Suzuki 2002 DL1000K2 Service Manual Download Page 1 | Manualshive

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Summary of Contents for 2002 DL1000K2

Page 1: ...DL1000...

Page 2: ...re 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 difference...

Page 3: ...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 othe...

Page 4: ...olant 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 brak...

Page 5: ...de 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...

Page 6: ...kcase Ventilation Crankcase Breather R RH Right Hand ROM Read Only Memory S SAE Society of Automotive Engineers STC System Secondary Throttle Control System STCS STP Sensor Secondary Throttle Position...

Page 7: ...ATION 1 4 FUEL OIL AND ENGINE COOLANT RECOMMENDATION 1 4 FUEL 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...

Page 8: ...t use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Proper...

Page 9: ...nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci fied tightening torque Whenever you remove oil seals gaskets packing O...

Page 10: ...equired especially for registering the machine and ordering spare parts FUEL OIL AND ENGINE COOLANT RECOMMENDATION FUEL FOR CANADIAN MODEL Use only unleaded gasoline of at least 87 pump octane or 91 o...

Page 11: ...not go down to freezing point Suzuki recommends the use of SUZUKI COOLANT anti freeze engine coolant If this is not available use an equivalent which is compatible with an aluminum radiator LIQUID AM...

Page 12: ...ercised during its early life The general rules are as follows Keep to these break in engine speed limits Initial 800 km 500 miles Below 4 500 r min Up to 1 600 km 1 000 miles Below 7 000 r min Over 1...

Page 13: ...ng label For E 33 5 Fuel caution label For E 02 24 6 Manual notice label For E 03 33 7 Tire pressure label 8 Warning safety label 9 Rear carrier warning label 0 Frame caution label A Steering warning...

Page 14: ...rs 2 Bore 98 0 mm 3 858 in Stroke 66 0 mm 2 598 in Piston displacement 996 cm 60 8 cu in Compression ratio 11 3 1 Fuel system Fuel injection system Air cleaner Non woven fabric element Starter system...

Page 15: ...e phase A C Generator Fuse 30 15 15 15 15 15 10 A Headlight 12 V 60 55 W H4 Position light 12 V 5 W 2 Except for E 03 24 28 33 Turn signal light 12 V 10 W License light 12 V 5 W Brake light Taillight...

Page 16: ...MATION COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s CODE COUNTRY or AREA E 02 E 03 E 19 E 24 E 28 E 33 U K U S A Except for California EU Australia Canada...

Page 17: ...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 1...

Page 18: ...18 24 Air cleaner element I I R I Exhaust pipe bolts and muffler bolts T T T Valve clearance I Spark plugs I R I R Fuel hose I I I I Replace every 4 years Engine oil R R R R R Engine oil filter R R I...

Page 19: ...ore lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle h...

Page 20: ...of removal Inspect every 6 000 km 4 000 miles 6 months and replace every 18 000 km 11 000 miles 18 months Always use air pressure on the throttle body side of the air cleaner element If air pressure...

Page 21: ...plug mounting bolts A and B Move the radiator forward Remove the spark plug cap 1 NOTE Be careful not to damage the radiator fins Remove the spark plug with a spark plug wrench Inspect every 6 000 km...

Page 22: ...Measure the plug gap with a thickness gauge If out of specifi cation adjust it to the following gap 09900 20803 Thickness gauge Spark plug gap A Standard 0 6 0 7 mm 0 024 0 028 in ELECTRODES CONDITION...

Page 23: ...on 2 when the valve mechanism is serviced and 3 when the camshafts are disturbed by removing them for servicing Tappet clearance when cold IN 0 10 0 20 mm 0 004 0 008 in EX 0 20 0 30 mm 0 008 0 012 in...

Page 24: ...a thickness gauge between the tappet and the cam If the clear ance is out of specification adjust it into the specified range 09900 20803 Thickness gauge Turn the crankshaft 270 degrees turns to set t...

Page 25: ...ometer to ensure its size Refer to the tappet shim selection table Pages 2 10 and 11 for details NOTE Be sure to apply engine oil to tappet shim top and bottom faces When seating the tappet shim be su...

Page 26: ...2 10 PERIODIC MAINTENANCE INTAKE SIDE...

Page 27: ...PERIODIC MAINTENANCE 2 11 EXHAUST SIDE...

Page 28: ...nd drain oil by removing the drain plug 1 and filler cap 2 Tighten the drain plug 1 to the specified torque and pour fresh oil through the oil filler The engine will hold about 2 7 L 2 9 2 4 US Imp qt...

Page 29: ...ntil you feel that the fil ter gasket contacts the mounting surface Then tighten it 2 turns using the oil filter wrench 09915 40610 Oil filter wrench NOTE To properly tighten the filter use the specia...

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