COMPONENTS INSPECTION AND SERVICING .................3-34
CYLINDER HEAD COVER ..........................................................3-34
CAMSHAFT/CYLINDER HEAD ...................................................3-35
CYLINDER/PISTON INSPECTION ..............................................3-47
CONROD/CRANKSHAFT ............................................................3-50
CLUTCH .......................................................................................3-54
TRANSMISSION ..........................................................................3-56
GEARSHIFT FORK ......................................................................3-62
PRIMARY DRIVE GEAR ..............................................................3-63
STARTER TORQUE LIMITER .....................................................3-64
STARTER CLUTCH .....................................................................3-65
GEARSHIFT .................................................................................3-66
CRANKCASE ...............................................................................3-66
CRANKCASE-CRANKSHAFT BEARING ...................................3-71
GENERATOR COVER .................................................................3-77
CLUTCH COVER .........................................................................3-77
GEARSHIFT COVER ...................................................................3-77
ENGINE REASSEMBLY ......................................................................3-78
ENGINE BOTTOM SIDE ..............................................................3-78
ENGINE TOP SIDE ..............
PRECAUTIONS IN SERVICING .....................................................................4- 2
CONNECTOR/COUPLER ......................................................................4- 2
FUSE ......................................................................................................4- 3
ECM/VARIOUS SENSORS ....................................................................4- 3
ELECTRICAL CIRCUIT INSPECTION PROCEDURE ..........................4- 5
USING TESTERS ...................................................................................4- 8
FI SYSTEM TECHNICAL FEATURES ............................................................4- 9
INJECTION TIME (INJECTION VOLUME) ............................................4- 9
COMPENSATION OF INJECTION TIME (VOLUME) ............................4-10
INJECTION STOP CONTROL ...............................................................4-10
FUEL DELIVERY SYSTEM ...................................................................4-11
FUEL PUMP ...........................................................................................4-12
FUEL PRESSURE REGULATOR ..........................................................4-13
FUEL INJECTOR ...................................................................................4-13
FUEL PUMP CONTROL SYSTEM ........................................................4-14
ECM (FI CONTROL UNIT) .....................................................................4-15
INJECTION TIMING ...............................................................................4-15
SENSORS ..............................................................................................4-16
FI SYSTEM PARTS LOCATION .....................................................................4-20
FI SYSTEM WIRING DIAGRAM .....................................................................4-22
SELF-DIAGNOSIS FUNCTION .......................................................................4-23
USER MODE ..........................................................................................4-23
DEALER MODE .....................................................................................4-24
TPS ADJUSTMENT ...............................................................................4-25
FAIL-SAFE FUNCTION ...................................................................................4-26
FI SYSTEM TROUBLESHOOTING ................................................................4-27
CUSTOMER COMPLAINT ANALYSIS .................................................4-27
SELF-DIAGNOSTIC PROCEDURES ....................................................4-29
SELF-DIAGNOSIS RESET PROCEDURE ............................................4-29
MALFUNCTION CODE AND DEFECTIVE CONDITION .......................4-30
C11 CMP SENSOR CIRCUIT MALFUNCTION .................................4-32
C12 CKP SENSOR CIRCUIT MALFUNCTION ..................................4-33
C13 IAP SENSOR CIRCUIT MALFUNCTION ...................................4-34
C14 TP SENSOR CIRCUIT MALFUNCTION .....................................4-36
C15 ECT SENSOR CIRCUIT MALFUNCTION ..................................4-38
C21 IAT SENSOR CIRCUIT MALFUNCTION ...................................4-39
C22 AP SENSOR CIRCUIT MALFUNCTION ....................................4-40
C23 TO SENSOR CIRCUIT MALFUNCTION ....................................4-42
C24 or C25 IGNITION SYSTEM MALFUNCTION .........................4-43
C28 STV ACTUATOR CIRCUIT MALFUNCTION .............................4-43
C29 STP SENSOR CIRCUIT MALFUNCTION ..................................4-44
C31 GEAR POSITION (GP) SWITCH CIRCUIT MALFUNCTION .....4-46
C32 or C33 FUEL INJECTION MALFUNCTION ............................4-47
C41 FP RELAY CIRCUIT MALFUNCTION ........................................4-48
C42 IG SWITCH CIRCUIT MALFUNCTION ......................................4-48
C44 HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION ......................4-49
FUEL SYSTEM ................................................................................................4-51
2 4 6
FI SYSTEM 4-1
FUEL TANK LIFT-UP .............................................................................4-51
FUEL TANK REMOVAL .........................................................................4-52
FUEL TANK INSTALLATION ................................................................4-52
FUEL PRESSURE INSPECTION ...........................................................4-53
FUEL PUMP INSPECTION ....................................................................4-54
FUEL PUMP RELAY INSPECTION .......................................................4-55
FUEL PUMP AND FUEL FILTER REMOVAL .......................................4-55
FUEL MESH FILTER INSPECTION AND CLEANING ..........................4-57
FUEL PUMP AND FUEL MESH FILTER INSTALLATION ....................4-57
THROTTLE BODY AND STV ACTUATOR .....................................................4-59
CONSTRUCTION ...................................................................................4-59
THROTTLE BODY REMOVAL ..............................................................4-60
THROTTLE BODY DISASSEMBLY ......................................................4-61
THROTTLE BODY CLEANING ..............................................................4-65
INSPECTION ..........................................................................................4-65
THROTTLE BODY REASSEMBLY .......................................................4-65
STP SENSOR ADJUSTMENT ...............................................................4-68
THROTTLE BODY INSTALLATION ......................................................4-69
TP SENSOR ADJUSTMENT ..................................................................4-69
FUEL INJECTOR INSPECTION ............................................................4-69
FUEL INJECTOR REMOVAL ................................................................4-70
FUEL INJECTOR INSTALLATION ........................................................4-70
FAST IDLE INSPECTION ......................................................................4-70
FAST IDLE ADJUTMENT ......................................................................4-71
THROTTLE VALVE SYNCHRONIZATION ............................................4-72
THROTTLE CABLE ADJUSTMENT ......................................................4-73
SENSOR ..........................................................................................................4-74
IAP SENSOR INSPECTION ...................................................................4-74
IAP SENSOR REMOVAL/INSTALLATION ...........................................4-74
TP SENSOR INSPECTION ....................................................................4-74
TP SENSOR REMOVAL/INSTALLATION .............................................4-74
STP SENSOR INSPECTION ..................................................................4-74
STP SENSOR REMOVAL/INSTALLATION ..........................................4-74
CKP SENSOR INSPECTION .................................................................4-75
CKP SENSOR REMOVAL/INSTALLATION ..........................................4-75
CMP SENSOR INSPECTION .................................................................4-75
CMP SENSOR REMOVAL/INSTALLATION .........................................4-75
IAT SENSOR INSPECTION ...................................................................4-75
IAT SENSOR REMOVAL/INSTALLATION ............................................4-75
ECT SENSOR INSPECTION ..................................................................4-76
ECT SENSOR REMOVAL/INSTALLATION ..........................................4-76
AP SENSOR INSPECTION ....................................................................4-76
AP SENSOR REMOVAL/INSTALLATION ............................................4-76
TO SENSOR INSPECTION ....................................................................4-76
TO SENSOR REMOVAL/INSTALLATION ............................................4-76
HO2 SENSOR INSPECTION ..................................................................4-76
HO2 SENSOR REMOVAL/INSTALLATION ...........................................4-77
ENGINE COOLANT ..............................................................................5- 2
COOLING CIRCUIT ..............................................................................5- 3
COOLING CIRCUIT INSPECTION ..............................................5- 3
RADIATOR ...........................................................................................5- 4
REMOVAL ....................................................................................5- 4
INSPECTION AND CLEANING ...................................................5- 5
INSTALLATION ...........................................................................5- 6
RADIATOR RESERVOIR TANK ..........................................................5- 6
REMOVAL/INSTALLATION ........................................................5- 6
RADIATOR CAP ...................................................................................5- 6
INSPECTION ................................................................................5- 6
WATER HOSE ......................................................................................5- 7
INSPECTION ................................................................................5- 7
COOLING FAN .....................................................................................5- 8
REMOVAL ....................................................................................5- 8
INSPECTION ................................................................................5- 8
INSTALLATION ...........................................................................5- 8
COOLING FAN THERMO-SWITCH .....................................................5- 9
REMOVAL ....................................................................................5- 9
INSPECTION ................................................................................5- 9
INSTALLATION ...........................................................................5- 9
ENGINE COOLANT TEMPERATURE SENSOR .................................5-10
REMOVAL ....................................................................................5-10
INSPECTION ................................................................................5-10
INSTALATION ..............................................................................5-10
THERMOSTAT .....................................................................................5-11
REMOVAL ....................................................................................5-11
INSPECTION ................................................................................5-11
INSTALLATION ...........................................................................5-12
WATER PUMP ......................................................................................5-13
REMOVAL AND DISASSEMBLY ................................................5-13
INSPECTION ................................................................................5-15
REASSEMBLY AND INSTALLATION .........................................5-15
LUBRICATION SYSTEM ......................................................................5-18
OIL PRESSURE ...........................................................................5-18
OIL FILTER ..................................................................................5-18
OIL PRESSURE REGULATOR ...................................................5-18
OIL STRAINER ............................................................................5-18
OIL JET ........................................................................................5-18
OIL PUMP ....................................................................................5-18
OIL PRESSURE SWITCH ............................................................5-18
OIL COOLER ........................................................................................5-18
REMOVAL ....................................................................................5-18
INSPECTION AND CLEANING ...................................................5-19
INSTALLATION ...........................................................................5-19
ENGINE LUBRICATION FLOW CHART .............................................5-20
ENGINE LUBRICATION CIRCUIT .......................................................5-21
EXTERIOR PARTS ......................................................................................................................................6- 2
CONSTRUCTION ............................................................................................................................6- 2
REMOVAL .......................................................................................................................................6- 4
FRONT WHEEL ...........................................................................................................................................6- 8
CONSTRUCTION ............................................................................................................................6- 8
REMOVAL .......................................................................................................................................6- 9
INSPECTION AND DISASSEMBLY ...............................................................................................6- 9
REASSEMBLY AND REMOUNTING .............................................................................................6-11
FRONT FORK ..............................................................................................................................................6-14
CONSTRUCTION ............................................................................................................................6-14
REMOVAL AND DISASSEMBLY ...................................................................................................6-15
INSPECTION ...................................................................................................................................6-18
REASSEMBLY AND REMOUNTING .............................................................................................6-19
STEERING AND HANDLEBAR ..................................................................................................................6-24
CONSTRUCTION ............................................................................................................................6-24
REMOVAL .......................................................................................................................................6-25
INSPECTION AND DISASSEMBLY ...............................................................................................6-28
REASSEMBLY AND REMOUNTING .............................................................................................6-29
STEERING TENSION ADJUSTMENT ............................................................................................6-32
REAR WHEEL .............................................................................................................................................6-33
CONSTRUCTION ............................................................................................................................6-33
REMOVAL .......................................................................................................................................6-34
INSPECTION AND DISASSEMBLY ...............................................................................................6-35
REASSEMBLY AND REMOUNTING .............................................................................................6-38
REAR SHOCK ABSORBER .......................................................................................................................6-42
CONSTRUCTION ............................................................................................................................6-42
REMOVAL .......................................................................................................................................6-43
INSPECTION ...................................................................................................................................6-44
REAR SHOCK ABSORBER DISPOSAL ........................................................................................6-44
REMOUNTING ................................................................................................................................6-45
SUSPENSION SETTING .................................................................................................................6-46
REAR SWINGARM ......................................................................................................................................6-47
CONSTRUCTION ............................................................................................................................6-47
REMOVAL .......................................................................................................................................6-48
INSPECTION AND DISASSEMBLY ...............................................................................................6-49
REASSEMBLY ................................................................................................................................6-52
REMOUNTING ................................................................................................................................6-54
FINAL INSPECTION AND ADJUSTMENT .....................................................................................6-55
FRONT BRAKE ...........................................................................................................................................6-56
CONSTRUCTION ............................................................................................................................6-56
BRAKE PAD REPLACEMENT .......................................................................................................6-57
BRAKE FLUID REPLACEMENT ....................................................................................................6-58
CALIPER REMOVAL AND DISASSEMBLY ..................................................................................6-59
CALIPER INSPECTION ..................................................................................................................6-60
CALIPER REASSEMBLY AND REMOUNTING .............................................................................6-61
BRAKE DISC INSPECTION ...........................................................................................................6-62
MASTER CYLINDER REMOVAL AND DISASSEMBLY ...............................................................6-63
MASTER CYLINDER INSPECTION ...............................................................................................6-64
MASTER CYLINDER REASSEMBLY AND REMOUNTING ..........................................................6-64
REAR BRAKE .............................................................................................................................................6-66
CONSTRUCTION ............................................................................................................................6-66
BRAKE PAD REPLACEMENT .......................................................................................................6-67
BRAKE FLUID REPLACEMENT ....................................................................................................6-68
CALIPER REMOVAL AND DISASSEMBLY ..................................................................................6-69
CALIPER INSPECTION ..................................................................................................................6-70
BRAKE DISC INSPECTION ...........................................................................................................6-71
CALIPER REASSEMBLY AND REMOUNTING .............................................................................6-72
MASTER CYLINDER REMOVAL AND DISASSEMBLY ...............................................................6-73
MASTER CYLINDER INSPECTION ...............................................................................................6-74
MASTER CYLINDER REASSEMBLY AND REMOUNTING ..........................................................6-75
CLUTCH RELEASE CYLINDER AND MASTER CYLINDER .....................................................................6-77
CONSTRUCTION ............................................................................................................................6-77
CLUTCH FLUID REPLACEMENT ..................................................................................................6-78
CLUTCH RELEASE CYLINDER REMOVAL AND DISASSEMBLY ..............................................6-78
CLUTCH RELEASE CYLINDER INSPECTION ..............................................................................6-79
CLUTCH RELEASE CYLINDER REASSEMBLY AND REMOUNTING ........................................6-79
CLUTCH MASTER CYLINDER REMOVAL AND DISASSEMBLY ................................................6-81
CLUTCH MASTER CYLINDER INSPECTION ...............................................................................6-82
CLUTCH MASTER CYLINDER REASSEMBLY AND REMOUNTING ..........................................6-82
TIRE AND WHEEL ......................................................................................................................................6-84
TIRE REMOVAL ..............................................................................................................................6-84
INSPECTION ...................................................................................................................................6-84
VALVE INSTALLATION .................................................................................................................6-85
TIRE INSTALLATION .....................................................................................................................6-85
CAUTIONS IN SERVICING ................................................................7- 2
CONNECTOR ...............................................................................7- 2
COUPLER ....................................................................................7- 2
CLAMP .........................................................................................7- 2
FUSE ............................................................................................7- 2
SEMI-CONDUCTOR EQUIPPED PART ......................................7- 2
BATTERY .....................................................................................7- 3
CONNECTING THE BATTERY ...................................................7- 3
WIRING PROCEDURE ................................................................7- 3
USING THE MULTI CIRCUIT TESTER .......................................7- 3
LOCATION OF ELECTRICAL COMPONENTS .................................7- 4
CHARGING SYSTEM .........................................................................7- 6
TROUBLESHOOTING .................................................................7- 6
INSPECTION ................................................................................7- 7
STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK
SYSTEM ..............................................................................................7-10
TROUBLE SHOOTING ................................................................7-10
STARTER MOTOR REMOVAL AND DISASSEMBLY ................7-11
STARTER MOTOR INSPECTION ...............................................7-12
STARTER MOTOR REASSEMBLY ............................................7-12
STARTER RELAY INSPECTION .................................................7-13
SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS
INSPECTION ................................................................................7-14
IGNITION SYSTEM .............................................................................7-17
TROUBLESHOOTING .................................................................7-17
INSPECTION ................................................................................7-19
COMBINATION METER .....................................................................7-22
REMOVAL AND DISASSEMBLY ................................................7-22
INSPECTION ................................................................................7-23
ENGINE COOLANT TEMPERATURE METER AND
INDICATOR ..................................................................................7-25
LAMPS ................................................................................................7-29
HEADLIGHT, BRAKE LIGHT/TAILLIGHT AND TURN
SIGNAL LIGHT ............................................................................7-29
RELAYS ..............................................................................................7-30
TURN SIGNAL/SIDE-STAND RELAY .........................................7-30
STARTER RELAY ........................................................................7-30
FUEL PUMP RELAY ....................................................................7-30
SWITCHES ...................................................................................7-31
BATTERY ............................................................................................7-33
SPECIFICATIONS ........................................................................7-33
INITIAL CHARGING .....................................................................7-33
SERVICING ..................................................................................7-35
RECHARGING OPERATION .......................................................7-35
TROUBLESHOOTING ........................................................................8- 2
FI SYSTEM MALFUNCTION CODE AND DEFECTIVE
CONDITION ..................................................................................8- 2
ENGINE ........................................................................................8- 4
RADIATOR (COOLING SYSTEM) ...............................................8- 9
CHASSIS ......................................................................................8-10
BRAKES .......................................................................................8-11
ELECTRICAL ...............................................................................8-12
BATTERY .....................................................................................8-13
WIRE HARNESS, CABLE AND HOSE ROUTING .............................8-14
WIRE HARNESS ROUTING ........................................................8-14
ENGINE ELECTRICAL PARTS SET-UP .....................................8-17
HIGH-TENSION CORD ROUTING ..............................................8-18
THROTTLE CABLE ROUTING ....................................................8-19
THROTTLE BODY INSTALLATION/HOSE ROUTING ...............8-20
CRANKCASE BREATHER HOSE ROUTING .............................8-21
CLUTCH HOSE ROUTING ..........................................................8-22
COOLING SYSTEM HOSE ROUTING ........................................8-23
FRONT BRAKE HOSE ROUTING ...............................................8-24
REAR BRAKE HOSE ROUTING .................................................8-25
FUEL TANK DRAIN HOSE ROUTING ........................................8-26
FUEL TANK INSTALLATION ......................................................8-27
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ........................8-28
SEAT LOCK CABLE ROUTING ..................................................8-29
SIDE-STAND SET-UP ..................................................................8-30
BRAKE PEDAL/FOOTREST SET-UP .........................................8-30
FOOTREST SET-UP ....................................................................8-31
HANDLEBAR BALANCER INSTALLATION ..............................8-31
SPECIAL TOOLS ................................................................................8-32
TIGHTENING TORQUE ......................................................................8-35
ENGINE ........................................................................................8-35
FI SYSTEM PARTS ......................................................................8-36
CHASSIS ......................................................................................8-37
TIGHTENING TORQUE CHART ..................................................8-38
SERVICE DATA ..................................................................................8-39
EMISSION CONTROL SYSTEMS ......................................................9- 2
FUEL INJECTION SYSTEM ........................................................9- 2
CRANKCASE EMISSION CONTROL SYSTEM ..........................9- 3
EXHAUST EMISSION CONTROL SYSTEM (PAIR SYSTEM) ....9- 4
NOISE EMISSION CONTROL SYSTEM .....................................9- 5
EVAPORATIVE EMISSION CONTROL SYSTEM
(Only for E-33) .............................................................................9- 5
PAIR (AIR SUPPLY) SYSTEM INSPECTION ....................................9- 6
PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING ..............................9- 8
HEATED OXGEN SENSOR (HO2S) INSPECTION ............................9- 9
HEATED OXGEN SENSOR WIRE ROUTING ....................................9-10
EVAPORATIVE EMISSION CONTROL SYSTEM INSPECTION
(Only for E-33) ....................................................................................9-11
CANISTER HOSE ROUTING (Only for E-33) ....................................9-12
WIRING DIAGRAMS
This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.
Language: English
Format: PDF
COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS
(WINDOWS 10, WINDOWS 8, WINDOWS 7, VISTA 32 and 64, XP, ME, 98, NT, 2000 ETC.)
Windows/Mac/Tablet/Phone Friendly
32 / 64 bit
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